Industrial Safety & Hazards

By
A.Gnana Visuvasam
01/18/18The Master Trainer 1

In this session, you will be able
 To understand the importance of safety in an industry.
 To identify different kinds of hazards.
 To familiarize with OSHA .
 To identify various PPE’s.
 To prevent accidents by controlling risk.

 Safety is the state of being "safe" , the condition of being
protected from harm or other non-desirable outcomes.
 Safety can also refer to the control of recognized hazards
in order to achieve an acceptable level of risk.
 Easy way to define a safety is free from accident or “zero
accident”
 Industrial safety refers to reduce the risk of injury or loss
and danger to persons, property from the industrial
hazards.

 To prevent accidents in the plant by reducing the hazard to
minimum.
 To eliminate accident caused work stoppage and lost production.
 To achieve lower workmen’s compensation, insurance rates and
reduce all other direct and indirect costs of accidents.
 To prevent loss of life, permanent disability and loss of income of
worker by eliminating causes of accidents.
 To evaluate employee’s morale by promoting safe work place and
good working condition.
 To educate all members of the organization in continuous state of
safety mindless and to make supervision competent and intensely
safety minded.

 “An accident is an unplanned &
uncontrolled event which causes
or is likely to cause an injury”.
It is some thing which un-expected
, un-predictable or intended or not
desired.
An accidents may cause a result of
some unsafe activity, act, working
condition etc ,…..

 Accidents do not happen, They are CAUSED
 Accidents are PREVENTATIVE
 Accidents happen due to UNSAFE ACTS
and / or UNSAFE CONDITIONS
 Accidents happen due to NEGATIVE
ATTITUDE towards safety practices

No, it is not Hazardous…..
If you are Safety Conscious
If you follow Safety Rules
If you are Alert when you work
Yes, it can be Hazardous……
If you are Careless
If you are indifferent to Safety Rules
If you are Absent Minded when you work

Loss of income
Loss of efficiency
Loss of money on medical expenses
Loss of family pleasures
Upset of future plans
Mental agony
Loss of production
Delay in completion of job
Loss of money
Loss of good employee
Loss of profits
Loss of goodwill
• Loss of good worker or efficiency
• Loss of effectiveness of the section
• Loss of time due to the shade and
diverted attention
• Damage to machines and equipment
• Loss because of sausage
• Loss of time for report writing
• Loss of productivity
• Loss of production
• Effect on progress
• Loss of image
• Loss of wealth
To Employee
To the Section
To Organization
To Nation

1. Do not wear loose fitting garments as they can
easily get caught in a moving of the machine wear
prescribed uniform and shoes.
2. Long and unruly hair is dangerous particularly
while working near the revolving parts of the
machine.
3. Never wear a ring, bracelet or a watch while
working, as they caught in a moving pat and
injure you or it may even drag your finger or hand
into machine.
4. Wear approved safety goggles or face shields
particularly when you are working on a job which
procedures flying chips or sparks.

5 Use personal protection equipment and safety
devices as required.
6 Do not play with swarf. The hot sharp chips may
burn or injure your hand.
7 Never run inside a workshop.
8 While walking watch your steps.
9 Do not walk or work under suspended loads.
10 Be watchful of blind corners. You may get caught
in the wrong way.
11 Do not carry too many tools or instruments at a
time.
RIGHT WORK PRACTICES TO PREVENTRIGHT WORK PRACTICES TO PREVENT
ACCIDENTSACCIDENTS

1. Do not operate any machine until you are authorized.
2. Fully understand the operations, controls and safety
aspects of the machine before operating
3. Know how to stop the machine before you start it.
4. Ensure that all controls of the machine are accessible
to you.
5. Ensure that all safety guards are in position.
6. Do not meddle with the limit switches.
7. Keep the machine clean-Don’t clean it with bare hands.
Use cloth, cotton waste or brush as per requirement.

8. Lubricate the machine as recommended.
9. Stop the machine while cleaning or oiling.
10. Do not operate the machine at unsafe
speeds, feeds and depth of cut.
11. Do not attempt to change the speed, feeds when the
machine is in motion unless designed for it.
12. Do not try to set the machine, job or take measurements
of a job while the machine parts or job is in motion.
13. Do not lean on the machine.
14. Switch off the machine immediately if any thing goes
wrong.

 Do not day dream
 Be alert and mind your jobBe alert and mind your job
 Be calm and patient while working
 A disturbed mind will invite troubleA disturbed mind will invite trouble
 Haste makes waste.Haste makes waste.
 Do not divert the attention of others or do not get yourself diverted by others while
working
 Do not be over confident
 It may even lead to major accidentsIt may even lead to major accidents
 Avoid horse playing / monkeying
 It is always dangerousIt is always dangerous
 Do not direct compressed air at your work mates or at your self.
 It can killIt can kill

1. Poor illumination
2. Poor Ventilation
3. Poor House Keeping
4. Hazardous storage
5. Congestion of Material and Equipment
6. Too Narrow passages

7. Material Projection
8. Unsafe Equipment defects
9. Inadequate safety devices
10. Inadequate warming system
11. Hazardous atmospheric conditions
12. Fire and explosion Hazards
13. Hazardous personal attire

1. Golden rule – No movement or minimum movement
2. While handling thin sheets and plates – be cautions to
prevent cuts
3. While handling rough jobs – wear gloves
4. While handling hot material – wear asbestos gloves
5. While moving metal turnings – Don’t spill
6. While handling materials take care to see that the limbs
are not caught or trapped
7. Give proper padding to ropes to prevent sharp edges
cutting the ropes while hoisting.

8. Balance the load.
9. Don’t lift load too high or too low
10. While handling long bars, keep the bars parallel
to the passage.
11. Regularly check and maintain all material
handling equipment
12. Take proper care of al slinging gadgets like
hooks, eye bolts, rods while using.
13. Ensure that the load carrying capacity is safe
enough before using the equipment

1. Plan to have a place for every tool, appliance and materials.
AN ORDERLY SHOP IS LESS HAZARDOUS TO WORKAN ORDERLY SHOP IS LESS HAZARDOUS TO WORK
2. Pay attention to the maintenance of equipment
3. Train employees to ensure that they keep their work place orderly and neatly.
4. Develop a habit in employees to keep the instruments, gages and tools in an
orderly manner.
5. Ensure that floors and passages are clean and dry.
6. A good house keeping and clean atmosphere makes employees happy and
promote a desire to turn out a quality job.
7. Good house keeping is the personal responsibility of every supervisor.
8. Every supervisor should be proud of making his section a better place to work.
CLEANLINESS IS NEXT TO GODLINESS.CLEANLINESS IS NEXT TO GODLINESS.

 Hazard is a term associated with a substance, That is
likely to cause injury to a personnel,
(or)
 One which may lead to loss of property, products etc;
(or)
 A substance that might prove fatal to the personnel.

 Hazard is any source of potential damage, harm or
adverse health effects on something or someone under
certain conditions at work.
 Risk is the chance or probability that a person will be
harmed or experience an adverse health effect if
exposed to a hazard.
R = f (H x E) = f (H x D x t)
Where R=Risk, f=function, H=Hazard, E= Exposure ,D=Dose,
t=time.

 Hazards may be in different form in different
kind of industries.
 For example:
Food Manufacturing Industries,
Pharmaceutical Industries, chemical Industries,
Mining Industries and Automobile
manufacturing Industries may have different
forms of hazards.
But these all industries have some common kind
of hazards.

 Fire hazards
 Mechanical hazards
 Electrical hazards
 Chemical hazards
 Biological hazards

 Fire is an exothermic chemical reaction
between oxygen and fuel.
Combustion
 Slow combustion eg: cotton waste burning
 Rapid combustion eg: petroleum product
 Spontaneous combustion eg: paint, scrap

Classification of Fire:Classification of Fire:
1. Class A fires:- Fires that occur in ordinary material such as
wood, paper rages, rubber and rubbish.
2. Class B fires:- With flammable material like oil, paint,
gasoline etc…….
3. Class C fires:- With gases and vapours .
4. Class D fires:- With combustible metals such as
magnesium, titanium, lithium, sodium etc….
5. Class E fires:- Involved electricity in any form..

NFPA Classification system:NFPA Classification system:
The NFPA diamond is an easy way to determine the
safety risks associated with hazardous materials.
According to the red section of the diamond, The
following numbering system is used to indicate
flammability
 0 - will not burn
 1 - must be preheated to burn
 2 -ignites when moderately heated
 3 -ignites at normal temperature
 4 -extremely flammable

Sources of Fire Hazards:Sources of Fire Hazards:
 Hot surfaces
 Combustible and flammable liquids
 Heat utilization equipment's (over heating)
 Chemical process equipment's
 Lightening
 Gas cylinders
 Ovens and furnaces
 Reactor
 Welding and cutting
 Spark from metal to metal contact
Carelessness

Causes of Fire Hazards:Causes of Fire Hazards:
1. Improper storage of flammable oils, greases and
fluids, combustible wastes etc.
2. Smoking by employees.
3. Poor house keeping.
4. Defective heating equipment, electrical equipment
and wiring.
5. Explosive gas leakage.
6. Ignition of gases, vapours or combustible dusts.
7. Inadequate protection of electric motors.
8. Sparking in electric wires and equipment.

Protection and prevention of Fire Hazards:Protection and prevention of Fire Hazards:
1)Prohibition of smoking in manufacturing area
2) Oxygen present in a flammable atmosphere may be
reduced by dilution with gases as nitrogen, carbon dioxide,
steam or combination of these inerts in exhaust gases from
fuels, automobile engines and jet engines.
3)Operating outside the range of flammability.
4) Eliminating the ignition sources:
a) Flames such as burner flames, matches& cigarette
lighters & heaters.
b) Hot surface such as heated wires, rods or
fragments

Protection and prevention of Fire Hazards:Protection and prevention of Fire Hazards:
5. Installation of combustible gas indicators.
6. Adequate ventilation facility.
7. Fire alarms & fire fighting equipment or fire extinguishers
to be installed in factory at suitable location.
8. Provide automatic sprinkles with adequate & reliable
water supply.
9. Proper storage of combustible materials & removal of
waste materials.

Detection of Fire Hazards:
Many automatic fire detection systems are used today in
industry.
Some include
 Thermal expansion detectors,
 Heat sensitive insulation,
 Photoelectric fires,
 Ionization or radiation sensors and
 Ultraviolet or I .R detectors.
These sound an alarm through which fire flames are detected.

Halotron 1 Fire extiguisher
Non-Magnetic stored pressure
deionized water mist fire
extinguisher
ABC Dry chemical fire
extinguisher
Carbon dioxide (CO2)
Portable fire extinguisher
K Class Wet chemical
extinguisher.
Spinkler systems

Pull the pin.
Aim the hose
or nozzle.
Squeeze the lever.
Sweep the
agent.

Exists in the form of gases, dust, corrosives, vapor and
liquids. These chemicals can become dangerous to
persons, when inhaled or absorbed through the skin.
Can cause breathing problems, skin irritation or burns.
To protect workers from chemical hazards, employers
need to supply their employees with protective clothing.

 These are associated with powers-driven machine, whether
automated or manually operated by steam, hydraulic and/or electric
power introduced new hazards into work place.
 Mechanical hazards are exacerbated by the large number and
different designs of equipment, crowded work place conditions and
different interaction between workers and equipment.
 Hazardous electrical and pneumatic thermal energy must be released
or controlled before working on active equipment.
 High sound levels may be generated by manufacturing equipment
there by increasing their exposure to noise.
 Injuries like cutting, tearing, shearing, puncturing and crushing may
occur with moving machinery.

Mechanical hazards can be reduced by the application of appropriate safeguards.
REQUIREMENTS OF SAFEGUARDS
 Prevent contact
 Securable and durable
 Protect against falling objects
 Do not create new hazard
 Do not create interference
 Allow safe maintenance.
TYPES OF SAFEGUARDS
 Point of operation guards-Fixed guards, interlocked guards and
adjustable guards.
 Feeding/ ejection method

FIXED GUARDS
 It provide a permanent barrier between workers and
point of operation.
INTERLOCKED GUARDS
 They shut down the machine when the guard is not
securely in place
ADVANTAGES
 Allow safe access for removing jams or for maintenance
ADJUSTABLE GUARDS
 They provide a barrier against a variety of different
hazards

FEEDING AND EJECTION SYSTEMS
 Automatic feed systems feed the stocks to the machine from rolls. It
eliminate the need of operators to enter the danger zone
 Advantages of this is the operators do not reach in to the danger zone to
retrieve work pieces
LOCKOUT/ TAGOUT SYSTEMS
 It is a method that was especially designed to protect against unexpected
startup of a machine
 In the lockout system a padlock is placed through a gate covering
 The lock usually has the label that gives the name, department and
telephone extension of a person. The lock is removed only by the person

 All the operator should be trained in the safe operation and
maintenance of their machine.
 All machine operators should be trained in the emergency
procedures to take when accident occur.
 All employee should know how to activate emergency shut
down controls.
 Inspection, maintenance, adjustment, repair and calibration of
safe guards should be carried out regularly.
 Supervisors should ensure the safe guards and properly in
place when machine are in use.
 Short-cuts that violate safety principle and practice should be
avoided.

 Electric shock
 Amputation
 Eye injuries
 Hearing loss
 Puncture wounds
 Cuts and abrasions

Contusions/crushing
 Burns

 A shock is caused by electrical current passing
through human body. The quantity and path of
this current determines the level of damage.
 The electrical hazards occurs when a person
makes contact with a conductor carrying a
current and simultaneously contacts the ground.

 Contact with a base wire carrying current.
 Working with electrical equipment that lacks the label for
safety inspection.
 Electrical equipment that has not been properly
grounded.
 Working with electrical equipment on damp floors.
 Using metal ladders to work on electrical equipment.
 Lighting strikes.
 Working on electrical equipment without ensuring that
the power has been shut off.

Improper wiring:
 One common mistake is to jump the ground wire to the
neutral wire.
 If the neutral circuit becomes corroded or loose, the
voltage on the ground wire increases to a dangerous level.
Insulation failure:
 The degradation of insulation can cause a base wire and
resulting shock to anyone coming in contact
 It is caused by environments toxics like
Direct sunlight
Sparks
Repeated exposure to elevated temperature

 Ensure that power has been disconnected from the system
before working with it. Capacitors can store current after power
has been shut off.
 Allow only fully authorized and trained people to work.
 Do not wear conductive materials such as metal jewelry.
 Periodically inspect insulation.
 If working on a hot circuit, use the buddy system and wear
protective clothing.
 Do not use a fuse with a greater capacity than was prescribed.
 Verify circuit voltage before performing work.
 Do not use water to put on electrical fire.
 Discharge capacitors before working on the equipment.
 Use fuses and circuit breakers for protection against excessive
current.

Disease due to biological hazards:
Brucellosis (dairy industry)
Byssinosis (textile industry)
Bagassosis (sugar-cane)
Loco motor disorder
Preventive measures
 Periodic health check up
 Personal protection
 The manufacturer should also provide
 First aid facilities
 Initial examination
 Facility for vaccination
 Routine sanitation programme

 OSHA stands for the Occupational Safety and
Health Administration.
 It is a governmental safety organization that is
responsible to reduce work related injuries

RED – Signals
danger,
emergency, and
fire equipment.

ORANGE – used
to indicate
safety guards
and machine
pinch points.

YELLOW – marks
walkways, railings
trip hazards and
machine
clearance areas.

WHITE – waste,
cleanup and
storage areas.

GREEN – Safety
equipment like
protective eyewear
and first aid
stations.

BLUE –
informational
and out of order
signs.

Fire Protection
Portable
Containers
Emergency
Stop Buttons
and Switches

Waste
Containers
Caution against
Starting, Using,
or Moving
Equipment that
Needs Repair
Identifying
Power Sources
Marking Hazard
Zones

Caution against Starting,Caution against Starting,
Using, or MovingUsing, or Moving
Equipment that NeedsEquipment that Needs
RepairRepair
Identifying PowerIdentifying Power
SourcesSources
Marking Hazard ZonesMarking Hazard Zones
(Orange is slowly being(Orange is slowly being
phased to yellow- but ifphased to yellow- but if
your shop still uses it, ityour shop still uses it, it
is important to know)is important to know)

- Safe
- Proceed or Go
- Location of First-
aid and Safety
Equipment

Right to know and chemical hazards
PPE, first-aid, and spills/leaks
Labels and MSDS

 OSHA created the Hazard Communication
Standard to help ensure your safety when
working with hazardous chemicals.
 You have a RIGHT TO KNOW about the
hazardous chemicals you use on the job and
how to work safely with those chemicals.

Chemical manufacturers must:
 Determine a chemical’s hazards
 Provide labels and MSDSs
Employers must:
 Provide a hazard communication program
 Maintain MSDSs
 Train on hazardous materials

Employees must:
 Read labels and MSDSs
 Follow employer instructions and warnings
 Identify hazards before starting a job
 Participate in training

Physical Hazards:
 Flammable
 Explosive
 Reactive
Health Hazards:
 Corrosive
 Toxic

 Skin and eye contact
 Inhalation
 Swallowing
 Penetration (skin absorption)

 Eyes: Flush with water for 15 minutes
 Skin: Wash with soap and water
 Inhalation: Move to fresh air
 Swallowing: Get emergency medical assistance

 Evacuate the area
 Notify a supervisor or the emergency response
team
 Remove ignition sources (if safe to do so)
 Stay away

 The identity of the chemical
 Name, address, emergency
phone number of manufacturer
 Physical and health hazards
 Special handling instructions
 Basic PPE recommendations
 First aid, fire response, spill
cleanup

NFPA = National Fire Protection Association
 Blue = Health
 Red = Flammability
 Yellow = Reactivity
 White = Other hazards or special handling = Other
hazards or Special handling
Scale: 0 (No Hazard) to 4 (Extreme Hazard)

4-Severe, 3-Serious, 2, Dangerous
1-Minor, 0-None / Negligible
Health Hazard Fire Hazard
4 Deadly Flash Points
3 Extreme Danger 4 Below 73 F
2 Hazardous 3 Below 100F
1 Slightly Hazardous 2 Above 100 F not
0 Normal Material exceeding 200 F
1 Above 200 F
0 Will not Burn
Specific Hazard
Reactivity
ACID = acid
4 May detonate
ALK = Alkali
3 Shock & heat may
COR = Corrosive
Detonate
W = use no water
2 Violent Chemical
Change
1 Unstable, if heated
4
4
4

 Chemical and manufacturer identity
 Hazardous ingredients
 Physical and chemical characteristics
 Fire, explosion, and reactivity
 Health hazards
 Routes of entry
 Exposure levels (PEL or TLV)
 Symptoms of exposure
 First-Aid and emergency information

 Identify chemical hazards by reading labels and
MSDSs
 Follow warnings and instructions, or ask your
supervisor if in doubt
 Use the correct personal protective equipment
 Practice sensible, safe work habits
 Learn emergency procedures

1) List the work that are your responsibility
A. People
B. Equipment
C. Activity
2) Identify the risk
A. Hazard
B. Who might be harmed
C. How?

3) Estimate
A. Likelihood
B. Outcome
4)Evaluate the risk
5)Record your findings .
6)Review your findings.

Risk control hierarchy
i. Eliminate the hazard
ii. Reduce the hazard
iii.Prevent from contact
iv.Safe system of work
v. Use Personal protective equipment

 It takes a minute to write a safety rule
 It takes an hour to hold a safety meeting.
 It takes a week to plan a safety programme.
 It takes a month to put a safety programme into
operation.
 It takes a year to win a safety worker.
 it takes a second to destroy it all with one
accident.
SAFETY
A WHOLE TIME JOB

Thank You

Industrial Safety & Hazards

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