READING MATERIAL: SAFETY MANAGEMENT S.K.

Sengupta
COVERAGE: NEED FOR SAFETY, SAFETY IS A GOOD BUSINESS HUMAN ELEMENTS IN SAFETY &
LEADERSHIP , SAFETY POLICY, ACTS, BASIC CONCEPT OF RISK, MANAGEMENT OF SAFETY, STATUTORY
COMPLIANCE ,GENERAL & SPECIFIC HAZARDS FOR CO &CC AND CONTROL
NEED FOR SAFETY: #LEGAL # ECONOMICAL # SOCIAL # MORAL
PREVENTABLE ACCIDENTS, IF THEY ARE NOT PREVENTED DUE TO OUR
NEGLIGENCE, IT IS NOTHING SHORT OF A MURDER - DR. S. RADHAKRNISHNA
EHS is
# CARE FOR PEOPLE THROUGH PRENENTION OF ACCIDENT BY RISK CONTROL
# MATERIAL PREVENTION FROM DAMAGE, WASTAGE, SPILL ETC
# ENVIRONMENT Protection through control of negative impact on Air, Water , Soil & Ground water ,
Wastage of water, Carbon Footprint, Waste generation and through ECODESIGN
Achievement of those possible by Team work and participation of all in Identifying the Hazards &
Risk, Action plan for improvement, implementation of same and Review for corrective action for
continuous improvement.
ACCIDENT is an Unplanned, Uncontrolled Event or Events
CAUSES: # Unsafe Condition / Work Environment and # Unsafe Act / Tendency to Unsafe Act
RESULT: 1) Death 2) Disability- Permanent/ Temporary 3) Material Damage
Is good health & safety good business? - How Safety in business is considered by the
Progressive Organization
We recognise the importance of costing loss events as part of total safety management. Good safety
is good business- Dr. J Whiston, ICI Group SHE Manager
Safety is, without doubt, the most crucial investment we can make, and the question is not what it
costs us, but what it saves.- Robert McKee, Chairman Conoco (UK) Ltd.
We saved 750,000 on insurance premiums through improving our systematic management of health
and safety.- Birse Group plc
Prevention is not only better, but cheaper than cureProfits and safety are not in competition. On
the contrary, safety at work is good business- Basil Butler, MD British Petroleum plc
ACCIDENTS ARE COSTLY-only little is visible
COST for VICTIM including Family & Friends Suffering, Disability, Loss of Earning, Extra Wages,
Effect on Family & friends
SUPERVISOR Worry, Loss prestige Time involvement in Report Writing, Association in
investigation, Extra work for Rectification, Training new staff etc
DEPARTMENT Adverse impact on Employee Morale & Capacity to Produce, Hiring new person
ORGANIZATION Loss of earning, Compensation, Penalty, Legal Expenditure, Damage to Plant &
Equipment, Lost Client, Extra Insurance Premium
NATION Loss of Income, Loss of Morale
ONLY TIP IS VISIBLE
ICE BERGE PRESENTATION

ONLY TIP IS VISIBLE

CAUSE WISE ANALYSIS OF ACCIDENTS :

Tendency towards Unsafe Act- 80 to 88%
Unsafe Work Environment/ Condition- 18 to 10%
Natural Disaster- 2%
CRITICAL UNSAFE ACTS- Haste, Over Confidence, Over Speed, Tension, Ignorance,
Negligence, Gambling, Short cut, Annoyance, Monkey Playing
ACCIDENT PREVENTION:
CAUSES
UNSAFE ACT- Human Error > *Improper Attitud *Lack of Knowledge *Physical
UNSAFE CONDITION- Work Environment> * Machine Guard * Work Place *Plant & Equipment
*Design *Apparel
PREVENTION: *ENGINEERING *EDUCATION *ENFORCEMENT
Control of Hazards, House Keeping Safe Procedure, Personal Protective Equipment
SAFETY MANAGENT:

P0SITIVE ATTITUDE OF MANAGEMENT AND EMPLOYEES TOWARDS SAFETY

Measurement of Safety Performance
Injury Frequency Rate = Number of accident x 10000000/ Man Hours worked (Total Exposure) [ Number ]
Injury Severity Rate Man days Lost x 10000000/ Man Hours worked (Total Exposure) [ Consequence]

SKSENGUPTA

ISR ie Injury Severity Rate Reduction by

Protection Collective & Individual Personal Protective Equipment
HUMAN ELEMENT
SAFETY DIRECTLY DEPENDS ON PERFORMANCE OF PEOPLE
AND ALL THAT INFLUENCES THAT PERFORMANCE IS HUMAN FACTORS
MORE THAN 80% OF ACCIDENTS ARE DUE TO HUMAN FAILURE
BUT REPEATEDLY STRESS IS GIVEN ON PEOPLE?
BECAUSE THEY *DESIGN PLANT & EQPT. * SET UP SYSTEMS *OPERATE & MAINTAIN.
*MANAGE *THEIR ACTIONS CAN LEAD TO INJURIES & INCIDENTS
Human Behavior is guided by Social Environment Fault of Person Unsafe Act / Unsafe
Condition Accident injury
In industry an employee is to be treated with sympathetic, cooperative and positively from
day 1 to generate a positive attitude as far as practicable. With proper care injury can be
reduced both in number and consequences at all of the three stages, specially at first two
stage of the Chain

ACCIDENT ARE CAUSED NOT HAPPENED.

 MOST OF THE ACCIDENTS ARE DUE TO HUMAN ERROR

REASONS FOR HUMAN ERROR

# Lack of knowledge # Lack of Skill # Incorrect Attitude
HUMAN BEHAVIOR DEPENDS ON FULFILMENT OF NEEDS
PHYSIOLOGICAL SECURITY EGO SOCIAL
CREATE SAFE & CORRECT ATTITUDE REQUIRERS REMOVAL OF THE FOLLOWING
FACTORS
Lack of effective job training
Incompetent or untrained supervisor
Lack of policies
Display of favoritism.
Poor working condition.
Political promotions.
FOR THE CHANGE OF ATTITUDE THERE ARE SOME BEHAVIORAL FACTORS
Resentment of criticism Resistance to change
Accident liability is situational
Organization atmosphere
Working condition
Attitude of immediate supervisor
Job satisfaction
Attitude of the Unions
Statutory Aspects:
INDIAN FACTORIES ACT, 1948 & WEST BENGAL FACTORIES RULES, 1958
INDIAN ELECTRICITY ACT & RULES
INDIAN BOILER REGULATION
INDIAN EXPLOSIVE ACT
ENVIRONMENT PROTECTION ACT ETC.
Manufacture, Storage and Import of Hazardous Chemicals Rule
Hazardous Waste Handling Rules
Other LABOUR LEGISLATIONS
FACTORIES ACT- OBJECTIVES
TO SECURE SAFETY OF THE PERSONS;
TO SECURE HEALTH OF THE PERSONS FROM HAZARDOUS OCCUPATION/PROCESSES;
TO ENSURE PROTECTION FROM HAZARDOUS EQUIPMENT;
TO ENSURE SOUND WORKING ENVIRONMENT;
TO ENSURE WELFARE OF THE PERSONS;
TO PROTECT THE ENVIORNMENT;
DUTIES OF OCCUPIER:
SAFE PLANT WORK PLACE SYSTEM MAINT. ACCESS EGRESS
EFFECTIVE SUPERVISION
DUTIES OF WOREKERS:
 NOT TO ENDANGER SELF, OTHER, PROPERTY / MISUSE OR INTERFERE H S & W PRVN. / NEGLECT
USE OF APPLIANCES FOR SAFETY & HLTH
RIGHT OF WORKERS
TO OBTAIN INFORMATION ON HEALTH & SAFETY/ GET TRAINED/ REPRESENT BEFORE I.F. ON
LAPSES OF MGMT
SAFETY POLICY- To contain
` THE INTENTION AND COMMITMENT OF THE MANAGEMENT TO SECURE SAFETY, HEALTH
AND ENV. AND TO COMPLY WITH ALL RELEVANT STATUTARY REQUIREMENT.
THE ORGANISATIONAL SET UP OF THE FACTORY TO CARRY OUT THE DECLARED POLICY
CLEARLY STATING THE RESPONSIBILITY ASSIGNED AT EACH STAGE OF THE ORGANISATION.
THE ARRANGEMENTS REQUIRED FOR MAKING THE POLICY EFFECTIVE.
To Specify
Health, Safety performance of the individual
.Responsibilities of the Contractors, Sub Contractors, Suppliers, Transporters and other
agencies within the Factory.
Arrangement for training of the employees at all levels.
Intention to integrate Health and Safety in all decisions.
Inclusion of Safety and Health performance of the Factory in its Annual Report.
Should be
SIGNED BY THE OCCUPIER OF THE FACTORY AND DATED.
DISPLAYED AT THE CONSPICUOUS PLACES IN LOCAL LANGUAGE ALSO.
DISTRIBUTED AMONG THE EMPLOYEES BY MAKING COPIES.
KNOWN TO ALL INCLUDING CONTRACT WORKERS AND OTHER AGENCIES WITHIN THE
FACTORY.
SUPPORTED BY A POLICY STATEMENT AND RESPONSIBILITIES.
KEPT READILY AVAILABLE FOR PERUSAL BY THE INSPECTOR OF FACTORIES.

Role & Responsibility of

MANAGEMENT SUPERVISOR WORKER TRADE UNION GOVERNMENT

RISK = Hazards (Potential Severity) X Exposure ( Likely hood & Frequency)
ACCIDENTS ARE UNPLANNED & UNCONTROLLED EVENTS
ACCIDENTS ARE CAUSED BY ENERGY & HENCE ALL ACCIDENTS ARE CONTROLLABLE
ACCIDENTS ARE CAUSED, NOT JUST HAPPENED ALL ACCIDENTS ARE PREVETABLE
CONTROL OF ACCIDENTS IS NOTHING BUT CONTROL OF EXPOSURE TO HAZARDS SO THAT IT IS NOT
CONVERTED TO RISK
DEVIATIONS CAUSES ACCIDENT A MINOR SPILL OF OIL MAY CAUSE MAJOR ACCIDENT OF
PERMANENT DISABILITY OR EVEN FATALITY
STUDIES GIVING INDICATIONS ON PROBABILITY PLACED BELOW,
1200 Deviations may have 600 Near Miss, 30 cases of Material Damage or Environmental
Pollution, 10 cases of Minor Injuries and a Serious Accident. But in this pattern which or
when the Serious injury will occur can not be predicted. Solution therefore is to identify
the Gap, investigate the accidents, near misses and take necessary corrective actions as
far as practicable to prevent the Accident
HAZARDS IN CO & CC
ROAD HAZARDS
MECHANICAL HAZARDS- PHYSICAL INJURY DUE TO CONTACT WITH MOBILE / STATIONARY
EQUIPMENT/ STRUCTURES
WORKING AT HEIGHT/ SAME FLOOR- SLIP & TRIP, FALL FROM HEIGHT
ELECTRICAL HAZARDS- ELECTRIC SHOCK , SPARK FOR BEING CONTACT/EXPOSURE, FIRE
CHEMICAL HAZARDS- CONTACT- INFECTIOUS, CARCIOGENIC, DARMATITES, TOXIC, EXPLOSIVE/ FIRE
SPECIFIC HAZARDS
WORKING ON & AROUND POWER LINE
 WORKING IN & AROUND CONVEYORS
FIRE & EXPLOSION
TOXIC GAS EXPOSURE
MOVING EQUIPMENT
DUST & SMOKE
HEAT
When working near any conveyor:
Wear hard hat and safety shoes.
Tie back (and tuck in) long hair.
Know the location of the emergency "shut-off" devices and how to use them.
Guard pinch points on rollers and wheels and between the conveyor and receiving table.
Provide adequate guardrails along sides to prevent all objects from falling off.
Do not climb, sit, stand, walk, ride, or touch the conveyor at any time
Do not perform maintenance on conveyor until electrical, air, hydraulic, and gravity energy
sources have been locked out or blocked
Operate equipment only with all approved covers and guards in place
Do not load a stopped conveyor or overload a running conveyor
Hazardous gases in Iron Making
Following Gases either directly or as mixed as Fuel in Iron & Steel Plant
COKE OVEN GAS
BLAST FURNACE GAS
BOF GAS
ALL OF THEM CONTAIN CO IN DIFFERENT CONCENTRATION & HENCE LETHAL
ALL OF THEM CONTAINS CO2 AT INDIFFERENT CONCENTRATION & HENCE ASPHYXIANT
THEY ARE EXPLOSIVE & HIGHLY COMBUSTIBLE
THEIR USE & REPAIR WORK THEREFORE CALLS FOR CONSIDERABLE SAFETY PRECAUTIONS &
ALERTNESS
TOXIC GAS RISK
LACK OF KNOWLEDGE/ SKILL
WORKING IN EMPTY STOMACH
NOT USING SAFETY APPLIANCES
SHUT DOWN WITH OUT PROTOCOL /CLEARANCE
USING IMPROPER TOOL

C0 AIR (PPM) DURATION EFFECT

(HRS)
50 8 None
100 <4 Tightness across forehead & slight headache
200 <2 Severe headache, dizziness, nausea
600 2 Severe headache, weakness, shortness of breath
800 2 Unconsciousness with depressed heart action and respiration
1000 2 Weak pulse , respiratory failure & death within 2 hrs.
COMMON CAUSES OF GAS POISIONING
Entering gas hazardous area without checking of gas concentration in the area.
Starting work near gas equipments without permission from operation I/C / with out proper
Protocol.
Working without gas masks in gaseous atmosphere.
Working in a gas area in empty stomach or for a very long duration.
FIRST AID
Remove the gas affected person from gassy atmosphere to fresh air
Loosen the clothing, shoes and belt. Take care of false teeth (if any).
If required , start artificial respiration
Administer oxygen and send the patient to the medical post giving oxygen on the way.
If the patient is not breathing:-
Apply artificial respiration by respirator or by mouth to mouth method
If the heart is not beating apply cardiac massage
Obtain medical assistance as quickly as possible.
Continue giving oxygen till doctors help comes.
Electrical Hazards:
While working directly with electric supply, machines or appliances using electricity, a person
may Get a *mild shock *severe shock *severe shock with burns * even die
ELECTRIC SAFETY PREVENTIVE MEASURES
Authorization & Work by Authorized persons
Proper maintenance of wiring & equipment
Metallic Frame of Electrical Equipment to be earthed. [ELB / GFCI preferred to be used]
No work on Electric equipment or maintenance work on electrical operated equipment with
out proper S/D [ preferred LOTO]
Equipment should be properly enclosed
Worker should avoid working in electric circuits or equipment in wet clothing or shoes.
Use of FLP / Intrinsically Safe Electrical Equipments
Earth & Bonding of metallic containers & pipe lines carrying Flammable Liquid/ Gas
FIRE
Following items are required for causing a Fire
FUEL OXYGEN (AIR) & IGNITION THESE FORM THE FIRE TRIANGLE
To prevent Fire all these not to come in contact. Oxygen ie Air is present at all the places . t is
present with Fuel and hence control is required for Ignition so that it does not have
uncontrolled contact with Fuel. Fire may be caused by CHEMICAL REACTION also.
Fighting Fire is therefore, removal of any one of these.
Methods are
Cooling- Removal of Heat causing the Fire to continue & spread. Best media is Water
Smothering- Reducing % of oxygen. Cutting off the supply of oxygen. (Blanketing, Use foam)
Starving- Removal of fuel or removal of combustible material