Category L T P CREDIT

INDUSTRIAL SAFETY
MCN401
ENGINERING OEC 2 1 0 3

Preamble: The course is intended to give knowledge of various safety management principles,
various safety systems, various machine guarding devices, hazard identification techniques,
energy sources, systems & applications and the need in the present context. Learners will be
able to compare different hazard identification tools and choose the most appropriate based on
the nature of industry. It aims to equip students in working with projects and to take up research
work in connected areas

Prerequisite: Nil

Course Outcomes: After the completion of the course the student will be able to

Describe the theories of accident causation and preventive measures of industrial

CO1
accidents. (Cognitive Knowledge level: Understand)
Explain about personal protective equipment, its selection, safety performance &
CO2 indicators and importance of housekeeping. (Cognitive Knowledge level:
Understand)
Explain different issues in construction industries. (Cognitive Knowledge level:
CO3
Understand)
Describe various hazards associated with different machines and mechanical
CO4
material handling. (Cognitive Knowledge level: Understand)
Utilise different hazard identification tools in different industries with the
CO5 knowledge of different types of chemical hazards. (Cognitive Knowledge level:
Apply)

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Mapping of course outcomes with program outcomes

PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PO10 PO11 PO12
CO1 2 2 2 2 2 1
CO2 2 1 2 1 1 1 1 1
CO3 2 2 2 1 1 1 1 1 1 1
CO4 2 2 2 1 1 1 1 1 1 1
CO5 2 2 2 1 1 1 1 1 1 1 1

Abstract POs defined by National Board of Accreditation

PO1 Engineering Knowledge PO7 Environment and Sustainability
PO2 Problem Analysis PO8 Ethics
PO3 Design/Development of solutions PO9 Individual and team work
PO4 Conduct investigations of complex problems PO10 Communication
PO5 Modern tool usage PO11 Project Management and Finance
PO6 The Engineer and Society PO12 Life long learning

Assessment Pattern

Continuous Assessment Tests

End Semester Examination
1 2
Remember 10 10 10
Understand 20 20 20
Apply 20 20 70
Analyse

Evaluate

Create

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Mark distribution:

Total Marks CIE Marks ESE Marks ESE Duration

150 50 100 3 hours

Continuous Internal Evaluation Pattern:

Attendance : 10 marks
Continuous Assessment - Test : 25 marks
Continuous Assessment - Assignment : 15 marks

Internal Examination Pattern:

Each of the two internal examinations has to be conducted out of 50 marks. First series test shall
be preferably conducted after completing the first half of the syllabus and the second series test
shall be preferably conducted after completing remaining part of the syllabus. There will be two
parts: Part A and Part B. Part A contains 5 questions (preferably, 2 questions each from the
completed modules and 1 question from the partly completed module), having 3 marks for each
question adding up to 15 marks for part A. Students should answer all questions from Part A.
Part B contains 7 questions (preferably, 3 questions each from the completed modules and 1
question from the partly completed module), each with 7 marks. Out of the 7 questions, a student
should answer any 5.

End Semester Examination Pattern:

There will be two parts; Part A and Part B. Part A contains 10 questions with 2 questions from
each module, having 3 marks for each question. Students should answer all questions. Part B
contains 2 questions from each module of which a student should answer any one. Each question
can have maximum 2 sub-divisions and carries 14 marks.

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 Syllabus
MCN401- Industrial Safety Engineering (35 hrs)

Module I (safety introduction- 5 hrs)

Need for safety. Safety and productivity. Definitions: Accident, Injury, Unsafe act, Unsafe
Condition, Dangerous Occurrence, Reportable accidents. Theories of accident causation. Safety
organization- objectives, types, functions, Role of management, supervisors, workmen, unions,
government and voluntary agencies in safety. Safety policy. Safety Officer-responsibilities,
authority. Safety committee-need, types, advantages.

Module II (Personal protection in work environment- 7 hrs)

Personal protection in the work environment, Types of PPEs, Personal protective equipment-
respiratory and non-respiratory equipment. Standards related to PPEs. Monitoring Safety
Performance: Frequency rate, severity rate, incidence rate, activity rate. Housekeeping:
Responsibility of management and employees. Advantages of good housekeeping. 5 s of
housekeeping. Work permit system- objectives, hot work and cold work permits. Typical
industrial models and methodology. Entry into confined spaces.

Module III (safety issues in construction- 7 hrs)

Introduction to construction industry and safety issues in construction Safety in various
construction operations – Excavation and filling – Under-water works – Under-pinning &
Shoring – Ladders & Scaffolds – Tunneling – Blasting – Demolition – Confined space –
Temporary Structures. Familiarization with relevant Indian Standards and the National Building
Code provisions on construction safety. Relevance of ergonomics in construction safety.
Ergonomics Hazards - Musculoskeletal Disorders and Cumulative Trauma Disorders.

Module IV (safety hazards in machines- 8 hrs)

Machinery safeguard-Point-of-Operation, Principle of machine guarding -types of guards and
devices. Safety in turning, and grinding. Welding and Cutting-Safety Precautions of Gas

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welding and Arc Welding. Material Handling-Classification-safety consideration- manual and
mechanical handling. Handling assessments and techniques- lifting, carrying, pulling, pushing,
palletizing and stocking. Material Handling equipment-operation & maintenance. Maintenance
of common elements-wire rope, chains slings, hooks, clamps. Hearing Conservation Program in
Production industries.

Module V (hazard identification and analysis- 8 hrs)

Hazard and risk, Types of hazards –Classification of Fire, Types of Fire extinguishers, fire
explosion and toxic gas release, Structure of hazard identification and risk assessment.
Identification of hazards: Inventory analysis, Fire and explosion hazard rating of process plants
- The Dow Fire and Explosion Hazard Index, Preliminary hazard analysis, Hazard and
Operability study (HAZOP)) – methodology, criticality analysis, corrective action and follow-up.
Control of Chemical Hazards, Hazardous properties of chemicals, Material Safety Data Sheets
(MSDS).

Text Books:

1. R.K Jain (2000) Industrial Safety, Health and Environment management systems, Khanna

Publications.
2. Paul S V (2000), Safety management System and Documentation training Programme

handbook, CBS Publication.

3. Krishnan, N.V. (1997). Safety management in Industry. Jaico Publishing House, New

Delhi.
4. John V. Grimaldi and Rollin H.Simonds. (1989) Safety management. All India Traveller

Book Seller, Delhi.

5. Ronald P. Blake. (1973). Industrial safety. Prentice Hall, New Delhi.

6. Alan Waring. (1996). Safety management system. Chapman & Hall, England.

7. Vaid, K.N., (1988). Construction safety management. National Institute of Construction

Management and Research, Mumbai.

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 8. AIChE/CCPS. (1992). Guidelines for Hazard Evaluation Procedures. (second edition).

Centre for Chemical Process Safety, American Institute of Chemical Engineers, New
York.

Course Level Assessment Questions:

Course Outcome 1 (CO1):

1. Which are the various accident causation theories? Explain.
2. Define terms: Accident, Reportable accident, Dangerous occurrence.
Course Outcome 2 (CO2):
1. Discuss different types of personal protective equipment
2. Discuss about how to compare the safety performance of two industries.
3. Discuss the significance of work permit system in accident prevention.
Course Outcome 3 (CO3):
1. Distinguish ladders and scaffolds along with their safety features.

2. Discuss the safety requirement for a confined space entry.

3. Explain the important provision in the National Building Code.

Course Outcome 4 (CO4):
1. Explain the various principles used in machine guarding.

2. Explain the issues in mechanical material handling.

Course Outcome 5 (CO5):

1. Selection of different types of fire extinguishers accordance to type of fire.

2. Conduct a HAZOP study for a batch rector of your choice.

3. Determine different types of Chemical hazards associated with industries

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 MODEL QUESTION PAPER
APJ ABDUL KALAM TECHNOLOGICAL UNIVERSITY
VII SEMESTER B. TECH DEGREE EXAMINATION
MCN401- INDUSTRIAL SAFETY ENGINEERING
Maximum: 100 Marks Duration: 3 hours
PART A
Answer all questions, each question carries 3 marks
1. Differentiate Unsafe act and Unsafe conditions with suitable examples
2. Discuss the significance of a safety committee in improving the safety performance of an
industry
3. Which are the different types of permit? Highlight its suitability.
4. Which are five ‘S’ used in housekeeping?
5. List the various safety features of ladders.
6. How safety of the workers can be ensured during a demolition operations.
7. Which are the hazards associated with manual material handling?
8. Discuss the safety issues of Gas welding operations.
9. Differentiate Hazard and Risk.
10. Why MSDS is mandatory for chemical products.
(10 X 3 = 30 Marks)
PART B
Answer one full question from each module
Module 1
11. List the various accident causation theories and explain any one in details. (14 Marks)
12. a) Discuss the significance of safety policy in reducing the accidents. (4 Marks)
b) Safety and productivity are the two sides of a coin’. Are you agreeing with this
statement? Explain with your arguments. (10 Marks)
Module 2
13. a) Classify the personal protective equipment. List the suitability of at least fifteen types of

PPEs. (10 Marks)

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 b) How will you calculate the frequency rate? Explain with an example. (4 Marks)

14. a) How will you compare the safety performance of two industries? Explain with suitable
example. (10 Marks)
b) Which are the steps to be followed in confined space entry to protect the life a worker.
(4 Marks)
Module 3
15. Discuss the safety and fire protection facilities required for a high rise building as per
National building code. (14 Marks)
16. a) Identify the various hazards during the different stages of building construction.
(7 Marks)
b) Discuss the important types of ergonomic hazards associated with industries.(7 Marks)
Module 4
17. Which are the various types of machine guarding devices used industries. Discuss the
suitability of each machine guarding devices. (14 Marks)
18. With suitable sketches briefly explain seven defects of wire ropes. (14 Marks)
Module 5
19. What is Hazard and Operability Analysis? How do you conduct a HAZOP analysis?
(14 Marks)
20. Discuss about different types of chemical hazards. (14 Marks)

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 Course Contents and Lecture Schedule

No. of Lectures/
No. Topic Tutorials
L-T

1 Introduction to Industrial safety Engineering

Need for safety. Safety and productivity. Definitions: Accident, Injury,
1.1 1
Unsafe act, Unsafe Condition, Dangerous Occurrence. Reportable accidents
1.2 Theories of accident causation. Safety organization. 2
Role of management, supervisors, workmen, unions, government and
1.3 3
voluntary agencies in safety.
1.4 Safety Officer-responsibilities, authority. 4
1.5 Safety committee-need, types, advantages. 5
2 Personal protection in the work environment
2.1 Types of PPEs, respiratory and non-respiratory equipment. 6
2.2 Standards related to PPEs 7
2.3 Monitoring Safety Performance: Frequency rate, severity rate 8,

2.4 Monitoring Safety Performance: incidence rate, activity rate. 9

Housekeeping: Responsibility of management and employees. Advantages
2.5 of good housekeeping. 5 s of housekeeping. 10

2.6 Work permit system- objectives, hot work and cold work permits. 11

2.7 Typical industrial models and methodology. Entry into confined spaces. 12
3 Introduction to construction industry and safety
3.1 Excavation and filling – Under-water works – Under-pinning & Shoring 13
3.2 Ladders & Scaffolds – Tunneling 14
3.3 Blasting –Demolition – Confined space 15
Familiarization with relevant Indian Standards and the National Building
3.4 16
Code provisions on construction safety.
3.5 Relevance of ergonomics in construction safety. 17
3.6 Ergonomics Hazards 18
3.7 Musculoskeletal Disorders and Cumulative Trauma Disorders. 19
4 Machinery safeguard

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4.1 Point-of-Operation, Principle of machine guarding - 20
4.2 Types of guards and devices. 21
Safety in Power Presses, primary & secondary operations - shearing
4.3 22
-bending - rolling – drawing.
4.4 Safety in turning, boring, milling, planning and grinding. 23
4.5 Welding and Cutting-Safety Precautions of Gas welding and Arc Welding, 24
4.6 Cutting and Finishing. 25
Material Handling-Classification-safety consideration- manual and
4.7 mechanical handling. Handling assessments and techniques- lifting, 26
carrying, pulling, pushing, palletizing and stocking.
Material Handling equipment-operation & maintenance. Maintenance of
4.8 27
common elements-wire rope, chains slings, hooks, clamps
5 Hazard identification
5.1 Hazard and risk, Types of hazards – Classification of Fire 28
5.2 Types of Fire extinguishers fire, explosion and toxic gas release. 29
5.3 Inventory analysis, Fire and explosion hazard rating of process plants - 30
5.4 The Dow Fire and Explosion Hazard Index. 31
5.5 Preliminary hazard analysis, Hazard and Operability study (HAZOP) 32
5.6 Chemical hazard- Classifications, Control of Chemical Hazards. 33
5.7 Hazardous properties of chemicals 34
5.8 Material Safety Data Sheets (MSDS). 35

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