Safety

PROCESS SAFETY

UNIT V-HEALTH HAZARDS AND LEGAL

ASPECTS
SYLLABUS:
Health hazards – occupational – industrial health hazards – health standards, and rules – safe working
environments – parliamentary legislations – factories act – labour welfare act – ESI Act – Workmen
Compensation Act .Role of Government, safety organizations, management and trade unions in
promoting industrial safety.

HEALTH HAZARDS:

Defined as source of danger involving chemicals which result in acute or chronic health effects on
exposed person.
(Inhalation,Ingestion,Skin contact,Injection).Chemicals by nature are toxic and unsafe for handling and
industries emit lots of such poisonous gases and pollute.

1)CORROSIVES,PYROPHORIC LIQ-Vapours breathed cause irritation,skin and eye burns

2)CARCINOGENS/IRRITANTS-Cause cancer/body itches,difficult breath and coughing
3)MUTAGENS/SENSITIZERS-Damages genes in sperm and egg cells/cause allergic rexn
4)TARGET ORIENTED CHEMICALS- Liver(Hydrocarbons),Lungs/Kidney(Cd),Brain(Hg)
5)TERATOGENS-Damages fetus during development
6)CRYOGENICS-Frostbite by freezing body contact
7)RADIOACTIVE-Prolonged exposure could be fatal to life
8)FLAMMABLE-Mix of first consequence and suffocation,dizzy
9)Manifestations of diseases,Poisoning due to lead,K,Hg,Mn etc.

NOISE:Threshold(0-4dB),Audiogram can be used to measure performance of ear and sensitivity of ear to

sound freq.Twice source only caused 3 dB increase.

EMR:IONIZING:DNA directly ionized,DNA altered chemically due to ionization of other cell constituents.(
2modes)
This prevents cell division and causes DNA death
NON-IONIZING:Short wavelength doesn't pass through skin and may result in burn or disease
overtime,can pass heat generated(depends on wavelength

OCCUPATIONAL HEALTH HAZARDS:(ILLNESS)

Occupational health hazard is defined a s a condition that results from exposure in a workplace to a
physical,chemical or biological agent to the extent that the normal physiology is affected and health is
impaired.

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1. Abnormal air pressure 2. Abnormal temperature and humidity 3. Defective illumination 4. Radiation
energy 5. Vibration and noisy operation

PREVENTION AND CONTROL:

Each exposure is different and has to treated differently:

1)Elimination or Reduction/Removal after use in the volumes or frequency of use of injurious substances
2)Strict control at point of origin
3)Provision for washing,cleaning,taking lunch away from unsafe places
4)Isolation and guarding of injurious substances
5)Provision of PPE
6)Control of unsafe,personal acts through instruction
7)Periodic physical examination and enforcement of rules for personal hygiene
8)Administrative controls like job rotation,work rest cycle etc.
9)Engineering Control : Substitution(Toluene instead of benzene/Chloroform instead of
(tetraCl),Isolation(by enclosing within containment structure,Ventilation(removal of air with hazardous
contaminant and its replacement)
10)Segregation:a)by time:when minimum number of worker are present b)Hazardous operations aat
one end of a workshop in separate room or building to minimize risk

SAFE WORKING ENVIRONMENT:

Company must provide and maintain a safe working environment to their workers by:1)ENTRY AND
EXIT(safely do this,for like people with disabilities or spcl needs)2)HOUSE KEEPING(clean tidy workplace
minimizes injury and more storage space)3)WORK AREAS(sufficient space for worker to move around
and also evacuate quickly in emergency)4)WORKSTATIONS(ergonomics)5)FLOOR AND
SURFACES(regular inspection adn should be suitable for type of work6)Lighting(sufficient for sight and
not cause strain) 7)AIR QUALITY(adequate ventilation,in toxic environments workers should be made
aware of THRESHOLD LIMIT VALUE,SHORT TERM EXPOSURE LIMIT and IDLH)

SAFETY ORGANIZATIONS:

BIS:Indian standards(ISO 45001 latest for occupational safety and health)(OSHAS 18001 widely accepted
std can be merged with ISO).Standardize PPE- 450 specifications.ISI mark not given before safety heck
done by separate safety cell.

Loss prevention association:Non profit set in 1978 for education training and consultancy in cases of
fire,damages to cargo and road accidents.Maintains data.

PARLIAMENTARY LEGISLATIONS:

THE FACTORIES ACT-1948 (1987)

provide safety and promote health and welfare of workers employed in factories.
Amendment reg potential hazards in chem.
Applicability-to industries or factories registered under the state government or established by
notification in the official gazette.premises with 10 or more people working on any day in next 12
months during manufacture with power.20 minimum for without power.

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DEFINITION:18+adult,15-18adolescent,<15child.week from sat.POWER(electrical or other form of

energy not gen by human)PRIME MOVER(engine,motor or such appliance).TRANSMISSION
MACHINERY(wheel,shaft,drum,pullet,coupling,clutch by which motion of PM is transmitted to
machinery)MANUFACTURING PROCESS(making,altering,ornamenting,finishing,packing,oiling,cleaning
any substance with a view to its use sale etc)WORKER(person employed directly or through any agency
whether for wages or not in any process or on any machinery or any work connected to the
manufacturing process.)
OCCUPIER(person with ultimate control over all affairs of the factory and where said affairs are
entrusted to a managing agent)
LICENSE AND REGISTRATION(1.permission for factory site from chief inspector.2.officer should approve
and then fees should be paid and factory registered)
INSPECTING STAFF:state government appoints (chief inspector and such to supervise the conditions in
factories and be vigilant)(certifying surgeons to examine young people medically and check with
conditions in factory and their safety)
HEALTH STANDARD AND RULES:1973
1)Cleanliness:clean and free from gases from drains.whitewashed once in 14m
2)Ventilation TEmperature:circulation of fresh air to give dis.temp as low as practical and insulate hot
parts
3)Overcrowding(14.2sqmt for each worker)4)LIghting(natural or artificial must be sufficient)
5)Drinking H2O(abundant and available and marked as drinking.6m away from contamination
6)BATH ROOMS-general7)LATRINES AND URINALS-separate urinal for genders.1 Latrine for 20f & 1 for
50 8)SPITTOONS:Sufficient quantity,washed regularly and kept clean.

LABOUR WELFARE FUND ACT(1973):

State based statutory contribution.frequency and amount depends on the state.can be annual or
monthly.can be as money,necessities etc
APPLICABILITY:15 states applicable -TN(promoting welfare of labour,applicable to all factories,15000/-
pm)
SCOPE:all benefits to everyone.
SCHEMES:(benefits):education for children,medical,transport,recreational,housing,libraries,vocational
training,nutritious food,tours,home industries,scholarships,special needs assistants.(in TN uzhaippavar
ulagam a magazine)

EMPLOYEE STATE INSURANCE ACT:1948

To all factories under the act and is to provide benefits to insured persons their family and Dependants -
Benifits (Medical,sickness,maternity,Disablement,Funeral Expenses,Rajiv Gandhi SHramik Kalyan Yojana
unemplyment allowance).
For socio economic justice based under part IV of constitution.ESI CORPORATION(Standing committee
and medical benefit council)funds from donors,grants,gifts.Courts are there for claims and disputes.

WORKMEN COMPENSATION ACT:(1923)

provides payment of compensation by employer to his employees or dependants,if personal injury is
caused to them by accidents due to employment.Encourages better safety and medical practices and
corresponding increase in efficiency.administered in all states.
NOT LIABLE(disablement doesnt last more than 3 days,no death,workers fault,not in course of
employment,repetitive case by same person to some other employer)
COMPENSATION-same for adult and minors(max-80000 fatal,90000 permanent disablement,2000/m for
5 years temporary).depends on nature of accident.

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MEDICAL EXAMINATION:workmen should produce medical certificate to commissioner.

ROLE OF INDIAN GOVERNMENT:

PROMOTIONS:Prohibition of employment of children under 14 in factories,mines etc.,aims to protect

health and strength of all workers by discouraging bad unsuitable work environments,OSH policies and
programmes from constitution’s framework,prevention is focused on more ,maximum permissible limit
for chemicals,medical pre and post been made mandatory

LAWS AND REGULATIONS:add the 4 acts

MINES ACT(1955)-labour safety in mines,DOCK WORKER SAFETY(1986):loading and unloading

ships,MOTOR TRANSPORT WORKERS ACT,1961,PLANTATION LABOUR,EXPLOSIVES ACT 1984- regulate
possession,import,export,use,sale of explosives-gas cylinder,pressure rules.,THE PETROLEUM ACT
1934:import,transport,storage,production of petroleum.INDIAN BOILERS ACT-1923,ENVIRONMENT
PROTECTION ACT,1968 - protection and improvement of environment and matters connected therewith
/hazardous chemicals,toxins,micro.org/pollution etc.THE WATER ACT(1974)-prevention and control of
water pollution and maintaining wholesomeness of water.The AIR ACT(1981)-,ENERGY conservation
act-2001

ROLE OF SAFETY ORGANIZATIONS:

OIL INDUSTRY SAFETY DIRECTORATE:rules for safe distances to be observed for various facilities in an
oil installation,LPG plants can be started only after approval,provide guidelines for safe operation of
petrol stations

SAIL Safety Organisation:safety,promotional,fire,health services of steel/manages secretariat of forum

of safety,guidelines/formulates and prepares stuff

PETROLEUM AND EXPLOSIVES SAFETY ORGANIZATIONS:Ensure safety during

transport,storage,handling of explosives,petroleum,nd gases./advisory role to govt bodies/find tech and
applications for adaptation in indigenous conditions

NATIONAL SAFETY COUNCIL:

4/3/66 in Bombay by ministry of labour as a non profit.Main objective is to generate ,develop and
sustain voluntary movement @ national level.To eliminate human suffering loss of production and
damage to material.Connected with international agencies like National fire protection
agency(US),International Labour org,British Safety council,World Safety Council.By screening
films,publishing safety chronicle,safety posters,training programmes and consultancy.write about safety
audit.AWARDS for Occupational safety and health(OSH) - (Manufacturing sector ,construction
sector,small scale),celebrating various campaigns.

ROLE OF MANAGEMENT:

Promotion:workplace free from serious recognized hazards and comply with standards,rules and
reg,,examination of workplace,use codes,poster to warn employees,provide PPE,check with

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communication language,train employees and create documents and manuals,provide medical

exams,keep data and analyze,form safety committee for appraisal.

SAFETY COMMITTEE:FUNCTIONS(assist in framing rules,carryout studies on accidents,diseases,.,review

effectiveness,workplace inspection,advisory role to management
DUTIES(report unsafe conditions,conduct meetings regularly,build enthusiasm,propose and create
safety checklists,direct involvement with safety training,sponsor contests safety drives etc,and perform
all functions

ROLE OF TRADE UNION:

Negotiate safe working conditions,disseminate collective bargaining agreements with regards to OSH
,educate all union leaders on OSH,take part in formulation of legislations and policies and
monitor,review,,Identify and expose bad workplace,conduct campaigns to educate
members,employers,public about importance of safety

UNIT 4-ACCIDENTS
Industrial accidents – accident costs – identification of accident spots; remedial measures; identification
and analysis of causes of injury to men and machines – accident prevention – accident proneness –
vocational guidance, fault free analysis. Fire prevention and fire protection.

ACCIDENT:an unexpected and undesirable event,especially one resulting in damage or harm:Eg.,an

unforeseen incident.
CLASSIFICATION:
1)Failure of equipments or machines:designed for safety but due to overwork may fail,maintenance
prevents it
2)Unsafe Operation/acts/condition:operation without authority,entering dangerous zones,operation at
more than rated speed,not using PPE
3)Employee behavioristic: improper attitude,deliberate disobedience of safety rules,lack of knowledge
etc
4)Environmental causes:improper - illumination,ventilation,housekeeping,guarding defective parts
5)Natural Causes-flood,storm,earthquake
6)Fire-improper housekeeping,bad storage of fuels,sparks due to friction
7)due to Chemicals-poisonous,corrosive/give fumes and vapors which can cause fires and other health
hazards.Leaks corrode equipments.Proper storage handling required.

ACCIDENT COSTS:
Realization that it pays to prevent accidents and injuries is driving force,the estimated cost acts as
incentive
2 types
DIRECT:25% of total accident cost(payment by compensation to accident victims,medical expense
incurred by the management for the injured in the accident.
INDIRECT:75% of total cost to victim,management,society1)Employer related(cost of preparing report
and investigation,cost of time lost by personnel ,damage of machinery,components.,cost due to
downtime after accident,loss of skilled personnel,loss of public confidence,prestige,revenue)2)Employee

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related(degradation of morale,payment loss,exodus of skilled people to other factories,loss of future

earnings due to morale3)Society,Government - escalation in price of products due to production
loss,quality loss,reduced tax collection,industrial unrest ,retention lockout leading to disturbance in
equilibrium of society.

IDENTIFICATION AND ANALYSIS OF CAUSES OF INJURY TO MEN AND MACHINE:

-to discover causative factors,hazardous conditions and practices.full information is collected and acted
upon.elimination of fixing blame is important.size of committee depends on scale of accident.from
department head to safety committee with special officers.
STEPS:on spot enquiry/careful and impartial analysis/nothing is dismissed saying worker was
careless/avoid looking for excuses/dont fix blame/thorough knowledge of all events must be gathered—
all lead to need for more information,education,training of worker nd close follow up of systems.

ACCIDENT REPORTS:std report for all accidents,tabulated with name,age,id,nature of work,cause,action

to be done

REMEDIAL MEASURES: discovering all causes of accidents,analyzing records,inspection,check

plans,purchase orders and contracts,provide guards for existing hazards,correction of defects,formation
of safe procedures,improve illumination and ventilation,provide safety gadgets,initiate job analysis

ACCIDENT PREVENTION:
METHODS:Regulation(mandatory prescription for working
condition,design,maintenance,inspection,testing,medicals)Standardization:standards for safe
construction,safe and hygienic practices of PPE.Inspection:Enforcement of mandatory
regulation.Technical research:investigation of material,guards,PPE,and more research,MEDICAL
RESEARCH:investigation of physiological and pathological effects of environmental and technological
factors,Physiological research:check patterns,Statistics,EDUCATION TRAINING PERSUATION-public
appeal to develop safety mindness Individual safety measure

PRINCIPLES:ACC CAUSES:unexpected due to unsafe acts or unsafe mech or physical conditions correct
this.
ACC SEQUENCE:faults o f

ACCIDENT PRONENESS:every worker does same job,same environment but some have more accidents
than others.they are accident prone employees and dis happens due to persisting characteristics. —
inattentiveness,poor eye sight,hearing,bad adjustment of work,dislike of superiors,insufficient
intelligence,unsafe behavior of worker.CONTROL:select qualified people mentally and physical,transfer
accident prone employees to comparatively low hazard areas,impart adequate training to a recruit,keep
morale high

FAULTY TREE ANALYSIS:

Top down,deductive failure analysis where boolean algebra is used to combine a series of lower level
events for an undesired state of system.used in safety and reliability engineering to determine
probability of safety accident.SYSTEM FAILURE CONDITION is the system and classified based on
severity.more severe more analysis
USED(logic leading to event,show compliance with reliability,create critical equipment list based on
contribution,minimize and optimize resources,monitor and control safety performance,diagnostic
tool,design systems and manuals

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METHOD:
Any system fails overtime.improved system design prevents this.
Logic diagram of overall system relating faults ,subsystems and redundant safety design elements
Undesired outcome at top/Eg.metal stamping press stamps human appendage/normal or
maintenance(OR)./in normal 2 ways(cycles into operator or into another person(OR))/design
improvement making operator press 2 buttons(AND)this may fail but its probability is calculated and if
the tree is labeled the computer can calculate failure probabilities.COMMON CAUSE-specific event
causes more than one effect,impact on several subsystems,event appears at many locations in tree,it
complicates calculations,software not available/tree is written using conventional logic gate
symbols.CUT SET - combination of events typically component failures cozing top event.minimal cut set-
no event can be removed from it.
EVENT TREES:(probabilistic risk assessment).from undesired initiator(loss of supply) to further system
events through to a series of final consequences.each new event is a node on a tree with split
probabilities.various probabilities for different top events can be derived.
ELECTRIC POWER RESEARCH INSTITUTE(CAFTA) software in nuclear power plants and US aerospace
manufactures SAPHIRE idaho,by US Govt.SCRAM-open source that uses open PSA model exchange
format

FIRE PROTECTION AND PREVENTION:

Fire is a chemical reaction in which a combustible material combines with oxygen in atmosphere to give
out heat and flame.change is oxidation and process is combustion.Rate(Slow-slow evolution of heat but
not light,rapid- evolution of heat and some light,spontaneous-heat by absorption of atmospheric O.
FIRE FIGHTING,DETECTION AND ALARM SYSTEM:
1)Water spray system(for offices,stores,boilers)2)CO2 system(in enclosed areas,switchgear room,cable
tunnels)3)Dry Chemical Powder used for control room,offices,electrical plant etc.4)Foam system(for
fuel-oil storage tank5)Halon(for computer room,control relay room)6)Hydrant (general use in
plant7)Water Hose reels(offices,stores,etc)
TOTAL SYSTEM:(smoke ,light,flame,heat confirm presence all of which used to detect fire
rapidly.located at various zones and connected to alarm,fire control and to automatic fire fighting
system.detector system initiates alarm and its operation starts giving a buzz sound in that zone and
initiates operations.
1)Fire Detection systems2)Fire Alarm systems3)FIre alarm and control panel4)Fire hydrant system

CLASSES OF FIRE:

CLASS A:combustible materials,flammable solids like wood,paper CLASS B flammable liquids

petrol,turpentine,CLASS C-flammable gases-hydrogen,butane,methane,Class D combustible
metals,Mg,Al,Electrical fires-electrical equipment,Class F-cooking oils

Fire fighting arrangement:(extinguishers and buckets at all locations,in isolated locations complete
facilities including fire tenders for size and importance of equipment,building must be developed.,water
should always be available at enuf pressure,fire exit and alarm must be available,Demo and training
must be done

FIRE PROTECTION:

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EQUIPMENT(hand appliances,portable extinguishers,hose reels,foam making ,fixed

systems)AGENTS(water,with additives,foams ,dry powders,CO2,high explosion foams,vaporizing liquids)

EXTINGUISHERS(WATER— ,water bases.,containing water,CACl2,soda used in CLASS A.pumps are used

with hose and a nozzle to throw from 30-50ft.Evaporates 1700 times its volume to give
steam,abundant,nontoxic.
Additives added like potassium in class A.Cacl2 causes corrosion.FACTORS(experience of employee,rate
of application,drop size of water,fire points,depress freezing point),not used for electrical fires if used
cut down source, sometimes effective for LPG fires.Not for molten metals due to sputtering of
them.RED,spray-larger spread,mist-microscopic particals released creating wall of mist.

DRY POWDERS:used more recently for all classes and as replacement of water and foam.Potassium or
sodium carbonate powder with additives to promote moisture repellence with particle size effecting
efficiency.It should be used alone.Salts of ammonium sulphate used in A to check flamming and
smothering.can be used for radio active fires too.Powders for metals contain salt with graphite,PVC
boron trioxide,plasticizing agent.Acts by forming a molten layer over surface of metal preventing further
combustion.BLUE,buisnesses, garages,LPG plant.
Spcl- L2 for lithium M28 for flammable metal

VAPORIZING LIQUIDS-B mainly but also for A sometimes,for electrical also but may coz corrosion.
CCl4 or CLBRCH4,depress freezing point.smother flames after vaporizing to heavy gases.

FOAMS:for water miscible flammable liquids,forms a bubble structure from solution of foaming agent
and gas.FOR air or mechanical foam waste protein like soya,blood used.Mixed with water 4-6% with
induced air at pipe and form the bubble.applied to surface as blanket to protect from surface from
flame radiation.can also use mix of AlSO4 and sodium bicarbonate with foam
additives(saponin,Liquorice) to produce CO2.MECHANICAL-outer water,inner goam and CO2.plunger
mechaniam at top CREAM.CHEMICAL-outer sodium bicarbonate,inner ALSO4

CO2:gas so no residue and not decomposed so no corrosion,non conductor of electricity,Electric.,Two

systems for fixed sprinkle and handheld(1 High pressure 300psi 0F with refrigeration.Fixed used in
rooms,buildings.in Tight spaces tight enuf to prevent leakage.different rates can be
administered,BLACK,offices,kitchens,server rooms
Draw with a discharge horn and inside compressed to liquid which later vaporizes,

AUTOMATIC CONTROL SYSTEMS:used primarily in industries,water is used.

AUTOMATIC SPRINKLER SYSTEM:water,pipework with sprinkles at regular intervals with reliable water
supply,zonal operation.automatic valves with heat sensitive elements with set point after which
sprinkler ruptures and fuses.Water should not freeze.WET(under pressure used when no
freezing)DRY(releases air in pipes used when susceptible to freezing)ALTERNATE can be used based on
season

DRENCHER SYSTEM:throw water through windows,doors and such openings.used in streets which are
congested.sealed drenchers used for automatic purposes(mounted at intervals at a projected
building)valve depends on air presssure and low P opens it warning is given

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SPRAY WATER system:for oils and flammable liquids tackled at source.conical spray of droplets at high
velocities.
Emulsification,cooling and smothering.high velocity breaks up oil and then forms emulsion.

FIRE PROTECTION:
STORAGE is also a good preventive method.OPEN YARD STORAGE(materials piled upto 20 ft
high,between piles 15 ft,all portable fire extinguishers made available INDOOR STORAGE(not affect
exit,all material segregated based on combustibility ,hazrd probability etc,piled stabily containers for
liquids must be inspected and stored safely,only 25 gallons spcl cabinets for more for upto 60 Category
1,2,3 and 120 fr category 4 liquids.3 cabinets per room.raised sills,ramps ,gravity exhausting system -
LPG — approval of equipment,welding on container probhibited,safety devices,dispensing, all similar
TEMPORARY buildings can be erected but not covering exit with non combusitble construction or 1 hr
resistance max 2000sqft
FIRE CUTOFFS:exits given priority,fire doors with automation should be developed ,
IGNITION HAZARD:electrical wiring and equipment installed with compliance to requirements ,ICE
powered equip located such that exhausts are well away from combustible,smoking prohibited,piping
outside building needs clearance of 6 inches with combustible material

UNIT-III-SAFETY PERFORMANCE
Appraisal; effective steps to implement safety procedures; periodic inspection and study of plant layout
and constant maintenance; periodic advice and checking to follow safety procedures; proper selection
and replacement of handling equipments; personal protective equipments.

SAFETY APPRAISAL:tool for developing as well as assessing safety awareness and performance at
workplace
TYPES(strategic plan,program review,interviews,safety perception survey),appraisal —
individual,group,multiple,by subordinates
SIGNIFICANCE:competence and commitment to manage safety,check if appropriate systems are in
place,necessary competence to carry out work,ability and willingness to allocate adequate
resources,effective implementation of health and safety
EG:Name,Dept,Id,type of appraisal-spcl,annual,time period TABLE(instructions ,exceed stds,achieve
stds,below stds for job knowledge,quality,productivity,dependability,attendance,commitment,relations
with others,overall raring)
POSITIVE INDICATORS(employee consistently follows safety procedure,standards and
responsibilities,prevents accident removing hazard,participates in training and campaigns,accident free
for long time,supportive manager with good execution) NEGATIVE(Careless employee must be
corrected and councelled,contributes to accident or experiences it review indicates workers fault,same
without property damage)

IMPLEMENT SAFETY PROCEDURE:SAFETY PROCEDURES-provides guidlines,documentation or practices

to perform any task safely and training,evaluation of contractors and performance review.

STEPS:in order

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MANAGMENTS COMMITMENT:(allocating budget for safety manpower,conduct assessment or

review,visible involvement in establishing a written health and safety policy signed posted,motivation
and resource provided for organizing and controlling)
EMPLOYEE INVOLVEMENT(safety commitee,incident investigation,inspections.emergency
response,development of operating procedure,Job safety analysis,presentation of training topics)
WRITTEN PROCEDURES AND PRACTICES:(proper meeting and control of safety and health hazards,5
and 6,emergency programs and procedure,division of responsibilities and accountability)
CONTROLLING AND MONITORING HAZARDS:proactive tools for safe condition:mechanical
integrity,industrial hygiene,housekeeping inspections,corrective action systems,design
concepts,operating procedure,safe work procedures)
TRAINING:(safety philosophy ,practices,contractors training,operating procedure,Hazcom,respiratory
protection,hearing conservation,permit system and communication during emergency
INCIDENT:(any incident viewed as better oppurtunity,written report with agency involved for
analysis,gives corrective action and tracks its implementation,communication to employees)

PERIODIC ADVICE:
Safety procedures may not be followed as(procedures are not correct,difficult,not readily
available,,easier ways to do it,peer pressure,failure to understand risks,pressure to get work done
ENCOURAGE COMPLIANCE:by design job or task such that correct procedure is hard to avoid (logic
controllers),informal procedure incorporated into the formal procedure,Incentivise following
procedure,adopt a control a review process

SAFETY AUDIT:(systematic independent exam to determining if activities are implemented effectively

and are they suitable to reach the goal.It examines all stages in HS management with compliance with
controls of organisation and assessing effectiveness and future validity
TYPES:HEALTH AND SAFETY AUDIT(performance in HS,checking on performance of manager and
others,compliance of company laws with HS)WALK AROUND AUDIT(check if HS policies are properly
implemented and to identify areas of improvement in a light manner)HS MANAGEMENT:(adequate
process for HS requirements,clear training and overlooking,procedures for identifying hazards,setting
and reviewing HS stds,procedure for HS audit,planning,implementing,controlling,monitoring and
reviewing measure)PROJECT HS ENVIRONMENTAL:(method for HSE activities and procedures
monitoring,formal audits ,regular and ad-hoc inspections)PRODUCT:(design and development stafes to
ensure protection of user- identify hazards of product,develop hazard risk index and priority setting,get
employee to present design alternatives and review)PROCESS(self evaluation,gather documents of
process safety requirements and determine program implementation and effectiveness,review for
feasibility)

PLANT LAYOUT:physical arrangement of equipment and facilitites within a plant.Optimising dis

increases productivity,safety,quality.FACTORS:(prevent domino effect,ensure safety in on site occupied
building,control access of unauthorized personnel,facilitate access of emergency)(design based on (new
site or addition,future expansion possible,type and quantity of product,operation convenience and
accessibility.Type of process and product control,economic distribution,building code and type,HS
guidlines,waste dispable problems,space available requires,auxiliary equipment,roads and railroads.)
CRITERIA:MAXIMUM FLEXIBILITY(modifiable plant layout),Max coordination(entry,disposal into any are
dept must be convenient,Max visibility(people and material observable and no hidden places,MAX USE
OF VOLUME(consider space as cub and utilize all volume)MAX ACCESSIBILITY(all service and
maintenance)MIN DISTANCE(necessary and direct move)MIN HANDLING(no handling is best)MIN
DISCOMFORT(poor light,excess sunlight,heat,noise )Inherent safety,max security,efficient process flow

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TOOLS:Flow process chart,process flow diagram,machine data card,templates,scale models

TYPES:
PROCESS TYPE: for systems with wide variety of products in small volumes(designed for processing
items in a variety of requirements,department or functional grouping based on kinds of activities
performed,EG.machine shop with separate drilling,milling,grinding.(LMDGAss)draw flowchart.
PRODUCT LAYOUT:job divided into series of standardized tasks with specialisation of labour and
equipment,large volumes handled,economical to invest huge money,smooth and rapid flow of
products,higher degree of labor utilisation,operations arranged in sequence required to produce,eg.in
series input to output via different sets of tasks
CELLULAR MANUFACTURING LAYOUT:machines are grouped into cells,groupings bases on operations
for similar parts,faster processing,less material handling,reduced setup time,moderate variety of
moderate volume
Eg.different products different series of tasks verticallly
FIXED POSITION LAYOUT:materials and components remain fixed while worker and equipment moved
around
,for bulky heavy fragile material,large construction projects,shipbuilding,farming,firefighting etc
HYBRID:most manufacturing facilities use this,departments arranged as processes but products flow
through a product layout,EG.supermarket layouts,roller type conveyors in stockroom and checkouts and
belt type at registers.

PROPER SELECTION AND REPLACEMENT OF HANDLING ITEMS:raw materials,products,wastes must be

handled based on factors like material character,size,weight,rate of handling,distance.method varies for
each material and dpt.mechanical methods over manual reduce accidents,mechanical must be
safer,with proper construction.HAZARDS:overloading,poor arrangement,lack of space ,skill,operating
speed high
Hand Lift Trucks,Wheel barrows,Overhead cranes,Conveyors,Shovels,elevators
HAND TOOLS:in metal construction etc,order cant be controlled but some steps can be taken,use
PPE,heat treatment only by skilled people,materials of tools must be good and appropriate,tools stored
safely

PERSONAL PROTECTIVE EQUIPMENT:— (adequate protection against the hazards ,maximum comfort
and minimum weight compatible,no restriction in movement,durability and susceptibility,construction
as per stds)

NEEDS:chemicals can be substituted and mechanical control can be used but sometimes it cant be done
and there maybe a breakdown leading to need for PPE.effective barrier between person and harmful
objects

TYPES:

RESPIRATORY PE:atmospheric contaminants toxic and harmful and even doe can be controlled in
extreme cases like enclosed settings ventilation isnt possible hence PPE must be used.used as last resort
HAZARDS:
OXYGEN DEFICIENCY:vats,tanks are confined spaces contain lower oxygen than normal.due to dilution
or displacement,oxidation over a long time,if 16% oxygen or less use — increased rate of
breathing,accelaration of pulse,death

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GASEOUS CONTAMINANTS:toxic gases cause displacement of oxygen,can be immediate or non

immediate danger
PARTICULATE CONTAMINANTS:not immediate danger ,solid or liquid TOXIC PARTICULATE C:inhaled into
lungs to blood,chemical irritation,allergies,Ar,Sb FIBROUS PRODUCING DUSTS:do not pass into blood
stream but remain in lungs ,pulmonary impairment, NUISANCE DUSTS:dissolve and pass into blood or
remain in lungs.

AIRLINE RESPIRATORS:air supplied through small diameter hose,continuous flow,air supply 110,for
demand system supply depends on breath rate using a valve and compressor.protection as long as
supply is there.air must be kept pure without odour,oil.

SUCTION HOSE MASK:face piece to larger diameter flexible hose.air from atmosphere.facepiece has a
filer length of hose 30ft PRESSURE HOSE MASK:similar except air through larger dia with motor instead
of manual breathing

AIR PURIFYING RESPIRATORS:

CANNISTER GAS MASK:(air through cannister,contaminant is blocked and neutralized using a chemical
specific design,not for O deficient)CHEMICAL CARTRIDGE RESPIRATORS:(half mask to one or two
cartridges,chemicals to absorb vapors,not for emergency,for low conc.)MECHANICAL FILER:(air through
filter,reusable filter,filter has to repaired for clogs,microfilters and ultrafilters)COMBINE BOTH(remove
toxic gases and vapours)SELF RESCUE(good protection with practicability,always carried on,small
filer,nose clip,mouth piece,>canister)

SELECTION(nature,severity of hazard,type and conc of contaminant,activity of wearer,operating

conditions);CARE(when,how used ,checking operating condition,proper use and maintenance,good
fitting);

NON RESPIRATORY PROTECTIVE EQUIPMENTS:

HEAD PROTECTION(hard hats and caps made of Al,PVC,fiber glass,laminated plastic, fitted with brackets
for masks,lamps etc.harness for clearance between top of head and shell,soft caps for heat,spark
protection)EYE AND FACE PROTECTION(caused by dusts,flying particles,splashes,radiation.difficult to
cover use goggles.safety spectacles,mano goggles,welding goggles,face mask,welding helmets,gas tight
goggles,HAZARDS(large flying objects chipping,sledging,dust and small flying objects
scaling,woodwork,splashing of metals casting,dipping of metals,splashing of gases-handling of
acids,chemicals,reflected light radiation foundry,furnaces,arc welding))HAND AND BODY(necessary for
handling,sharp ,hot metals,chemicals,corrosive subs,gauntlet gloves,wrist gloves,mittens,sleeves
etc.material wrt hazard);FOOT AND LEG(handling heavy materials,corrosive liquids,wet conditions,
safety shoes,boots,foot guards and leg guards, steel toe and inner steel sole and ankle or calf high ,made
of asbestos,neoprene,natural rubber Leggings till shin,ankle or knee high held in by straps or
snaps);BODY(aprons,jackets,head to protective suits,Nature degree of hazard and nature of activities
considered)
Ear muffs, against noise safety belts for working in pits

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UNIT-II INDUSTRIAL SAFETY

SYLLABUS:
Chemical process industries; potential hazards; chemical and physical job safety analysis; high pressure;
high temperature operation; dangerous and toxic chemicals; highly radioactive materials; safe handling
and operation of materials and machineries; planning and layout.

CHEMICAL PROCESS INDUSTRIES:risk of accidents and harmful exposure can lead to potential hazards

DANGEROUS MATERIALS-Explosives,toxic gases ,inflammable liq,sol.radioactive,toxic,oxidicing

HAZARDS OF PRESSURE VESSELS-leaking or bursting,design defects,lack of proper
instrumentation,corrosion,lack of routing check,hydraulic pnuematic testing
HAZARDOUS CHEMICAL REACTION-anamolies in rate vs temp graph— normal,anamoly draw
HAZARDOUS UNIT OPERATION-HT-surface fouling leakage,scaling error.MO- dust explosion
FLAMMABLE GASES,VAPORS DUST HAZARD-explosion vents must be provide,fire control and prevent
sparks,hazard zones declared
HEALTH HAZARD-medical exams,PPE,hygiene and decontamination
HAZARDS DUE TO CORROSION-Waking and falling of structures,spills and toxic releases,leakages and
bursting
ENTRY IN TO CONFINED SPACES-lack of ventilation,failure to escape,oxygen deficiency,flammable
environment,toxic gas envmt,
WORKING WITH PIPELINES-leakages and bursting,collision with vehicles,condensates in pipelines
PLANT ALTERATION AND MODIFICATION-alteration in plant,equipment,component due to
difficulty,failure in unforeseen aspect of system
SAMPLING AND GAUGING-exposure of gases,vapours,approaching odd locations,splashes
spillages,exposure to toxic gases
HAZARDS DUE TO INSTRUMENT FAILURES-absence of fail safety inst,lack of interlocks and trip
systems,human failure

JOB SAFETY ANALYSIS;procedure which helps integrate accepted safety and health principles and
practices into a particular task or job.Also JHA ,it gives safest way to do a job,can be expanded to total
job analysis.job and task can be used interchangeably and JSA is not suitable for too broad job
descriptions or very narrow tasks.
BENEFITS:(identify undetected hazards,increase job knowledge,HS awareness,communication is
improved,acceptance of safe work procedures,written guide can serve as aid for training )
STAGES:(selecting the job to be analyzed,breaking down the job into series of tasks,identifying potential
hazards,determining preventive measures to overcome these hazards).TO(eliminate hazard,contain
it,revise work procedure,reduce the exposure.)EG.GRINDING CASTING AND PUTTING IN A BOX-taking
from box,push casting against grind wheel ,keep in next box.HAZARDS: drop casting on toes,cut hand on
burr,sparks dust strike hand on wheel,sleeves caught in machine,hand against metal box PREVENTIVE
MEASURE-PPE gloves and foot protection,larger guard wheel ,local exhaust system,safety goggles,fitting
sleeve,automated removal of completed stock.
METHODS:
To directly observe the worker at present doing his job,advantage doesnt rely on individual memory,and
prompts recognition of hazards,or have a group of experienced workers and supervisors complete the
analysis by discussion.adv - wider base of experience and a more ready acceptance.

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HAZOP:technique to identify hazard to people plants and environment,AIM : to simulate imagination of

designers in a systematic way so that identification of potential hazards is easy PROCESS:consider full
description of process,systematically question everything,discover deviations from the intention of the
design and identify hazards
DEFINITIONS:DESIGN INTENT(how it should operate);DEVIATION(departure from the
intention):CAUSES(reasons for the deviation):CONSEQUENCE(results of the
deviations):HAZARDS(consequences which can damage,injury):SAFEGUARDS(administrative or
engineered controls):
STEPS:select PID(R) — select study node and identify on PID(R)- define design intent-select process
parameter(R)-guide word describing deviation(R) - identify and record cause and then consequence-
evaluate and record severity of consequence-record risk level-identify and record recommendation for
preventing consequency
(R)— repeat for all of the last r and then go upwards
EG. Columns - guide word and then definitions — heat exchanger organic side flow

HIGH PRESSURE OPERATION:HAZARDS(impact from blast,from release of high P steam,from failed

equipment parts,fire from explosion or flammable liquids.)causes of failure - inadequate design or
material,defective manufacture,poor installation,corrosion,improper operation,envmt
factors.TYPES:(boiler,piping,compressed air,pressure gauges,valves,steam traps,heat
exchangers)PROTECTION:(SAFETY RELIEF VALVES(pressure at which relief starts - set point,MAWP -
design pressure for a given temp,OPERATING PRESSURE-10% of MAWP,ACCUMULATION:pressure
increase over mawp,OVER PRESSURE - pressure increase over set P);RUPTURE DISC(will break and allow
vessel to have positive pressure,relieve excess pressure);FUSIBLE PLUG)
PRECAUTIONS:pressure gauge like bourdon - free of air,good earthing,rupture discs must be checked
regularly might harden,2 safety valves one at very low P for high P system,High P equipment in confined
system with thick walls,fired vessels shouldnt be emptied suddenly,venting height must be
sufficient,have more than one person working,dnt allow mixing,pressure joints must not be
tightened,oils should never be used as lubricant.leaks repaired quickly.use of SITEC components cos
reliable overtime
High T:use of Ni Co alloys ,increased danger of corrosion.Low T:brittle fracture possible prevent by
increase Ni
Cycling Pressure-reduce material strength after 106-107 cycles.use autofrettage or shrunk cylinders to
increase life by 80-150%

DANGEROUS AND TOXIC CHEMICALS:threshold,LPG -25 tonne Benzidine-25 kg,

Hazardous materials classification diagram red-fire yellow - instability blue- health white- specific
PROTECTIVE MEASURES:hazardous processes segregated,ventilation adequate,local exhaust
needed,enclosed space to prevent contamination of air,house keeping maintained,PPE,Protective
clothing

HIGHLY RADIOACTIVE MATERIALS:neutron,proton,electron when moving very fast with kinetic energy
is known as radiation. EMR:radiation with visible light,x rays,gamma rays,alpha rays
etc.RADIOACTIVITY:very heavy substances occurring not stable,atoms disintegrate and change
themselves into some other elements IMPACTS:skin is liable to develop fatal cancer after
irradiation,lens of eyes damaged by neutrin,UV radiation causes skin darkening,erythema reddening of
eyes,Ultra sound - cell disruption,tissue heating,retardation of cell growth.IR causes heating up of body
PREVENTION:time,decay,distance,shielding judicious use to reduce exposure

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 Safety

SAFE HANDLING OF MATERIALS:

POTENTIAL HAZARDS:strains and sprains from lifting loads improperly or from carrying loads that are
either too large or too heavy, fractures and bruises by caught in pinch points,cuts and bruises cosd by
falling materials due to cutting ties or improper storage PERSONAL PE:write stuff PRECAUTION:
MANUAL(attach handles to loads,PPE)MECHANICAL(center load on forks as close to mast and minimize
truck tipping potential,adjust load to lowest position when traveling,avoid overloading,no extra weight
on rear of a counter balanced forklift.
SAFETY FOR SLINGS:remove damaged slings,no knots to shorten slings,do not kink sling and load slings
over capacity,no shock loading or sudden accelaration
SAFETY FOR OPERATING CONVEYORS-install emergency button to stop,emergency stop cables accessed
from other location,prevent employees riding on material conveyor,guards near conveyors to prevent
accidents,Inspect and restart after overload
OPERATING CRANES:adjustable boom with angle indicator,telescopes to determine boom length to find
load rating,load rating charts on cranes,chains and ropes free of ink,train all workers to attach load to
slings,pad sharp edges,maintain proper sling angles

EMERGENCY PLANNING:accident that has potential to cause serious injury,property damage and affect
environment.
APPLICABILITY:occupier of a hazardous factory,factory with chemicals,hazardous subs
OBJECTIVES:contain and control accident,rescue and treatment of casualty,safe guard
people,rehabilitate area affected,preserve record,provide information to media and govt.
ESSENTIALS:assessment of size and nature and probability of occurrence,appointment of key personnel
and defining duties,provision for emergency control center,procedure for alarm and communication.

ONSITE:major emergency within battery limits.KEY PERSONNEL:WORK INCIDENT CONTROLLER:(takes

full charge of situation — assess situation ,decide,direct rescue and fire fighting at site,coordinate with
emergency services,preserve evidence for enquiry,communication with control center,search for
casualitites and arrange proper aid)
WORK MAIN CONTROLLER:(directing action from control centre,direct shutting down of plant,control
traffic,ensure treatment,rehabilitation efforts,communication with media);SENIOR MANAGER,Trained
first aid,operators,emergency staff,public relations,roll call leaders,traffic controllers.running
messengers.

OFFSITE EMERGENCY:emergency outside battery , local administration ,factory administration provides

plan,.ESSENTIALS:clear org structure,command structure,efficient communication,availability of
specialist,plans for evacuation,safe routes,system to inform public and media,list of available
equipments.DISTRICT MAGISTRATE,POLICE DEPT,REVENUE DEPT,MUNICIPALITY,GRAM
PANCHAYAT,PRESS AND MEDIA,TELEHON FACTORY ELECTRICITY EXPLOSIVE POLLUTION CONTRLOL
DEPT.

PLANT LAYOUT:arrangement of machines within a factory OBJECTIVES:minimum utilization,lighting and

ventilation,space for future,better working,neatness.ESSENTIALS:segregation of hazardous
proces,ventilation and lighting,provision of separate location for furnaces,separate are for
flammable,hazardous

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UNIT -1 INTRODUCTION TO SAFETY

PROGRAMMES
Safety in industries; need for development; importance safety consciousness in Indian chemical
industry; social environmental setup; tolerance limit of the society; psychological attitude towards
safety programmes. Elements of safety programme; effective realization; economic and social benefits;
effective communication training at various levels of production and operation

SAFETY IN INDUSTRIES AND IMPORTANCE:

Safety-state of being safe(protected against physical social spiritual financial political emotional
occupational psychological educational consequences like failure damage,error accidents harm —
anything undesirable)(control of recognized hazards to achieve acceptable level of risk.being protected
from event or from exposure to something that causes health or economical losses.protection of people
or possession.chem industry important part of world economy,produce important products like
antibiotics,cement,drugs,gasoline,paper,explosives,plastics,fertilizer,food etc.industries handle
hazardous material and large amounts of energy,best safety recors of all manufacturing sectors but
when something goes wrong the effect can be catastrophic-accidents are result of unexpected
interaction bet automation and manual labour and other such causes,process facilities use automation
and use instrumentation,logic controllers to improve safety and reliability,to increase energy efficiency
and reduce pollution,various pieces are connected nd make process more complex therby leading to
many potential errors.if the disruptions in process arent under control of operators or the system a
severe accident can occur leading to disasters
ROLE OF HUMAN ENGINEERING:
Accidental losses greater than natural losses, and mostly from lower age group,most accidents can be
attributed to workers in places dat havent been mechanized,men work at all equipments and process
jobs vary bet steel mills,industries,refineries,building etc and they are exposed to hazards like - name all
.to combat this along with preexisting safety programmes new discipline called dis.reduce accidents by
relating mechanical design to biological and psychological characteristics.,machine designed from
outside considering instrument and controls as appendages,machine and buildings built around
operators rather than other way.cos it is unfair to blame workers for accidents.this should reduce
accidents and training costs reduced.

SOCIO ENVIRONMENTAL SETUP :

Most of envt problems avoided if industries located on basis of envt conditions.placement can affect
flora,air,water and such of a habitat.present factors for location are raw material availability,transport
facilities,techno economic considerations.change dis.INDUSTRIAL LICENSING PROCEDURE states
entreprenuers should get clearance from air,water pollution control boards,all quality stds should be
checked with
Detailed envt impact analysis for industries (altering landscape ,manufacture,handling of hazardous
materials.sited near ecologically sensitive area,cumulative envt damage)
CONDITIONS FOR CLEARANCE:site should have approval from state director of industry,commitment by
entrepreneur that he will install and implement all necessary safety conditions precautions,coastal areas
.5 km from tide line,25km from ecological or sensitive area depending on geo climatic conditions.,.5 km

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 Safety

from flood plain-affected by dam in upstream or by food control system.Transport or communication .5

from highway and railway.

TOLERANCE LIMIT OF SOCIETY:

GI TRACT:(food or drink is usual mech of exposure.airborne particles in mucous of upper respiratory

tract)SKIN(most chemicals not absorbed readily some are very permeable,Phenol.leading to
death)Respiratory system:(function transfer O and CO2 to blood and inhaled air.250 ml O and 200 ml
CO2 /min.
TOXICS eliminated by(EXCRETION- kidney,lungs,liver/DETOXIFICATION-changing chemicals to something
less harmful/STORAGE-in fatty tissue/liver is most dominant
RESPONSE TO TOXICS:IRREVERSIBLE :(CARCINOGEN(cancer):MUTAGENE(chromosome
damage):REPRODUCTIVE HAZARD(damage to reproductive system):TERATOGEN(birth defect);
REVERSIBLE:(DERMATOXIC()HEMOTOXIC()NEPHROTOXIC(kidney)NEUTROTOXIC(nervous
system)PULMONOTOXIC())

THRESHOLD LIMIT VALUES:lowest value on response vs dose curve,below this detox and elimination
can be done without damage

ERGONOMICS;applies information about human behaviour,abilities and limitations,such characteristics

to design of tools,machines,jobs,tasks and envt for productive ,safe comfortable and effective human
use.goal at industry is to take into account as many people as possible and have understanding
ergonomics of posture and movement which is important for safe,healthy comfortable
work.PRINCIPLES:activities should permit worker to adopt many different safe and healthy
postures,muscle work should be done by largest appropriate muscle groups available,performed by
joints at about mid point of ROM

NEEDS:exposure during manual handling is bad,by improving fit this can be

avoided:IMPROVEMENTS:(reducing preventing injuries,decreasing effors,reduce risk factors for
disorders,increase productivity ,product,service quality,lowering costs by reducing or eliminating
production bottlenecks,medical services.

ROUTES OF EXPOSURE:

SKIN:(absorption)-redness dermatitis,innocuous,more severe as destruction of skin tissue or other

stuff,chemicals can cross skin barrier cause system damage to organs and eye,short exposure can cos
diseases.
INGESTION:chemicals in GI harm if they are corrosive irritating,insoluble fluids are excreted,transported
by blood to other organs ,absorbed by linings
INJECTION:enter body through skin penetration or punctured,effects thru blood,chemicals are
metabolized or stored or excreted.some excreted fast some take lifelong

DOSE-RESPONSE RELATION:given amount of toxin will give a intensity response ,basis of measurement
of harmfulness of a chemical,it is a consistent mathematical and biological connection between dose
and response of an individual

TOXICITY:ACUTE(occurs immediately,short latency,high exposure,minor or severe,small NH3 irritation

more death,knowledge based on human exposure,general relation)CHRONIC(occurs over time,long

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latency,low exposure,involves inflammation and scarring of organs,chronic effects unknown,knowledge

from animal,difficult to establish relationship)

PSYCHOLOGICAL ATTITUDE TOWARDS SAFETY:(different disciples tackle safety differently but all focus
on frequency and severity,psychologists focus on individual traditional approaches,Hygienist views
disease as a conseq of recurring events,safety eng see it as result of acts with conseq,1988 cooper
described Domino effect saying influence of management in accident,xplain leads to unsafe acts.
APPROACHES:PERSONAL SELECTION(selection based on possession of desirable
characteristics)PERSONAL TRAINING APPROACH(train people in necessary skills,attitrude)ERGONOMIC
WORK DESIGN APPROACH(modifying work place to match abilities)ENGINEER APPROACH(modifying
tools,equipment and machinery,machines must aid human and give belief in training,human
engg)BEHAVIOUR APPROACH(effectiveness of psyclogical factors must be understood,human errors are
very high and this is a reason,goal of safety programme is to make employees be receptive of training
and adopt safety,)

ELEMENTS OF SAFETY PROGRAMME:

HAZARD,RECOGNITION,Evaluation,Control:proactive hazard recognition,JHA,Std operating procedures

as a product as per Hygiene plan,elimination/substitution controls PPE administrative controls in that
order against hazards
Workplace design and engineering:dsigning in safety,many fail in this,building code controls some other
like ergonomics ,ventilation tc of
Safety performance management :accountability for meeting stds and regulatory requirements and
performance should reflect reality
Regulatory compliance management:animal care facilities must meet OSHA,EPA,DOT
accreditions,mechanisms for regular compliance important,keep up to date and self assessment is a
good tool,non compliance leads to fine,reputaion loss etc,
Occupational health:OSH varies per company,medical surveillance,prejob health check,injury
protocols,data and record maintenance
Information Collection:lifeblood of proper decision making,management of info like analyze,distribute
act on
Employee involvement:in all aspects of HS,more and different input by them,better coms
Motivation,behaviour,attitudes:change behaviour and attitude,reinforcement of desired
behaviour,value on leadership and support changing unsafe ehaviours,attitudes etc
Training and orientation:classroom to hands on,critical that employees know how to perform their job
Envmt management:overlap of details,under HS,very broad,proper permitting to preventing liability
Organizational communication;coms very important and keeps everyone from low to high level
updated,flow of info is critical for effective HS,avenues from front line to upper management in
devlopment,revision of laws
Mgment Control of external exposures:emergency planning,plans for natural or man made accidents
Workplace planning and staffing:effective HR mgmt is crucial,development of accurate job descriptions
and pre employment checking,limit exposure by administrative controls and develop rules
Assessments,audits and evaluations:final tools,to monitor compliance,behaviours,springboard for
improvement,performed by in house staff,commitees

EFFECTIVE REALIZATION OF SAFETY PROGRAM:(design of workplace safety consistent with org

needs,commitment by board and management,ADA considerations built in to workplace,safety issues
relative to size and arrangement and physical demands of tasks and design of tools addressed ,sufficient

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 Safety

time and resources,all employees can activate emergency response,employees and volunteers are
trained ,employees involved in policy making,Orgs HS posted for all to see,management understand
importance of safety,

EFFECTIVE COMMUNICATION TRAINING AT VARIOUS LEVELS OF PRODUCTION AND OPERATION:

Effective communication if employees are involved in discussion,narration and
exhibition,meetings.suggestions welcome and analyzed,prompt action and delays explained ,rewards
are given for good and reasonable suggestions,safety quiz,questionnaire for employees are tested
periodically for knowledge and skill,give example questions.,questions put on display at right place
where safety gadget mentioned of utmost importance-acid storage and handling.

SOCIAL AND ECONOMIC BENEFITS:SYSTEM VIEW AND EFFICIENCY APPROACH,COST REDUCING,COST OF

ILLNESS ANALYSIS,COST EFFECTIVE ANALYSIS,MICRO APPROACHES,MANAGEMENT CONTROL,FINANCIAL
APPRAISAL,VALUE BASED HEALTH PROMOTION,SAVE LEGAL AND
INSURANCE,REPUTATION,PRODUCTIVITY,RETAIN STAFF,REDUCE ABSENCES,PROTECT
STAFF,CALCULATION MODELS:Productivity(product of lost hours and value of a productive hr -
productivity gap)Potential(input output based,compares 2 affairs and gives financial benefit,annually)

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