Industrial Safety

MET’s Institute of Technology- Polytechnic
Bhujbal Knowledge City, Nashik
Prof. A P Vadnere
Head of Department
Mechanical Engineering
MET’s Institute of Technology-Polytechnic, Nashik
UNIT FOUR: (Marks 14)
Safety Management
Prof. A P Vadnere, HOD-Mech. Engg., MET BKC IOT-P, Nashik

Expected Unit Outcomes
[1] State the general safety norms required to be taken in the given case.
[2] Suggest preventive measure of plant activities in the given situation.
[3] Describe the safe procedural steps required to be taken to prevent the given
type of accident.
[4] Prepare a work permit in to conduct the given maintenance activity.
[5] Explain the causes of specified type of accidents in the given situation.
[6] Prepare the specifications of the firefighting equipments require for the
given type of fire.

Introduction to Industrial Safety
• Safety is very important aspect for any industry as an accident free environment
boosts the morale of the team members working in any hazardous situations.
• Safety means “continuing and healthful living without injury”.
• Safety is free from “harm or danger of harm”.
• Safety also refers to the precautions people take to prevent accident, harm,
danger, damage loss and pollution.
• Safety also deals with improvement in working conditions for better health.
• Similarly, all hazards, i.e. source/situation capable of injury or ill health,

damage to property or workplace environment etc., should be identified and
action plan drawn for safeguard against them.

Need of Safety in Industry
• All industries have different type of tools, equipment and machinery.
• There is always a risk of hazard while operating machines.

• They may be physical, biological, psychological, electrical, etc.
• It is crucial for all employees to be aware of the risk of hazards associated with
the industry they work in.
• While handling tools and machines, employees should follow safety instructions.
• Specialized training must be given to the employees to prevent injuries from
these hazards. ;

Need for Safety Management System (SMS)
A Safety Management System (SMS) is a continuous improvement process that
reduces hazards and prevents incidents.
• SMS protects the health and safety of employees and should be integrated into
everyday processes throughout the organization.
• SMS is a comprehensive management system designed to manage safety

elements in the workplace.
• The SMS is used in industries that manage significant safety risks, including
aviation, petroleum, chemical, electricity generation and others.
SMS includes;
Policy Objective Plans Procedures
Organization Responsibility

The Evolution of Safety Thinking

Causes of Accidents

Need for Safety Management System (SMS)
• Workplace safety is so important for every industry because workers desire to work
in a safe and well protected environment.
• Industrial Safety reduces risks to people, and processes.
• SMS ensure better working environment for employee and place employees in jobs
suitable to their work restrictions.
• SMS using software system helps to record, manage and analyze safety related data,
enhance communication and sharing of appropriate data among supervisors,
managers and medical staff.
• SMS ensures centralized compliances from all locations to avoid accidents.
• SMS make standardization and automates the safety investigation process.
Industrial safety is important as it safeguards human life, especially in high risk areas such
as nuclear, aircraft, chemical, oil and gases, and mining industries, where a fatal mistake can
be catastrophic.

Types of Hazards
• There is always a threat of hazards and risks to the health and safety of people at
workplace. These may be;
Chemical hazards
Physical hazards
Psychological risks
Allergies
Adverse ergonomic conditions

Physical Hazards
• They often affect many workers in the workplace, E.g. occupational hearing loss,
postural defects, falls, accidents, etc.
• Hearing loss is one of the most common problems in a manufacturing unit with heavy
noise-making machines like the sewing machining or a cutter; postural defects like
cervical and bone shape change can occur if a person needs to sit or stand in a particular
position all the time.
• Accidents and falls are also a common cause of occupational injuries and deaths in
industries, like transportation, construction, extraction, healthcare, building, cleaning and
maintenance.

Problems associated with Physical Hazards
S.N. Problems
➢ Chest infection, allergies, flu, etc., caused due to excessive dust.
(a)
➢ Adequate ventilation, exhaust fans, etc. are helpful to make the environment
clean and dust-free.
A low light environment for working, and shortage of eye protective glasses, which
(b) can cause eye problems.
➢ Prolonged sitting, and continuous needle work involving the eye, creates eye
(c) problems (strained eyes) and back bone problems for the embroidery workers.
➢ Repetitive Strain Injury (RSI) is likely to occur at an embroidery workplace due
to long hours of sitting to complete the embroidery work.
➢ Problems like backache, stiffening of neck, cervical and wrist joint problems can
also occur during embroidery.

Remedies for Problems associated with Physical Hazards
S.N. Remedies
(a) Use a hoop stand, embroidery frame to keep both of the hands free to focus.
(b) Keep the stand on a height till bust level and straight wrist position to avoid bending
your neck and back for long time.
(c) Use wrist rests to avoid strain in the hand and wrist joint.
(d) Take short breaks from long sittings, may be after an hour or two, to relax the strain
in the back.

Fire Hazards
• They are common in those industries that use a lot of flammable material, like cotton,
chemicals, etc.
• Fire hazards occur mainly due to the following reasons:
S.N. Causes of Fire Hazards

(a) Improper working of fire and smoke alarm bells in industries
(b) Absence of fire and smoke alarm systems in many industries
(c) Improper maintenance of fire exits or emergency staircase
(d) Lack of proper exit route or emergency staircase to reach the place of safety
Every industry should keep fire extinguishers as a safety measure.

Biological Hazards
• These involve contagious bacteria, viruses and toxins.
• It can be due to non-airy and dark rooms, suffocation (bad ventilation), and unhygienic
conditions of washrooms.
• E.g. influenza affects a broad population of workers.
• Outdoor workers, like farmers, gardeners and civil or building workers have a high risk of
infection due to biological hazards.
• These also include animal bites and stings, problems from toxic plants, and transmitted
diseases through animals.
Healthcare workers, veterinary health workers face high risk coverage to blood-borne
pathogens and various infectious diseases in comparison to others. Dangerous chemicals
can cause a hazard in the work area. There are many categories of hazardous chemicals.

Psycho-Social Hazards
• This means that the status of mental health and emotional well-being of the workers and
employees in an organisation may not be normal.
• These could be due to a feeling of job insecurity, long working hours, lack of enthusiasm
towards work, frustration about not being allowed to deliver quality product due to
pressure of quantitative production, harassment at work place and poor work-life
balance due to lack of appreciation.
• This aspect should be dealt with care, as these are sensitive issues.
This review also demonstrated that behavioral therapy, like continuous counseling,
meditation, yoga, participation in recreation centers, music therapy or occupational
care are effective in reducing sick leave days and poor work efficiency at the workplace.

General Safety Norms for an Industrial Unit
1. Be sure you know how to perform the job and perform it safely.
2. Be sure you know its hazards and how to protect yourself,

e.g., head protection, eye and face protection, hearing protection.
3. Report all near mistakes, incidents, injuries and illnesses immediately.
4. Wear the required Personal Protective Equipment (PPE) necessary for

the job during welding and working on cutting tools.
5. Always work clear of suspended loads – head and foot protection.
6. Inform Supervisors of Unsafe Conditions.
.
General Safety Norms for an Industrial Unit
7. Wear Safety Equipment like protective clothing and personal hygiene.
8. Use Equipment, Machines, and Tools Properly.

E.g., hand tool and portable power, tool safety.
9. Prevent Slips and Trips and Eliminate Fire Hazards.

.
10. Avoid lack of oxygen on a space that could cause immediate respiratory failure.
11. Serious care must be taken where toxic gases or vapours can poison the workers.
12. Keep Work Areas and Emergency Exits Clear.
13. Avoid Tracking Hazardous Materials, lockout of energy sources.

Preventive Measures in Industry while Working
Safe workplace and working condition
Safe material handling
Personal protection equipment’s (PPE)
Safe activities in the trouble situation
Prevention of electric accidents
Good housekeeping

Safe workplace and working condition
▪ Good layout includes sufficient space for movement, non-skid type floors.
▪ Reduced Noise level by using such machines which produces less noise, provide
separate space for such works which produces noise, make efforts for reducing the
vibrations help in minimizing harmful effects of noise.
▪ Inflammable materials should be stored separately.

▪ Machines/parts should be fenced when it is not possible to provide safeguards.
▪ All boilers and other pressure vessels must be kept in proper condition.
▪ Safety valves, Pressure gauges and water gauges must be examined thoroughly at
regular intervals.
▪ Physical conditions, sufficient illumination, ventilation and height should be

provided.
▪ Floor Should be free from oiliness and clean.

Safe material handling
▪ Hoist, cranes, lifts along with its accessories must be periodically tested.
▪ All the MH Equipments must be of sound in construction.
▪ The crane must be fitted with interlocks and limit switches.
▪ The load lifting capacity or safe working load should be prominently marked on
the equipment.
▪ The lifting and carrying operation should be steady and free of jerks.
▪ Avoid fatigue of workers, use handling devices where possible.

Personal protection equipment’s (PPE)
The Personal Protective Equipment (PPE) is used to save from the danger from sharp
edge, hot surface, dust, toxic gas etc.
A PPE cannot remove the hazard but it acts as barrier between the danger and the user.
Human Body Protection Needed PPE Protection Provided Area
Hand protection Hand gloves
Foot protection Leather/Rubber shoes
Head protection Safety helmet
Eye protection Safety goggles/shield fitted with special dark glass
Face protection Face shield
Skin and Body Protection Apron, Boiler suit
Protection against fall Safety belt, Rope, Anchoring point
Hearing conservation/protection Air plugs, air muff
Respiratory protection Respirator, Breathing apparatus, Ventilators

Safe activities in the trouble situation
▪ Repair work on the machine should not be done when it is running.
▪ All the tools should be kept at their proper places.
▪ Chips should not be removed by hand.
▪ Worker should be trained about correct procedures and they should be educated
about safety Precautions.
▪ Constant warning, publicity and play cards carrying slogans are also helpful to
reduce accidents.
▪ To avoid danger, inflammable materials should be kept away from general

storage at a safe distance (15.25m).
▪ Fire extinguishers should be kept at suitable places .

Prevention of Electric Accidents
▪ Electrical insulation should be periodically tested.
▪ Use proper tools for testing and repairing.
▪ Repair Work should be done after switching the power off.
▪ Use safety equipment's such as insulated tools and rubber gloves whenever
necessary.

Good housekeeping
Housekeeping includes cleanliness in building, work area, rest areas, equipment's,

and machinery tools etc.
Benefits of Good Housekeeping
• Good housekeeping minimizes fatigue and discomfort to the workers and

motivate them with following benefits;
Reduces the chances of fire and other hazards
Increases the life of machinery, equipment and tools
Improves productivity and quality of the products
Better utilization of floor space
Enhances the moral of workers

SOP: Safe Operating Procedure
Safe Operating Procedure (SOP) is a written document setting out the logical sequence
of steps that must be followed to safely perform a workplace activity.
SOP is work procedure that is created and written after;
(a) Identifying and assessing the health and safety risks involved in a work activity.
(b) Identifying how to eliminate the risks.
(c) Identifying what reasonably practicable actions can be done to minimize the risks.
• Basically, an SOP is the "how to do

this work activity and remain safe
and healthy".
• A safe operating procedure is

sometimes also called a “Safe Work
Procedure” or a “Safe Work
Method statement”.

SOP: Benefits
SOP provide a stable reference point for employees on “how to do work activity with safety.
SOP controlling workplace risks and helping employees to comply with their duty.
SOP is a procedure in the category of risk controls also known as an “Administrative control”.
SOP must be reviewed periodically to ensure they are accurate and effective.
SOP should be readily available to workers for reference.

Contents of SOP
S.N. SOP Includes
1 Name/ Description of the work task
2 Date of SOP was created and Date it was last reviewed or revised
3 Hazards that may cause harm to a worker
4 Equipment / devices, PPE necessary to perform the task safely
5 Required training/documentation needed to perform the task safely
6 Steps to perform the task safely including safe body positions or movements
7 Employers must ensure that workers are to be trained and follow as per SOP

Definition and Types of Accidents
An Accident is an unplanned and undesired event, which results in to unacceptable and
undesired consequences.
The consequences might be injury and / or damage to equipment, machinery, raw
material or finished product or damage to environment.
Types of Accidents • Accident is an unfortunate

A person may receive a minor physical or and sudden miss happening
Non-Reportable bodily injury while working as the outcome which causes damage or
Accident of accident.
loss of property, material or
After such injury he resumes his duties human.
within 48 hours when such an accident.
In this, the injured person remains absent
Reportable or for 48 hours or more due to injury at
Lost Time workplace. • Safety Management is
Accident concentrating on
The injury in such case is called as “Major
or Disabling injury”.
preventions of accidents.

Losses due to an Accidents
Direct Loss:
This type of losses measured in terms of money.
Employer has to pay to the worker for compensation; medical expenses are coming under
direct losses.
Indirect Losses
Sources of Indirect Losses
1. Loss of time of injured person and also of his 2. Loss of time of supervisors:
fellow workers, who stop work at the time of a) in assisting injured worker;
accident. b) in making alternate arrangement;
c) in investigating and preparation of report of accident;
d) In selecting and training the new worker to replace the
worker who lost his life in accident.
3. Loss due to damage caused to machine. 4. Loss due reduction in the efficiency of worker and
other workers due to fall in their moral
5. Losses to the injured worker due to loss to his income, loss in medical expenditure and pain felt by worker
which cannot be compensate.

Types of an Industrial Accidents
An Accident is an unplanned and undesired event, which results in to unacceptable and
undesired consequences.
The consequences might be injury and / or damage to equipment, machinery, raw
material or finished product or damage to environment.
Types of Industrial Accidents
Cause due to inadequate safeguard of machines.

Machinery Accidents
These can be reduced by providing safety guards on belts,
gears, etc.
Cause due to personal reasons such as age, physical weakness,

Non Machinery Accidents inexperience and carelessness or from the plant conditions
such as poor ventilation and illumination.


Classification of Accidents
On basis of Severity, Durability and Degree of Injury

Minor ▪ Less harmful in nature;
Accidents ▪ Preventing employees for the period less than 48 hours from working.
▪ Not necessary to report to higher management.
Fatal ▪ It result in to death of employee

Accidents ▪ Reporting to top management, legal bodies and police is must
Temporary Accident which causes disability to worker for a short period (a day/a week)
Accidents
Permanent Accident Injury after accident disable the affected worker permanently
Accidents due to ▪ Explosion, fire leakages are the reasons for this type of accidents
Dangerous ▪ Man and property both can be damage
Occurrences ▪ It gives greater loss to the industry

Causes of Accidents
Majority of industrial accidents are due to transmission machinery E.g. Gear, Belts,
Pulleys, Coupling, Shafting, Cutters , Tools and Clutch of Cutting Machines etc.
Accidents due to These accidents occurs from boilers, pressure vessels, prime
Dangerous Machines movers, transmission system
Unsafe Physical It includes improper guard, improper illumination, improper
Conditions Ventilation, unsafe clothing.
Moving Objects Sometimes moving objects or foreign objects causes accident.
Personal Factors Lack of knowledge, physical weakness are the personal factors
which Causes accidents.
Unsafe Act These includes working at unsafe speed, loading machine beyond
capacity, not Using safety devices, adopting unsafe procedure.
Exposure to Harmful Injuries due to accidents are also caused due to exposure to harmful
Substances substances, like toxic gases, fumes, dust, vapor mist and aerosols

Work Permit or Permit to Work (PTW)
➢ A “Permit-to-Work” system is a formal written system used to control certain types of
work that are potentially hazardous.
➢ A “Permit-to-Work” is a document which specifies the work to be done and the
precautions to be taken.
➢ A “Permit-to-Work” form an essential part of safe systems of work for many
maintenance activities.
Objectives of PTW
• PTW can assist in the management of work activities, including non-routine work.
• PTW allows Occupiers, Authority & Users to communicate hazards involved in the work.
• PTW enable safe execution of onsite work activities.
• PTW is a means of communication between different departments, plant supervisors,
operators, agencies etc.
• It sole purpose is to “Save life and avoid accident”.

Common Factors includes Work Permit Application
• The objectives, methodology, issue of Permit.
• Execution and termination of Permit.
• Foreseeing of hazards and arrangement for their controls.
• Testing and Certification of working atmosphere.
• Use of tools and Personal Protective Equipment (PPE).
• First-aid and Rescue Equipment.
• Training of workers for such work.

Types of Work Orders
Work order for working at height
Hot work permit:

Spark producing tools, hammering in high risk gas areas,
explosives, welding
Cold work permit:

Routine maintenance, inspection, hand tools
Permit for Electrical maintenance
The types of work for which PTW systems

shall be applied include Maintenance and
Repair, Inspection, Testing, Construction,
Dismantling, Modification and Cleaning.

Work Permit Requires at @
• Normally hazardous works of maintenance or modification need work permit system.
• It is given for the following category of works;
S.N. Category Details

1 Operations Excavation, vessel entry, working at height, hot work,
welding and cutting, equipment removal, pipe breaking, line
breaking, lining in furnace, waste disposal, ship breaking and
cutting.
2 Equipment Electrical, pneumatic, hydraulic lifting machine, crane,

sprinkler or hydrant system.
3 Hazardous Area Explosive, flammable, corrosive, radioactive or toxic

atmosphere.
4 Time Overtime or after hours work.

Meaning of Responsible Persons related to PTW
A person authorized by manager who will responsible for keeping his area and staff safe.
S.N. Category Details

A person trained, competent and authorize to issue a permit to
1 Issuer work after insuring that all the hazards associated with the
work being done in that area and all necessary safety
precautions are being implemented to ensure that the work
can be completed safely.
A person who is trained, competent and authorized for the

2 Executor work being completed as described in the permit to work.
3 Field operator A competent person an supports the isolator at site, checks the
site compliance to permit conditions and signs the permit.
Note: In emergency and in routine activity, work permit is not required.

Features of Permit to Work System
• A hazard and Risk Assessment.
A standard procedure essential of work
• Standard Operating Procedure. permit system consists of ;
• Instruction in the issue, use and closure. 1. Training of authorized person.
• A tool box sign by all workers. 2. Formal recorded process.
• The permit issue, extension and

3. Clearly defined responsibilities.
withdrawal details.
4. Preparatory work method statement.
• The name & signature of those who are
responsible for the job. 5. Audits and monitoring the system works
as intended
• Essential control measures, mitigating
actions and precautions. 6. It is for authorize person.
• The equipment and tools used.

Elements of PTW
S.N Category Details

▪ It means pre-job check.
▪ Description of work to be carried out.
1 Issue ▪ Description of plant and location.
▪ Assessment of hazards.
▪ Identification of controls.
▪ It means handover of permit.
▪ Competent and authorized person issues permit to workers.
2 Receipt ▪ Work can now start.
▪ Workers sign to say the accept control.
▪ Plant is now under the control of workers.
▪ It means hand back to permit.
3 Clearance ▪ Workers sign to say they have left the job site & equipment’s can restart.
▪ Authorized person accept plant back and can remove isolation.
4 Cancellation ▪ Plant is now returned to the control of the site.

Industrial Safety – Related Videos
• https://youtu.be/OPs4MQOlZAQ
VIDEO on Industrial Safety Gui delines
• https://youtu.be/BBu-yBJgsPM
VIDEO on Safety measures for Chemical industry
• https://youtu.be/FdyBy2s9I5c
VIDEO on Bhopal Gas Disaster-Union Carbide Chemical Plant Explosion
• https://youtu.be/oKZeTQ6PreY
VIDEO on Chernobyl incident-Nuclear Power Plant Explosion
• https://youtu.be/w4jHpHoYZhk
VIDEO on How to operate Fire Extinguisher-Fire Safety Training
• https://youtu.be/cnn-yvszLXE
VIDEO on Fire Safety Training

MET’s Institute of Technology- Polytechnic
Bhujbal Knowledge City, Nashik
Thank You
Prof. A P Vadnere,
HOD-Mechanical Engineering
MET’s Institute of Technology-Polytechnic, Nashik
www.metbhujbalknowledgecity.ac.in
[email protected]

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MET’s Institute of Technology- Polytechnic

Bhujbal Knowledge City, Nashik

Prof. A P Vadnere, HOD-Mech. Engg., MET BKC IOT-P, Nashik

Prof. A P Vadnere, HOD-Mech. Engg., MET BKC IOT-P, Nashik

• Safety means “continuing and healthful living without injury”.

• Safety is free from “harm or danger of harm”.

• Similarly, all hazards, i.e. source/situation capable of injury or ill health,

Prof. A P Vadnere, HOD-Mech. Engg., MET BKC IOT-P, Nashik

• There is always a risk of hazard while operating machines.

Prof. A P Vadnere, HOD-Mech. Engg., MET BKC IOT-P, Nashik

• SMS is a comprehensive management system designed to manage safety

Policy Objective Plans Procedures

Prof. A P Vadnere, HOD-Mech. Engg., MET BKC IOT-P, Nashik

Prof. A P Vadnere, HOD-Mech. Engg., MET BKC IOT-P, Nashik

Prof. A P Vadnere, HOD-Mech. Engg., MET BKC IOT-P, Nashik