1. Statutory Provisions
Rationale : Every Supervisory personnel working in Chemical
Industry must know the various laws relating to Industrial Safety as these
provide guidelines in decision making in any situation.
1.1 The Factories Act & Rules
1.2 The Environment (Protection) Act 1986 with special
emphasis on MSIHC Rules & Handling of Hazardous wastes Rules
1.3 The Indian Petroleum Act 1934 & Rules
1.4 The Indian Explosive Act 1984 & Rules
1.5 The Static & Mobile Pressure Vessel Rules
1.6 The Indian Boiler Act & Rules
1.7 The Insecticides Act & Rules
1.8 Gas Cylinder Rules
Detailed Contents :
1.1 The Factories Act & Rules - Definition – Adult,
adolescent, young person, child, competent person, hazardous process, manufacturing
process, worker, factory, occupier.
- General duties of occupier & manufacturers, powers of
Inspectors & certifying surgeons.
- Provisions relating to Safety, health and welfare measures
and rules made there under.
- Dangerous operations and schedule on chemical works.
- Notice of accidents, dangerous occurrences & certain
diseases.
- Obligation & Right of Workers.
1.2 Environmental Protection Act:
- Manufacture, Storage & import of hazardous chemical
rules 1989
- Hazardous waste (Management & Handling) Rules 1989.
1.3 Petroleum Act & Rules :- Petroleum & its
classification, General Provision for Transportation of Petroleum by vehicles
& pipe lines, bulk storage, type of licences & their terms &
conditions, electric installation in hazardous areas.
1.4 Indian Explosive Act & Rules:
- Handling, precautions & general provisions of
explosive rules 1983, classification of explosives & safety distances,
magazines & store house, transport of Explosive by road.
1.5 SMPV Rules :
- Definition of Design pressure, pressure vessel, compressed
gas, filling density
- Test & Inspection of Pressure Vessels
- Fittings on vessels
- Provision relating to loading & unloading & other
operations.
- General provision for storage & licences for storage
& transport
- Any other notification under SMPV Rules 1981.
1.6 Indian Boiler Act & Rules :
- Definition of Boiler, Inspection procedure &
preparation of boiler for inspection &
Hydraulic test, defects & repairs of boilers.
1.7 Insecticide Act
& Rules :
- General Provisions
1.8 Gas Cylinder Rules :
- General Provisions, licence, notice of accidents,
conditions for storage of LPG
Cylinders.
2. Basic Principles of Accident Prevention
Rationale : Accident Prevention is an integrated programme,
a series of coordinated activities directed to control unsafe personal
performance & unsafe mechanical conditions so as to operate the plants
& processes in a manner that protects the environment & safety of
employees & the public, commitment by all levels of management for protecting
& promoting the health & safety of people working at sites.
2 .1 Basic Philosophy of Industrial Accidents – Causation
& Prevention near miss reporting and learning lessons; Accident causation
models
2.2 Safety &
Health Policy
2.3 Types of Hazards – Physical, Chemical, Electrical,
Mechanical, biochemical, radiological, etc.
2.4 Role of Supervisor in promoting Safety & Health
2.5 Accident and root cause analysis
2.6 Principal Factors for classification
2.7 Formulation of Accident Prevention Programme
2.8 Electrical Safety
2.9 Case Study
Detailed Contents:
2.1 Basic Philosophy
of Industrial Accident – Causation & Prevention near miss reporting and
learning lessons; Accident causation models: 10 axioms of Industrial Safety,
theories of accident occurrence – Heinrich domino sequence & updated frank
bird model, Multi-causation theory, Foundation of Major Injury, Basic Motives
for the occurrence of unsafe acts, basic methods for
preventing accident, Accident Causation Models.
2.2 Safety & Health Policy:
Legal requirement for safety policy, basis for formulation
& effective implementation of safety policy, Areas to be touched in safety
policy.
2.3 Type of Hazards:
Physical – Heat stress, Noise, Fatigue, Radiation,
Vibration, Illumination Chemical – Exposure to toxic material, contact with
corrosive material, spillage Electrical – Fire, Burn, Shock Mechanical –
Hazards due to in running nips of machinery parts & mechanism,
working at height, hazards due to improper manual &
mechanical handling.
Biochemical – Radiological – Different types of radiation
hazard
2.4 Role of
Supervisors in promoting Safety & Health:
- Responsibilities of Supervisors, Acceptance of
Responsibility for safety,
- Role of Supervisor in safety.
2.5 Accident and
root cause analysis:
- Injuries, employment, No. of working factories, rate of
injuries, injuries by states/union
territories, injuries by industries, injuries by causes.
- Frequency Rate, Severity Rate, Incidence Rates, Accident
free period, use of accident rates.
2.6 Principal Factors for Classification:
- Standard classification of factor associated with
accident. (IS-3786)
2.7 Formulation of Accident Prevention Programme:
- Planning - Management leadership, Goal setting, budgeting
- Organising - Organisation structure, delegation of power,
span of control, safety education & training and 5 min. pep talk, safety
content. - Directing - Communication system, safety committee, safety manual,
SOP’S,
Suggestion Scheme. - Coordinating – Motivational Activities
(safety contest, display of posters,
Celebration of safety day and safety week)
- Controlling – Accident reporting, record & analysis,
accountability, surveillance.
2.8 Electrical
Safety
2.9 Case Study:
Bhopal disaster, flix borough disaster, mexico disaster etc.
3. Techniques of Identification of Hazards and Risk
Management
Rationale : Hazard identification is the process of finding
all items, activities & situations that could lead to the potential of
injury or illness. Supervisors should be conversant with such technique.
3.1 Plant Safety Inspection
3.2 Accident
Investigation
3.3 Job Safety
Analysis (JSA)
3.4 Fault tree
Analysis (FTA)
3.5 Failure Modes and Effect Analysis (FMEA)
3.6 Hazard &
Operability (HAZOP) study
3.7 Hazard Identification and Risk Assessment (HIRA)
3.8 Risk and Risk
Management
Detailed Contents:
3.1 Plant Safety Inspection:
Responsibility for inspection, types of inspection, planning
for inspections, conducting inspections, inspection reports, Development of
checklist for storage & process areas and Safety sampling.
3.2 Accident
Investigation:
Need for accident investigation, pre-accident plan,
investigation at accident site, persons to make investigation, identifying key
facts & causes, first aid report, supervisor’s, investigation report,
notification of accident, accident record register, personal injury record
card.
3.3 Job Safety Analysis (JSA)
3.4 Fault tree Analysis (FTA)
3.5 Failure Modes and Effect Analysis (FMEA)
3.6 Hazard &
Operability Study :
Objective, operating deviation, guide words, principles of
examination,
methodology, benefits of HAZOP study and a case study.
3.7 Hazard
Identification and Risk Assessment (HIRA)
Responsibility for J.S.A. & its use, conducting J.S.A.
with an example.
3.8 Risk and Risk Management
HIRA work sheets, Risk Matrix, Probability and Consequence,
Prevention and Control Measures
4. Prevention and Control Techniques
Rationale : The segregation & separation of materials
within storage area largely depends upon classification of materials &
electrical areas, industrial ventilations, other control techniques, help in
improving the work environment.
Knowledge of such control technique is essential for plant supervisor.
4.1 Hierarchy of Controls
4.2 Dilution &
Substitution, etc.
4.3 Segregation, Enclosure, Isolation, Barricading,
Guarding, Interlocks
4.4 Industrial ventilation
Detailed Contents:
4.1 Hierarchy of
Controls
4.2 Dilution &
Substitution, etc.
Substitution : Replacing material/process with less
hazardous substances/process.
Dilution : Handling of material in dilute form like use of
dilute nitric acid in place of concentrated fuming nitric acid & similar
examples.
4.3 Segregation, Enclosure, Isolation, Barricading,
Guarding, Interlocks
- Segregation : Material classification for volatile
liquid, Electrical Area Classification
and Various methods of Isolation of equipment & pipelines.
- Equipment barricade & provision of enclosures.
- Principles of machine guarding, type of guards, selection,
maintenance & repair of guards.
- Interlocks
4.4 Industrial
ventilation
5. Chemical
Hazards & Specific Control Measures
Rationale : Unplanned, sudden release of chemicals from
manufacturing processing, handling & onsite storage facilities causes
pollution to the air, water or land & increase the risk of fire, explosion
or pollution. Hence supervisory personnel should be aware of various requirements
of safe task activities.
5.1 -Storage, handling & transportation of chemicals
(Safety in bulk storage, handling of hazardous chemicals,
chemical process safety)
-Industrial Classification
5.2 Permit to work – procedure & compliance
5.3 Safety in shutdown & startup procedures
5.4 Colour coding of pipelines, cylinders & valves
5.5 Labelling & Hazard Communication (HAZCOM)
5.6 Personal Hygiene
5.7 Tankfarm Safety and dyke arrangements
5.8 Chemical Safety data sheets / MSDS
5.9 House Keeping
5.10 Personal Protective Equipment
5.11 Standard Operating Procedures (SOP)
5.12 Standard
Maintenance Procedures (SMP)
5.13 Safety Instrumented System (SIS)
5.14 Concept of Reliability and calibration
Detailed Contents:
5.1 Storage, handling & transportation of chemicals
(safety in bulk storage, Handling of
hazardous chemicals, chemical safety), Industrial
Classification :
- Handling & storage of dangerous materials & their
classification (U.N.)
- HAZCHEM Code
- TREM Cards
- Types of Bulk Storage & their lay out, bunds, pressure
vacuum valves, flame arrester, atmospheric vents, fire relief, inspection of
storage tanks. - Storage of chlorine, L.P.G., Ammonia, Class ‘A’ petroleum
product, hydrogen
- Loading & unloading facilities of chemicals.
- Hazard Communication
- Industrial Classification
5.2 Permit to Work– procedure and compliance:
Need for permit to work system, areas to be covered, types
of work permit, contents of permit format, operation of permit, monitoring of
permit system, confined space work permit system.
- Standard operating
procedure, Standard Maintenance Procedure, start up procedure (Phases of
start up), typical errors on start up of plants, start up after emergency shut
down
- Shut down procedure - Normal shut down, Emergency shut
down - Modification procedure – classification of modification.
5.4 Colour coding
of pipelines, cylinders & valves :
- Pipe work & valves, inspection, examination &
testing of pipelines, cylinders valves, colour coding of pipe lines (IS
2379-1990)
- Tankfarm Safety
- Dyke arrangements
5.5 Labelling and Hazard Communication (HAZCOM)
5.6 Personal Hygiene
Washing facilities, drinking water, facilities for storing
work clothings & personal clothing & drying clothes (clock room),
storage of food items in plant & prohibition of consuming food etc in work
room. Special bathing accommodation, health awareness do’s and don’ts.
5.7 Tankfarm Safety
and dyke arrangements
5.8 Chemical Safety Data Sheets/ MSDS
- Contents of M.S.D.S.
of MSIHC Rules 1989 & its preparation.
- M.S.D.S. of Cl2, NH3, LPG & benzene
- Hazard Communication
5.9 House Keeping
Typical accidents due to poor house keeping, disposal of
scrap & other trade wastes,
prevention of spillage, marking of gangways & other
locations, clean up campaigns.
5.10 Personal Protective Equipment
- Non Respiratory
personal protective devices – head protection, ear protection, face
& eye protection, hand protection, feet protection, body
protection
- Use care & maintenance of personal protective
equipment & breathing apparatus
- Classification of respiratory personal protective devices
& their uses, selection of respirators.
5.11 Standard Operating Procedures (SOP)
5.12 Standard Maintenance Procedures (SMP)
5.13 Safety Instrumented System (SIS)
5.14 Concept of Reliability and calibration
- Basic Instrumentation & designed safety methods like
- Control of variables like temperature, pressure, level,
PH, density, flow ratios etc.
- Multipoint recorders, process alarms, interlock system
- Operators records like log book, log sheet.
- Safety Instrumentation System
6. Fire & Explosion Hazards
Rationale : Fire hazard is a term which includes not only
the causes of fire but embraces those circumstances which increase the
probability of fire occurring or which
enable or permit fire. Hence supervisory
personnel must know an effective fire loss control program.
6.1 Fire and Explosions
6.2 Flash Point, Explosive limits etc
6.3 Fire Prevention and control Portable & Fixed Fire
Fighting Systems
6.4 Hazardous Area classification & safety aspects including
flame proof electrical equipment
6.5 Dow Fire & explosion index
6.6 Reporting
deviations for inspection, refilling,examination etc of fire fighting system
6.7 Consequence Modelling Fire and Explosion
6.8 Electrical Safety; bonding, earthing and Hazardous Area
Classification
6.9 Static Electricity hazards and its prevention and
control
Detailed Contents :
6.1 Fire and
Explosion
Definition :
Flammability, flash point, fire point, flammable range, auto
ignition, boiling point, vapour pressure, vapour density, ignition energy,
spontaneous ignition.
Chemistry of Fire :
Factors contributing towards fire, chemistry of fires,
classification of fires, common causes of industrial fires.
6.2 Flash point,
explosive limits, etc.
6.3 Fire Prevention and Control; Portable &
Fixed Fire Fighting System:
- Portable extinguishers, water system, CO2 system, foam
extinguisher system, chemical extinguishing system. - Fire detection &
alarm system – heat detector, smoke detector, detector for special purpose etc.
- Sprinkler system
6.4 Hazardous Area
Classification and safety aspects including flameproof electrical Equipment:
Hazardous area classification, control of hazards due to static electricity, flame
proof electrical equipments, precautions in their selection, maintenance &
use.
6.5 Dow Fire &
Explosion Index :
Knowledge of exothermic & endothermic reactions &
their hazards, material factor, assessment of fire & explosion index,
toxicity index.
6.6 Reporting
deviations for inspection, refilling, examination, etc, of fire fighting
System:
Importance of Maintenance, preventive maintenance program
for portable & fixed fire fighting equipment, extinguisher card, fire alarm
system inspection, testing & maintenance.
6.7 Consequence
Modeling
Health hazard due to fire and explosion and its first-aid measures.
- Burn
- Unconsciousness
- Shock
6.8 Electrical Safety, bonding, earthing and Hazardous Area
Classification
6.9 Static Electricity hazards and its prevention and
control
7. Health Hazards due to Chemical Exposure
Rationale : Industrial Hygiene activities includes surveys,
measurements, evaluation, controls & recommendations. Properly documented
exposure – illness records serve to determine safe or unsafe, healthy or
unhealthy working conditions & limits of exposure.
Industrial hygiene integrate s three elements i.e.
recognition, evaluation and control of different physical and chemical stresses
/agents at the work place.
The trainees should be given brief orientation at least on
the following topics :
Introduction to different physical stresses /agents like heat ,noise ,illumination etc and
chemical agent and their effects Chronic and acute effects , Dose Response
relationship , Classification of airborne chemical agents (including based on
physical nature i.e. dust, gases, fumes, mists, vapours and smoke).
Routes of
Entry of Hazardous Chemicals in human body, Exposure evaluation and air
sampling. The concept of threshold limit values, Control techniques of airborne
Contaminants, Industrial Ventilation and personal Protective Equipment.
The trainees should be demonstrated on following main
laboratory exercises:
1.Detection of
Carbon Monoxide, NOxx Hydrogen Sulphide, Ammonia, SO2by Gas
Detectors and other direct reading instruments.
2.Measurement of
Concentration of Dust using Personal Sampler by Gravimetric Method.
3. Sampling and analysis of Ammonia.
4. Estimation of
Hydrogen Sulphide in Air.
5. Estimation of Chlorine in Work Environment.
6. Measurement of
illumination level by Photo Meter.
7. Assessment of
Heat Stress in Work Environment using WBGT Intex
8. Measurement of number of air changes in a room by
Velometer
9. Measurement of
Sound Levels.
10.Determination
of concentration of inflammable vapours.
7.1 Factors contributing to hazardous situation
7.2 Routes of entry
7.3 Concentration and
types of exposure
7.4 Work environment monitoring– techniques & procedure
7.5 Toxic effects of chemicals
7.6 Health monitoring
7.7 First Aid
7.8 PLE, TLV, IDLH,
LC 50 and LD 50
7.9 Toxicology; Dose
Vs. Response Relationship
7.1 Factors
contributing to hazardous situation
Permissible limit of exposure : TLV – TWA, STEL, Ceiling,
Skin, Additive effect, Nuisance Dust, Carcinogenesis.
7.2 Routes of entry
The modes of entry & action of toxic materials : Classification of
contaminants & route of entry - Physical classification – Gases &
vapour, particulate matter like dust, jog, fume, smoke, smog, aerosol etc .-
Chemical classification – Irritants, Asphyxiants, Anesthetics & Narcotics, Systemic poisons, Sensitizers,
particulate matter other than systemic poisons (Bacteria & other micro
organisms).
7.3 Concentration
and types of exposure
7.4 Work Environment Monitoring – Techniques & Procedures
:
- Strategy for representative quantitative surveys. - Air
sampling– Integrated sampling, gas sampling, impingement - Analysis of samples
– Gravimetric technique, colorimeter procedure & evaluation of samples.
- Direct Reading Techniques – colorimetry, explosive meter,
other electronic monitor.
- Industrial Hygiene Engineering Control.
7.5 Toxic effects
of chemicals
7.6 Health Monitoring
:
- Common occupational diseases & mode of causation of
these disease.
- Diagnostic methods & methods of prevention.
- Pre employment & periodical medical examination.
- Monitoring of occupational health by maintaining records.
7.7 First Aid :
Artificial respiration techniques and cardiac message (CPR),
bandaging, burn, fracture etc.
7.8 PLE, TLV, IDLH, LC 50 and LD 50
7.9 Toxicology; Dose Vs. Response Relationship
Demonstration of Equipment in laboratory :
- Measurement of dust concentration in work environment by
counting method using midget smpinger & microscope.
- Estimation of H2S in air
- Sampling & analysis of NH3 & Cl2
- Determination of concentration of inflammable vapours.
- Visit to medical laboratory.
8. Chemical Emergency Procedures :
Rationale : Emergency plan should be prepared for
significant events that threaten the viability of the organisation,
periodically tested & reviewed.
8.1 The Onsite Emergency Plan
8.1.1 Key persons and their responsibilities
8.1.2 Alarms
8.1.3 Control room
8.1.4 Evacuation
8.1.5 Assembly points
8.1.6 Emergency Control Centre
8.1.7 Rehearsals
8.1.8 Rehabilitation of the affected area
8.2 Off site E.P.
8.3 Other Emergency
Procedures Disaster Management Planning
8.1 The Onsite Emergency Plan :
- The general contents of onsite emergency plan,
identification of credible events, categorisation of emergency level.
- Key persons & their responsibilities, alarms, control
room, evaluation, assembly points, medical organisation/responses for major
accident hazard control
- Rehearsals & Rehabilitation of the effected area.
- medical response in chemical emergency.
8.2 The off site Emergency Plan :
- Response time, contents of off site E.P. together with
responsibilities
- Role of emergency planning officer.
- Rules on Emergency, Planning, Preparedness & Responses
for chemical accidents-96
8.3 Other Emergency Procedures :
Emergency eye wash & showers, emergency kit for chlorine
& ammonia.
Disaster Management Planning Disaster Management Planning in
Chemical Industries – Disaster Management Act – Legal Compliance
9.Counseling and motivating for safety & health
Motivation, Communication &
Appraisal for Safety & Health
Rationale : Process measures provide not only a better tool
for safety improvement but also a means of measuring employee involvement and
commitment. Periodic audit should be conducted for a critical & appraisal
of all elements of OH&S management system.
9.1 Techniques
9.2 Strategies
9.3 At Risk Behaviours
9.4 Discretionary Performance
9.5 Motivational Models
9.6 Human Error – Prediction, Prevention and Control
9.1 Techniques
9.2 Strategies
9.3 At Risk
Behaviours
9.4 Discretionary Performance
9.5 Motivational Models 9.6 Human Error – Prediction,
Prevention and Control
10. Others Behavioural aspects of safety, Physiological
aspects of safety– Resilience Engineering
10.1 Total quality management and ISO Series.
10.2 Safety audit and OSHAS
10.3 Environmental Management System (EMS)
10.4 Communication skills for safety & health at work 1
10.5 Behavioural aspects of safety
10.6 Physiological aspects of safety
10.7 Total Safety Culture
10.8 Resilience Engineering
10.1 Total quality management and ISO Series.
10.2 Safety audit and OHSAS Safety Audit – Definition,
Objectives, Types of Audit, Methodology, Developing checklist for safety audit
– technical aspects & management aspects.OHSAS
10.3 Environmental Management System (EMS)
10.4 Communication skills for safety & health at work
Types of communication, barriers of effective communication
and how to overcome these barriers.
10.5 Behavioural aspects of safety
10.6 Physiological aspects of safety
10.7 Total Safety Culture At Risk Behaviour – Discretionary
Performance - Motivational Models – Human Error – Prediction, Prevention and
Control
10.8 Resilience Engineering
Basic Laboratory facilities/equipments to be maintained:
I- Industrial Hygiene Laboratory
1. Personal Samplers
2. Filter Discs
3. Analytical
Balance
4. Rotameter
5. Detector tubes
for Carbon Monoxide , ammonia, Chlorine etc
6. Gas Monitors
for common chemical gases like Carbon Monoxide , ammonia, Chlorine etc
7. Glassware and
chemicals
8. Analytical
Instruments like Spectrophotometer etc
9. WBGT Meter or Globe Thermometer and Whirling Hygrometer
10. Explosimeter
II -Safety Engineering Laboratory
1. Sound Level Meter
2. Illumination Level Meter
3. Vibration Meter
4. Static Electricity Meter
III- Industrial Medicine Laboratory
1. Audiometry
2. Titmus Vision
Test
3. PFT
No comments:
Post a Comment