SAFETY CONCEPTS

MODERN SAFETY CONCEPTS

• Safety is a state in which hazards and conditions leading to physical, psychological or material harm are controlled
in order to preserve the health and well-being of individuals and the community through a continuing process of
hazard identification and safety risk management.
• Attaining an optimum level of safety requires individuals, communities, governments and others to create and
maintain the following conditions, whichever setting is considered :
➢ a climate of social cohesion and peace as well as of equity protecting human rights and freedoms, at the
family, local, national or international level;
➢ the prevention and control of injuries and other consequences or harm caused by accidents;
➢ the respect of the values and the physical, material and psychological integrity of individuals; and
➢ the provision of effective preventive, control and rehabilitation measures to ensure the presence of the three
previous conditions.
• Safety management refers to the management of all operations and events within an industry in order to protect its
employees and assets by minimizing hazards, risks, accidents, and near misses.

NEED FOR SAFETY

• An accident is by virtue of unsafe factor or unsafe condition or the combined effect of two. An unsafe act results in
the form of operator/people doing thing without proper authority, misuse of safety devices, ignoring warnings and
precautions etc.
• Industrial Accidents are caused by chemical, mechanical, civil, electrical, or other process failures, negligence or
incompetence, in an industrial plant which may spill over to the areas outside the plant causing damage to life and
property.
• These may originate in:
➢ Manufacturing and formulation installations including during commissioning and process operations;
maintenance and disposal.
➢ Material handling and storage in manufacturing facilities, and isolated storages; warehouses and go-downs
including tank farms in ports and docks and fuel depots.
➢ Transportation (road, rail, air, water, and pipelines).
• Probable causes of accidents
➢ Process deviations i.e. pressure, temperature & flow.
➢ Parameters with regard to the state of the substance i.e., solid, liquid or gas, proximity to other toxic
substances.
➢ Runaway reaction.
➢ Hardware failure, resulting in large-scale spills of toxic substances.
➢ Boiling Liquid Expanding Vapor Explosion (BLEVE) on the chemicals during transportation.
• Major Consequences
➢ Loss of life / injuries
➢ Impact on livestock
➢ Damage to Flora/fauna
➢ Environmental Impact (air, soil, water)
➢ Financial losses to industry.
• Safety is very important aspect for any industry as an accident-free work environment boosts the morale of the team
members working in any hazardous situations.
• There are some direct costs/ effects of an accident but there are certain indirect costs involved in it also.
• The Occupational Safety and Health Association (OSHA) is the primary regulatory body in the United States
dedicated to ensuring industrial safety.
• It is essential to identify/examine the causes of industrial accidents and take steps to control them.
• The following steps may be taken to effectively and efficiently eliminate an unsafe working environment:
(1) Elimination if possible, of the causes of accidents.
(2) If it is not possible to eliminate the cause of accidents, make arrangements to shield the hazardous place by guards,
enclosures or similar arrangements.
• So, safety measures would not only eliminate/ avoid above cost but would mean performing their moral responsibility
towards workmen/operators also.
• Main reasons for the importance of safety
1. Economic
– worker compensation
 – medical bills
– abatement costs
– equipment damage
– OSHA fines
– loss of productivity
2. Legal
– OSHA regulations and fines
– Worker compensation laws
– Third party lawsuits
3. Moral
– Safety is just the right thing to do for your employees.
• Safety is no longer just the following of Occupational Safety & Hazard Analysis OSHA regulations. It is the
coordination of all departments to produce the greatest profit for the company at the most minimal risk.
OSHA NORMS
• Occupational Safety and Health Administration (OSHA) standards are rules that describe the methods that employers
are legally required to follow to protect their employees from hazards.
• Examples of OSHA standards include requirements to provide fall protection, prevent trenching cave-ins, prevent
infectious diseases, ensure that workers safely enter confined spaces, prevent exposure to harmful substances like
asbestos, put guards on machines, provide respirators or other safety equipment, and provide training for certain
dangerous jobs.
• As part of the OSHA regulations, employers must:
1. Follow all relevant OSHA safety and health standards.
2. Find and correct safety and health hazards.
3. Inform employees about chemical hazards through training, labels, alarms, color-coded systems, chemical
information sheets, and other methods.
4. Notify OSHA within 8 hours of a workplace fatality or within 24 hours of any work-related inpatient
hospitalization, amputation, or loss of an eye.
5. Provide required personal protective equipment at no cost to workers.
6. Keep accurate records of work-related injuries and illnesses.
7. Post OSHA citations, injury and illness summary data, and the OSHA Job Safety and Health. It’s The Law poster
in the workplace where workers will see them.
8. Not retaliate against any worker for using their rights under the law.
• The role of employees is also well defined under the OSHA Act. According to the Act, employees have the right
to:
1. Working conditions that do not pose a risk of serious harm.
2. Receive information and training (in a language workers can understand) about chemical and other hazards,
methods to prevent harm, and OSHA standards that apply to their workplace.
3. Review records of work-related injuries and illnesses.
4. Get copies of test results done to find and measure hazards in the workplace.
5. File a complaint asking OSHA to inspect their workplace if they believe there is a serious hazard or that their
employer is not following OSHA rules. When requested, OSHA will keep all identities confidential.
6. Use their rights under the law without retaliation. If an employee is fired, demoted, transferred, or retaliated
against in any way for using their rights under the law, they can file a complaint with OSHA. This complaint
must be filed within 30 days of the alleged retaliation.
SAFETY MANAGEMENT SYSTEM

• A Safety Management System is a comprehensive approach to reducing the number of injuries and accidents in an
organisation.
 • Safety Management Systems help organizations offer products or services at the highest level of safety and maintain
safe operations.

Purpose of Safety Management Systems

• The main purpose of a safety management system is to provide a systematic approach for managing safety risks in
operations.

SAFETY MANAGEMENT FUNCTION

Job Safety Analysis (JSA) - JSA is a formal process for evaluating the hazards of a particular task or job. In doing this, all
potential hazards and potential incidents that might happen while doing the task are identified and control measures are
put in place to prevent or mitigate the effects of these incidents.

WHS Compliance - Workplace Health and Safety regulations requires that employers provide a safe and healthy
workplace. And as part of meeting compliance, the employer must communicate and implement procedures, which will
help protect employees from work related injury. This is in addition to other duties like incident reporting and assessment,
first aid competency and emergency response.

Employee Training - Employees need to be aware of the risks so that they know what control measures are in place at their
workplace. A good safety management system can provide employees with training and updates on new hazards in the work
environment, as well as best practice methods to mitigate these risks.
Data Collection and Management - Data collection and management is the foundation of any safety management system.
Without this essential function, no matter what other steps are taken to prevent accidents, the risk of an incident
happening is still high. It starts with implementing a standard for data collection, such as paper-based records or
electronic data.
Auditing and reviewing performance- Safety management systems are designed to audit and review performance. When
the safety data is analysed, it should be used as a learning opportunity to identify best practices and areas for
improvement. Safety management systems should be designed to support and drive organisational change when
necessary, rather than being used as a punitive tool.

Communication and Feedback

SMS allows employees to let managers know about risks in their work areas and to share ideas for preventing accidents. It
also helps managers address the causes of safety problems without waiting until a major accident occurs.
COST ANALYSIS OF ACCIDENTS
Accidents at work are a heavy burden in social and economic terms, and action to improve health and safety standards at work
offers great potential gains not only to employers, but also to individuals and society as a whole.
The starting structure of accidents cost analysis tool:
1. Cost of the accident
• Injury first aid
• Transport to healthcare structures
• Cost of repairs/replacement of tangible asset (equipment, machinery, etc.)
• Period of absence by the injured worker
• Loss of time by other workers
• Loss of business due to a halt in production
• Health cost withheld for injured and non-injured staff
• External communication concerning the incident
2. Cost of the accident root cause analysis
• Incident cause analysis (field investigations)
• Completion of incident reports for injury management
• Completion of other internal documentation necessary to manage the injury
 • Completion of documentation for public authorities (documents for INAIL − the Italian social security organization,
etc.)
• Meetings with public authorities to analyse incidents
• Time dedicated to people involved in internal meetings relating to the analysis of the cause of the injury
• Cost of external consultation to assess injury
3. Cost of damages caused to and/or replacement of equipment
• Cost of damaged structure (impairment)
• Cost of repairs/replacement of tangible asset (equipment, machinery, etc.)
• Cost of new equipment, including cleaning and disposal
4. Cost for resuming business activities
• Reorganisation of production
• Overtime to recover production losses
• Time for selecting new staff
• Staff training in order to resume business after injury
• Cost of staff hired for the period in which the injured person is absent from work
• Cost of any outsourcing of a service/activity Increased insurance premiums
5. Compensation for damage caused
• Compensation and penalties
• Contractual penalties
• Orders cancelled or lost (lack of revenues)
• Cost of lawsuits (legal expenses)
• Fines/administrative sanctions
• Increased insurance premiums
• Absence of return on capital

SYSTEM SAFETY ANALYSIS TECHNIQUES

1. Fault Tree Analysis

Fault Tree Analysis (FTA) helps to identify potential causes of system failures before the failures actually occur. FTA uses
statistical measures of failure rate, failure probability, and repair rate, often with both qualitative and quantitative risk
assessment.

Fault tree diagrams (or negative analytical trees) are logic block diagrams that display the state of a system (top event) in
terms of the states of its components (basic events). Like reliability block diagrams (RBDs), fault tree diagrams are a graphical
design technique, and as such provide an alternative methodology to RBDs.
Event Symbols in FTA
Gate Symbols in FTA

2. Failure Modes and Effect Analysis

• Failure Mode and Effects Analysis (FMEA) is a structured approach to discovering potential failures that may exist
within the design of a product or process.
• FMEA was one of the earliest methods of systematically looking at the potential problem in a product or process.
• It looks at similar products or processes and reviews their past failures. It also considers the physical characteristics
of the material. Depending on the analysis, changes in processes or products are made to avoid errors.
• Failure Mode and Effects Analysis is designed to identify, prioritize and limit these failure modes.
HAZARD

• A hazard is defined as "any workplace condition or practice that could cause an injury or illness to an employee."
• There are two forms of exposure to hazards:
1. Physical exposure. When an employee is within arm's length of a hazard. Examples include noise, hazardous
atmospheres, and temperature extremes.
2. Environmental exposure. The employee can be anywhere in relation to the hazard. Environmental hazards could
affect one employee or everyone within a facility.

HAZARD IDENTIFICATION AND CONTROL

Some basic steps in the hazard identification and control process are:
Step 1: Identifying Hazards
The first step in the process is to identify hazardous conditions, unsafe behaviors, and system weaknesses that might result in
accidents. The safety inspection process and observation are two effective hazard identification tools.
Physical hazards: This first category includes: materials, tools, equipment, machinery, and the physical environment. Each
of these represent hazardous physical conditions. It may seem counterintuitive, but physical hazards actually account for the
fewest number of workplace accidents.
Behavioral hazards: This second category describes unsafe employee behaviors and practices in the workplace. Unsafe
behaviors and practices account for most workplace accidents
Systemic hazards: The last category includes weaknesses in the safety management system structure, design, and
performance. System weaknesses contribute to the unique hazardous physical conditions and unsafe personal behaviors and
are ultimately responsible for most injuries and illnesses in the workplace.
Two common methods are used to identify hazards in the workplace: safety inspections and observations. Both of these
methods should be accomplished regularly. The frequency of inspections and observations should be based on the nature of
the hazards in the workplace.
Step 2: Analyzing Hazards
Once hazards are identified, we need to analyze them. To make sure the analysis process is successful, it's important to assume
all hazards can be prevented, eliminated, reduced, or controlled. The Job Hazard Analysis (JHA) is an excellent tool for
analyzing the hazards inherent in specific jobs.

• Two common methods are used to analyze hazards and exposure: The Job Hazard Analysis (JHA) and
incident/accident investigation.

I. Job Hazard Analysis (JHA)

The Job Hazard Analysis (JHA) can answer weaknesses of the walk-around inspection process. It uncovers unsafe work
practices as well as hazardous conditions because sufficient time is given to close analysis of one unique task at a time. A
typical JHA is accomplished by a team composed of at least one employe.
II. Incident/Accident Investigation
Investigating a worksite provides employers and workers the opportunity to identify hazards in their operations and
shortcomings in their safety and health programs. Most importantly, it enables employers and workers to identify and
implement the corrective actions necessary to prevent future incidents and accidents.

Step 3: Controlling Hazards

Once hazards are identified, it's important analyze and control them using a systematic strategy. It's important to assume that
all hazards can be prevented, eliminated, reduced, or controlled. A systematic strategy, called the "Hierarchy of Controls," is
an effective approach for keeping the workplace safe and protecting workers.
Hazard controls
These three control methods focus on controlling the hazard.
1. Elimination: The best solution is to totally eliminate the hazard. For instance, a simple way to eliminate the need to work
at elevation is to eliminate the need to use a ladder to change ceiling light bulbs by using a extension pole.
2. Substitution: Substitution is the next-best solution. For instance, the employer might replace large heavy containers with
smaller containers.
3. Engineering Controls: Design or redesign equipment. In this case, printing equipment might be designed to prevent the
possibility of a worker getting caught by a rotating shaft.
Exposure Controls
These three control methods focus on controlling behaviors to reduce exposure to the hazard. These controls are farther
down the hierarchy because they work only so long as employees comply with the controls' requirements.
1. Warnings: Warnings may be visual, audible, or both. They may also be tactile. Visual warnings include signs, labels,
tags, and lights. Audible warnings include alarms, bells, beepers, sirens, horns and announcement systems. Tactile warnings
may include vibration devices or air fans. For example, a sign would be posted outside a confined space that forbids entry.
2. Administrative Controls: These controls focus on mandating safe behaviors and work practices using written safety
policies, procedures, rules, supervision, and training. These controls effectively is a challenge because supervisors must
regularly monitor their employees as they perform tasks. Bottom line, these controls work only so long as employees follow
them.
3. Personal Protective Equipment (PPE): The use of PPE is probably the most common control method used for
controlling hazards. PPE forms a barrier between workers and hazards. For instance, knee pads might be used to protect the
knees when laying carpet.

PRESSURE HAZARDS

• Pressure hazards exist within pressure systems due to the stored energy of the compressed gas and the chemical
nature of that gas.
• Measurement of pressure hazards
Several methods of detecting pressure hazards:
➢ Sounds can be used to signal a pressurized gas leak. Gas discharge may be indicated by a whistling noise.
➢ Workers should not use fingers to probe for gas leaks. Cloth streamers may be tied to the gas vessel to
indicate leaks.
➢ Soap solutions may be smeared over the vessel surface so that bubbles are formed when gas escapes. A
stream of bubbles indicates gas release.
➢ Leak detectors that measure pressure, current flow, or radioactivity may be useful for some types of gases.
➢ Corrosion may be the long-term effect of escaping gases.
 • Common causes of gas leaks:
➢ Contamination by dirt can prevent the proper closing of gas valves, threads, gaskets, and other closures.
➢ Over-pressurization can overstress the gas vessel.
➢ The container closure may distort and separate from gaskets, leading to cracking.
➢ Excessive temperatures applied to dissimilar metals that are joined may cause unequal thermal expansion,
loosening the metal-to-metal joint.
➢ Materials may crack because of excessive cold.
➢ Operator errors may lead to hazardous gas release.
• Reduction of Pressure Hazards
➢ Pressurized vessels should be stored in locations away from cold or heat sources, including the sun.
➢ Hoses should be firmly clamped at the ends when pressurized whipping action of pressurized flexible hoses
can be dangerous.
➢ Gas compression can occur in sealed containers exposed to heat.
➢ Aerosol cans may explode violently when exposed to heat.
➢ Pressure should be released before working on equipment check gauges before any work begins.
➢ Water hammer is a shock effect caused by liquid flow suddenly stopping & produces loud noises. The
momentum of the liquid is conducted back upstream in a shock wave and may damage pipe fittings & valves
in a shock wave, and may damage pipe fittings & valves.

FIRE HAZARDS
• Fire hazards are workplace hazards that involve the presence of flame or the risk of an uncontrolled fire and thereby
endanger life.
• Fire hazards include:
➢ Live flames
➢ Sparks
➢ Hot objects
➢ Flammable chemicals
➢ Chemicals that can aggravate a fire.
• OSHA requires workers to train all employees to recognize fire hazards, use fire extinguishing equipment and systems
in a safe and effective manner, and how to evacuate safely in the event that a fire cannot be controlled.
• Every workplace that has potential fire hazards must be equipped with a sufficient number of conveniently located
and easily accessible fire exits.
• The following fire hazards are found in various workplaces:
➢ Open flames used in various applications (such as welding)
➢ Electric wires, higher loads, loose connections, and old electrical equipment
➢ All cooking and heat generating appliances
➢ Smoking and the use of personal lighters or matches
➢ Insufficient capacity and numbers of emergency exits and stairs
➢ Hindrance to sight or reach firefighting equipment, markings, and alarm systems
➢ Insufficient numbers and types of fire extinguishers
➢ Absence of fire detection and alarm system

ELECTRICAL HAZARDS

• An Electrical Hazard can be defined as a serious workplace hazard that exposes workers to burns, electrocution, shock,
arc flash / arc blast, fire, or explosions.
• Common electrical hazards in the workplace and electrical safety tips to mitigate these risks are:

1. Overhead Power Lines

Overhead powered and energized electrical lines have high voltages which can cause major burns and electrocution to
workers. A minimum distance of 10 feet from overhead power lines and nearby equipment should be maintained.
2. Damaged Tools and Equipment
Exposure to damaged electrical tools and equipment can be very dangerous. Anything should not be fixed unless anyone
is qualified to do so. Cracks, cuts, or abrasions on cables, wires, and cords should be thoroughly checked. In case of any
defects, that should be repaired or replaced.
3. Inadequate Wiring and Overloaded Circuits
Using wires of inappropriate size for the current can cause overheating and fires to occur. The correct wire suitable
for the operation and the electrical load to work on should be used.
4. Wet Conditions
Electrical equipment should never be operated in wet locations. Water greatly increases the risk of electrocution
especially if the equipment has damaged insulation.
5. Exposed Electrical Parts
Examples of exposed electrical parts include temporary lighting, open power distribution units, and detached
insulation parts on electrical cords. These hazards can cause potential shocks and burns.
6. Improper Grounding
The most common OSHA electrical violation is the improper grounding of equipment. Proper grounding can
eliminate unwanted voltage and reduce the risk of electrocution.
7. Damaged Insulation
Defective or inadequate insulation is a hazard. One should be aware of damaged insulation and report it immediately.
All power sources should be turned off before replacing damaged insulation and attempt should never be made to
cover them with electrical tape.
• Causes of Electrical Hazards:
➢ Faulty or damage wiring or equipment.
➢ Loose connections.
➢ Lack of earthing/bonding and grounding.
➢ Use of overrated fuse or jumper.
➢ Working on live equipment.
➢ Overloading of power sockets and equipment.
➢ Poor housekeeping.
➢ Lack of safe working procedure and communication.
➢ Lack of warning signs.
• Electrical Safety Control Measures:
➢ A competent and experienced person shall be allowed to do electrical jobs.
➢ Don’t work on live equipment, isolation and multi lock system shall be followed.
➢ Don’t hang cloth or any material on electrical equipment.
➢ Handling of electrical equipment or switchgear shall not be done with wet hand or body.
➢ Electrical switches or access to them shall not block by any material.
➢ Use appropriate PPE while working on electrical equipment.