Safety Refresher Training Manual PDF (Southern Petrochemical Industries Corporation Ltd)

SOUTHERN PETROCHEMICAL INDUSTRIES CORPORATION LTD & GREENSTAR FERTILIZERS LIMITED TUTOCORIN - 628005 1 First Edition 1974 Revised Edition 2024 SAFETY REFRESHER TRAINING MANUAL 2 Contents… 1. WORKING A...

SOUTHERN PETROCHEMICAL INDUSTRIES CORPORATION LTD & GREENSTAR FERTILIZERS LIMITED TUTOCORIN - 628005 1 First Edition 1974 Revised Edition 2024 SAFETY REFRESHER TRAINING MANUAL 2 Contents… 1. WORKING AT HEIGHT PROCEDURE 7 2. ROAD BLOCK PROCEDURE 7 3. COMMUNICATION PROCEDURE 8 4. HAZARDOUS SUBSTANCE CONTROL SYSTEM 12 5. SAFETY SYSTEM IN SPIC 16 6. ACCIDENT PREVENTION 33 7. ACCIDENT REPORTING AND INVESTIGATION 35 8. MAINTENANCE SAFETY 52 9. MACHINE GUARDING 63 10. SAFETY IN USE OF HAND TOOLS 68 11. RIGGING 71 12. MATERIAL HANDLING AND STORAGE 86 13. PROCESS SAFETY 94 14. SAFETY IN STORAGE, HANDLING AND TRANSPORTATION OF 101 HAZARDOUS CHEMICALS 15. SAFETY PERMIT SYSTEM 113 16. SAFETY IN CONFINED SPACE 116 17. PERSONAL PROTECTIVE EQUIPMENT 121 18. GOOD HOUSEKEEPING 127 19. SUPERVISOR’S ROLE IN SAFETY 130 20. HAZARD ANALYSIS 133 21. SAFETY AUDIT 143 22. RISK ASSESSMENT 145 23. FIRE PROTECTION SYSTEM AT SPIC 151 24. PORTABLE FIRE EXTINGUISHERS 159 25. FIRE RISK – ASSESSMENT 165 26. ELECTRICAL SAFETY 171 27. OCCUPATIONAL HEALTH 182 28. FIRST AID 186 29. ENVIRONEMTNAL MANAGEMENT SYSTEM 195 30. SAFETY QUIZ 208 3 FERTILIZER COMPLEX, TUTICORIN 4 5 6 7  PREFACE In the modern era of globalization, the growth of fertilizer industry is inevitable. New industries are coming up and newer types of hazards are being introduced in the processes. It is imperative to update our technical knowledge so as to put maximum effort for increasing productivity without compromise to safety. Our HSE Management system not only focuses on "Accident Prevention" but also on the concept of "Total Loss Control". Learning is a continuous process. We believe that "Knowledge is Power". To refresh and update our knowledge in tune with the latest changes/ developments, refresher training is imparted to the employees. In addition to the inputs from the faculties, this manual is provided as a reference. Topics such as Risk Management; Accident Reporting and Investigation, Environmental Systems, Occupational Safety, Safety in Confined Space, etc., have been updated. Wherever possible pictorial representation has been provided for better understanding. We hope that this manual will provide the necessary inputs to enhance your knowledge and will be helpful in achieving productivity with zero accident. 8  WORKING AT HEIGHT PROCEDURE We are committed to providing a safe and comfortable working environment in all our work activities including the work at height. Where practicable, working at height using temporary access shall be prevented and / or minimized by modification to work equipment, work arrangements, etc. and erection of well-designed access. Workers engaged in such work shall be suitably informed, instructed, trained and supervised. Safety equipment such as safety belts shall be utilized for this purpose. The personal protective equipment used for this purpose shall be maintained and regularly inspected. We are committed to ensuring that this policy is implemented forall activities at height whether by directly employed staff or bycontractor. ROAD BLOCK PROCEDURE 1. If any of the factory roads which will be used by Fire Tender or Ambulance during emergency are to be blocked for any civil work or for any other job, the blocking of road is to be intimated immediately to Fire Control Room/Safety & Environment Department. 2. Alternate route for reach of Fire Tender/Ambulance to the emergency spot (in case of emergency in that area) is to be planned and ensured before road blocking. 3. There should be proper signs displayed to indicate diversion and to mention about the road blockage. Area to be cordoned off with cordon off tape. During night time there should be a flickering red lamp provision in the area of blocking to warn the vehicles of the blockage. Signs displayed should be of fluorescent/reflective type. 4. The jobs are to be carried out with a valid safety permit from the concerned area In charge. 5. After completion of the job, it should be informed to the Fire Control Room/ Safety & Environment Department. 9  COMMUNICATION PROCEDURE To translate our commitment enumerated in our "Safety Policy" and "Communication Policy" regarding the provision of information and training to all employees, the following Communication Procedure has been evolved and followed up. I. COMMUNICATION THROUGH TRAINING: Basic Training: All the new recruits are trained in the basic aspects of Safety, Health and Environment. The syllabus has been derived on the basis of their job requirements and continually reviewed and modified. After the completion of the training period, the performance of the traineesare evaluated through a written examination and viva voce conducted by the Committee consisting of senior management personnel. Refresher Training: Refresher training is imparted to all the employees on a regular monthly basis. It is ensured that all the employees are covered within 2 years. During the training program apart from Safety, Health and Environment matters, latest technological advancements, Plant modifications, associated risks, control measures etc., are discussed. Hazard identification and Risk assessments are also discussed. 10 Contractors Training: Contractors are given the specific training pertaining to their job based on their occupation (Welders, Electrician, Scaffolders, Operation workers, Riggers, etc) Contractors Training programs are also arranged for the supervisors with the assistance from Factory Inspectorate, Government of Tamil Nadu in a periodical basis. During the training,accidents occurred, accident prevention, Personal protective equipment compliance etc. are discussed. Induction videos are also played for effective communication. New contractor workers coming to the site are given induction training explaining about the rules and regulations, the objectives of contractor's safety policy, hazards envisaged in the job and accident prevention methods. They are appraised about the Emergency Preparedness Plan and their role. On the spot training is also given to contractors on regular basis. II. COMMUNICATION THROUGH SAFETY CIRCULARS / POSTERS: The safety messages are communicated regularly through safety circulars and also displaying safety posters. III. COMMUNICATION THROUGH INTRANET: The following messages are circulated to all the employees through Intranet. 1. Rules and regulations to be followed 2. Accident case studies 3. Safety, Health and environment Posters 4. On the job Safety 5. Occupational Health and Safety Also, Process Safety Beacon is published on monthly basis. Apart from this, external case studies are also published with illustrations. IV. COMMUNICATION THROUGH SCROLLING SCREEN: The following messages are circulated to all the residents of Spic Nagar through scrolling in Screen. 1. Home Safety 2. LPG Safety 3. Road Safety 4. Do’s and Don'ts during emergency 11 V. COMMUNICATION THROUGH DOCUMENTS : Documents relating to their job on Safety and Health matter like Safety Manual, Standard Operating Procedure, and Material Safety Data Sheet are made available to all the employees. VI. EMPLOYEE CONSULTATION : We are having the following forums for employer - employee consultation. 1. Central safety council 2. Plant Safety Committees 3. Safety Coordinators Committee 4. Central Services Group committee 5. Contractors safety committee In the above forums all safety, health and environment related matters are discussed. The minutes of the meetings are displayed in all notice boards. VII. HAZARD COMMUNICATION: Hazards associated with the work / equipment’s are communicated through warning boards / mandatory signs at the appropriate locations. VIII. COMMUNICATION THROUGH "PEP TALK": The new concept of PEP talk on safety related matters was introduced from January 2002. PEP talk is being conducted in their work areas for few minutes on specific topic on safety, health related matter. IX. COMMUNICATION THROUGH "TOOLBOX TALK": While mechanical/electrical/maintenance jobs are being carried out just before taking up maintenance job, the supervisor explains to the employee/contractor about the hazards associated with the job and necessary precautions which have to be followed for prevention of any incident/accident. X. COMMUNICATION THROUGH "HANDS ON EXPERIENCE": Employees who have to handle chemicals are trained and retrained in the usage and wearing of breathing apparatus/airline masks in their respective areas. Employees are provided with hands on experience in operating first aid firefighting appliances. 12  ENORMOUS PRODUCTION IS OUR GOAL EXCELLENT SAFETY IS OUR TOOL HAZARDOUS SUBSTANCE CONTROL SYSTEM PURPOSE : To outline a procedure to control the use of substances hazardous to health. OBJECTIVE : To eliminate/minimize the risk of exposure to such chemicals and to implement the control measures. ROLE OF MANAGEMENT : The management is committed to providing a safe and healthy work environment to protect the employees from occupational disease pertaining to their employment. The management is implementing all control measures to reduce the use of hazardous chemicals and to eliminate / minimize the risk of exposure. 13 A) INFORMATION: 1. The list of chemicals used in each department is maintained, together with the Material Safety Data Sheets. 2. The information about the hazardous nature of such chemicals, routes of entry; the potentiality to cause harm and the first aid measures have been provided to the employees. 3. Proper training is given explaining about the safe storage, handling and transportation methods. 4. Labeling of chemicals and color coding of pipelines carrying hazardous materials are followed up. 5. Enforcement in using PPE by declaring "Mandatory Wearing of PPE" 6. While procuring chemicals, MSDS is obtained from the suppliers. 7. Proper labeling is ensured. B) ASSESSMENT OF RISK: The following points are considered while assessing the risk involved in the use of hazardous chemicals: 1. Hazardous nature of the chemicals 2. Quantity of chemicals stored/handled/transported 3. Potentiality to do harm 4. Likelihood of occurring any ill health. 5. Severity of ill health that may be caused 6. Examination of work practices 7. Length of exposure 8. Level of exposure 9. Degree of supervision 10. Level of training C) CONTROL MEASURES: Depending upon the risk control measures are implemented. 1. Prohibiting the use of such substance. 2. Substitute with less hazardous substance, so far as is reasonably practical. 3. Control the inventory at optimum level. 4. Enclose the process of source of hazardous vapors 5. Provision of dykes / bunds to contain spillages. 6. Design the equipment to minimize the generation of harmful vapors 7. Provide suitable and adequate ventilation 8. Reduce the number of people exposed 9. Reduce the period/time of exposure 10. Provide safe storage and disposal 11. Provide safe handling methods/procedures 14  12. Clean the spillage then and there 13. Provide suitable personal protective equipment 14. Provide adequate hygienic facilities/decontamination facilities 15. Storage of flammables in flameproof cabinet 16. Provision of eye wash fountain/safety showers. 17. Provision of eye wash bottles. 18. Storing of chemicals by considering the incompatibility. D) INVENTORY CONTROL: The inventory of all the chemicals stored/used is kept at the optimum level so that the hazard posed by the chemicals during storage/ handling and transportation is minimum. The following procedure is adopted in SPIC for inventory control: Indentor: The indentor must study the properties of chemicals to be used, any alternate/ less hazardous chemical and to raise the purchase requisition. Materials Management: The inventory control officer has to ensure the available quantity at stores, the consumption pattern and the cost of quantity intended. Then the purchase requisition is forwarded for initiating the purchase order. The purchase of chemicals is effected in two ways : 1. Levelled Item: Minimum stock has been specified for certain chemicals used in Quality Control Laboratory, and Cooling Water Treatment. Purchase orders are raised when this stock comes to the minimum level. 2. Non-Levelled Item: Indentor/user department has to raise the purchase requisition. The purchase department arranges to purchase the required ensuring proper labeling and materials safety data sheets. The quantity purchased is stored taking care of all precautionary measures. 15 E) MONITORING OF CONTROL MEASURES:  The work activities are monitored to ensure that the control measures are in place and maintained properly.  The correct type of Personal Protective Equipment are provided and ensured for compliance.  The inventory is controlled.  The vendors/visitors are prohibited to bring chemicals for trial purposes without prior approval of Management.  The chemicals are stored considering the compatibility and as per therequirements of relevant statutes.  Chemical handling is restricted to authorized persons only.  The necessary information and training have been provided.  The spillage of chemicals is controlled.  The disposal of chemicals is done as per the norms set out by TNPCB/CPCB/ relevantActs and Rules. F) MONITORING OF EXPOSURE : The level of hazardous nature present, the length of exposure, the number of times of exposure are monitored regularly. 16 G) HEALTH SURVEILLANCE: The following Health Surveillance program is in place and in operation. 1. Pre employment screening 2. Periodical medical check up 3. Special clinical examination if necessary 4. Inform the results of surveillance 5. Provide adequate medical treatment/facilities. II. ROLE OF EMPLOYEES: 1. To be aware of the chemicals used in their work area. 2. The MSDS of the above chemicals. 3. Reduce the level of exposure. 4. Use proper PPE. 5. Adopt safe methods in storage, handling, and transportation. 6. Inform/educate the contractors. 7. Clean the spillage. 8. Use proper labeling systems. By having the above systems in operation and monitoring the effectiveness of control measures, the chemical management system is practiced in a very safe manner. 17  SAFETY SYSTEMS IN SPIC SPIC considers safety as a line function and believes that "Safety is a team effort". The employees are fully aware that "Safety is everybody's business". Everyone takes an active part in the safety programmes, to obtain a continuous improvement in performance. Based on past experience and by means of various studies such as safety audits, HAZOP study, and risk analysis safety- related key-result areas have been identified and systems and procedures have been evolved and implemented successfully. 1. Safety, Health and Environment Policy: We have declared Safety Health and Environment Policy which reflect our management's dedication and strong commitment towards safety and health of our employees and the society around us. Our environment policy enumerates our sincerity to comply with applicable environmental regulations and to prevent pollution. The contents of the policy and the means to achieve the objectives of such policy is communicated to all employees. 2. Built in Safety Systems: Care is taken to apply appropriate standards in the selection of the processes and designs to ensure that all safety parameters are met. Early warning alarms, automatic trip initiation devices (with remote operated valves) and adequate pressure relieving systems are incorporated in critical areas to prevent possible mishaps. 3. Condition Monitoring System: The mechanical condition and soundness of the various process equipment and vessels are monitored continuously, using on-line and off-line condition monitoring methods, with different types of non-destructive testing techniques. This helps to reduce the plant down- time and to plan "major equipment replacement" programmes in advance. 18 4. Critical Parameters Monitoring System: Critical parameters of the processes are closely monitored on day-to-day basis by the Process Engineering Group, which is independent of the Operations Group. They identify any deterioration of process efficiency by analysing the trend of parameters. This helps to optimise the process conditions and also to predict the residual life of catalysts so that their replacement may be planned at the appropriate time. 5. Safety Survey and Inspection: Spot checks and vigilance checks are carried out by personnel from Safety and Engineering Services to identify deviations from standard procedures, if any, and to implement appropriate correction measures whenever required. Qualified and competent personnel are available to monitor the work environment. Safety survey is conducted on machine guarding, safety Valves, storage tanks, sulphur pit, scrap yard, belt conveyors, gratings, platforms, structures, ladders, hand rails, trenches etc. 6. Safety Audit: The objective of the safety audit is to review and critically assess the existing safety programme, to prevent and control the hazards in the plant. Internal safety audit team, which comprises the representatives from operation, maintenance, process engineering and safety, audits the entire plant once in a year and recommends the measures for improvingthe effectiveness of the system. The recommendations are implemented. 19 External Audit: The plants are subjected to external audit by HSE experts like British safety Council's accredited auditors. So far our plants have been audited by British safety Council 5 times and we have received5 Stars grading 4 times and `Sword of Honor', the 'Oscar of safety World' 4 times. External Safety Audit is also carried out as per IS: 14489: 2018 standard by accredited safety auditors as approved by DGFASLI/DISH once in 2 years to comply with requirement of Tamil nadu control of IndustrialMajor Accident Hazard Rules 1994. 7. Job Safety Analysis: The Team comprising of safety, process and mechanical engineer will analyses the possible hazards that may arise during the execution of jobs and categories the risks with their effects. They will suggest the safest methods to carry out the jobs safely. 8. Toolbox talk system: While handing over the work order to maintenance technician, for executing a job, the Asst. Manager /Officer Maintenance explains the nature of the inherent hazards associated with the work and the safest methods to be followed for eliminating the hazards by using right tools. 20 9. Hazard and Risk Management System: Risk assessment is carried out for the entire plant and the recommendations are implemented. To identify hazards and operational problems, HAZOP studies are carried out for entire plants by internal HAZOP teams. HAZOP studies are carried out priorto all plant modifications. 10. Safety Permit System: A well-planned work permit system is in force. All Class-I permits are categorized into 6 groups, viz. (1) Hot work - Hazardous, (2) Hot work - Non-Hazardous, (3) Higher Elevation, (4) Confined Space Entry, (5) Acidline/other hazards jobs and (6) Earth excavation, with separateidentification colour codes for each group All class-I permit are authorised by Safety personnel after checking the area completely. Safety permits are displayed at the work spot. Other minor jobs are covered under Class -II permits. 21 11. Safety Permit Audit System: We have developed safety permit audit system under which permits issued are audited for the compliance of the conditions stipulated in the permits. 12. Environmental Monitoring System: SPIC and Greenstar’s commitment to protect the environment is unique. Utmost care is taken to maintain harmony with nature. On line monitoring of SO 2 and NO2 in Ammonia plant reformer stack, SOx and NOx in GT HRSG main stackand Aux boiler-III and Ammonia and Particulate matter in urea Prilling tower in our SPICplant , Sulphur di oxide in sulphuric acid plant stack, ammonia PM and HF in DAP I & II ,HF & PM in SSP ,PM in RG mill exhaust stack and HF inPA Stack in Greenstar are installed. Continuous online ambient Air Quality monitoring station is installed in two locations and on line display of the ambient air and stack emission parameters are lined with TNPCB Care air center. The parameters like Date, Time, Temperature, Relative Humidity, Ammonia, HF, PM10, PM2.5, NOx, SO2 and stack parameters are being displayed for the generalpublic. 22 Ambient Air Quality survey is carried out regularly at six permanent stations. Treated effluent is regularly analyzed and treated effluent is mostly consumed in Greenstar plants, Greenbelt development and remaining effluent is disposed to sea through marine outfall system. Effluent quality monitoring station has been installed and parameters such as pH, AN, Sea disposal flow and TSS are connected to TNPCB and CPCB. Environmental monitoring is carried out regularly. 23 13. Occupational Health Monitoring System: All the employees are subjected to a comprehensive medical check-up prior to employment and periodically thereafter, by SPIC’s and Greenstar’s own medical team, to ensure that all employees have the required physique and sound health. Occupational Health Center is functioning in our Hospital. Audiometry, vision test and lung function test are performed regularly. 14. Machine Guarding System: All prime movers, transmission machines and the rotating and dangerous parts of every machine have been provided with adequate and suitable machine guards. Machine guards have been painted in orange colour for easy identification. The suitability and adequacy of machine guards are checked every month by operation personnel using a check list system and the record is maintained. 15. Preventive and Predictive Maintenance System : A "preventive maintenance schedule" has been drawn up and implemented, to facilitate to maintain of all equipments in a sound condition. Similarly, predictive maintenance is carried out based on the feedback from condition monitoring system. Both the systems have been evolved on the basis of the performance record of individual equipments in the past. These programme have helped to reduce down time and accidents. 24 16. Look, Listen and Feel Technique : A unique vigilance survey system is operated in the plants. The equipment in each plant are inspected by independent groups from the operations, maintenance, inspection, process engineering and safety departments, to identify any abnormalities with respect to unsafe condition, leakage, noise, vibration, etc. Abnormalities, if any, are dealt with immediately, thus avoiding failures and improving the productive time of the plants. 17. Hand Tools Checking System : All hand tools owned by the Company as well as the contractors are checked regularly and kept in a centrally located workshop. Electrically operated hand tools, Earth Leakage Circuit Breakers, Welding Machines Transformers and extension boards are checked by Electrical Department before issue and are recorded. 25 18. Access Equipments Checking System : All fixed ladders, platforms, hand rails, steps and structures are inspected jointly by Inspection and Safety personnel and the defects are noted, reported to the concerned and rectified. All portable ladders have been numbered by electrical department and the issue is controlled and they are checked by using check list before issue. All scaffoldings are erected by authorized contractors under the guidance of Civil Department. Only tubular scaffolds are used. The scaffolds are checked through permit system before use by using a check list. After ensuring the suitability and soundness of the scaffolds, "GOOD FOR USE" tag is provided. If found not suitable "DEFECTIVE DO NOT USE" Tag is Provided. 19. Lifting Equipment Checking System: All lifting equipment been provided with necessary controls, which are easily accessible and with safe means of access and egress to and from lifting equipment. They are thoroughly examined and tested by competent person for the installation, strength and stability. All of them have been marked with safe working load. The hook spread of each lifting equipment/tackle is being measured for identification of any deflection. All the lifting equipment and tackles are stored as per procedures and all the users have been trained. The records are maintained by safety and central workshop personnel. 26 20. Pressure Vessels Testing System : They are thoroughly examined and tested by competent persons and records are maintained. The red marking is done on the dial of the pressure gauges indicating the design operating pressure to identify any abnormality in the pressure system. All portable gas containers have been provided with adequate gaps and they are kept in place properly secured. A suitable system is followed for transporting the gas cylinders. All pressure vessels and portable containers conform to Static and Mobile Pressure Vessels Rules and Gas Cylinder Rules and other relevant standards. 21. Critical Valve Locking System: We have developed a unique system by which during the isolation of process lines, before handing over the jobs to maintenance, the valve handle is tied with a chain and locked. This ensures the positive isolation of the system. 22. Occupational Health and Safety ,Quality & Environmental Management System: SPIC and Greenstar plants are having got the best Quality Management System and is one of the ISO 9001 – 2018 Standards certified fertilizer plants. Steps are taken to maintain quality at each and every level, conforming to standards and specifications. Our Environmental Management system mainly aims at the prevention of pollution and comply with the statutory regulations Our Environmental Management system has obtained ISO 14001-2018 certification. Recently we have got certified under ISO 45001: 2018 Occupational Health and Safety Management system. 27 23. Contractor Safety: The contractor's safety is treated in par with the employee's safety. They are provided with the necessary training. Safety shoes are issued to them at reduced price and all other personal protective equipments for plant use on returnable basis to carry out the job safely. Contractor's meeting and the contractor's coordinators meeting are conducted once in three months and they are briefed about the accidents if any and near miss incidents, the causes and the steps to prevent the recurrence. 24. Emergency Preparedness Plan: A well knitted on-site emergency preparedness plan approved by Director of Industrial Safety and Health is available to prevent/ mitigate the consequences arising out of any release of toxic gases like ammonia. All the employees, the public (in SPIC Nagar, HWP and TAC Nagar) and the school children are well aware of the above plan. Emergency coordinator and other key personnel have been identified and the role of every individual connected with the plan, is clearly spec ified. Emergency drills are being conducted for bothon-site and off-site once in 6 months. The plan is reviewed based on the observation of thedrill. 28 25. Electrical Locking System : We have developed a unique electrical locking system to isolate electrically driven equipments before handing over for maintenance, cleaning and inspection. Under this system, before issuing any electrical clearance, the electrical personnel will isolate the module and fix a lock on the module specially designed with triple lock handle. The maintenance and operation personnel will fix their additional locks before doing any maintenance jobs or cleaning and inspection. After the job is over, the locks will be removed by the respective personnel (maintenance and operation). After returning EC by operation, the electrical will remove the electrical side lock and energize the system. In case of any electrical work like cable disconnection, etc. the electrical maintenance will fix a separate lock and follow the same procedure. 26. ELCB and Plug Point Check System: A system has been developed to check Earth Leakage Circuit Breakers for safe trip before issue and the record is being maintained. A check list is used to check all plug points in the factory premises. 29 27. Fire Prevention and Fire Protection: We have active and passive fire protection system as per the norms laid up. To ensure its availability always, these systems are checked at a specified periodicity. This helps us to locate any deficiency in the system and gives us adequate time for rectification and makes them available always. All the flammables such as, Diesel Oil, etc. are stored safely in tanks in a Dyke wall enclosure, designed, constructed and maintained as per the Indian Explosives Act and Petroleum Rules. These installations are inspected by Inspector of Explosives every year and the certificates are renewed. A Fire Survey on the potential fire hazards in various sections of the plant is conducted and based on the outcome of the survey, fire protection and prevention plan is reviewed. All the plants are provided with Safety / Fire cabinets which are fully equipped with adequate number of fire hoses, branch pipes, foam compound etc. to be used in case of an emergency. 28. Fire Alarm System: The areas of high fire risks have been provided with fire alarm call points, duly marked and easily accessible. When the fire alarm is operated, the sound can be heard with visible lighting indicating the area of fire, both in the plant control room and fire control room "FIRE ORDER" has been displayed and communicated to all employees. 30 29. Accident Reporting System: A well prepared accident/ near miss incident reporting and investigation system is in place. All accidents including first aid injuries, disabling injuries, diseases, dangerous occurrences, and near misses, damage to the plant, equipment, property and environmental aspects are reported by the concerned. All reportable accidents are reported to Directorate ofIndustrial safety and Health and other authorities specified in the Factories Act, 1948 and other relevant acts and rules.. All the employees are encouraged to report near miss incidents. 30. Accident Investigation System: Every accident/incident is investigated in detail by Safety Department / a committee assigned for the purpose. It will bring out the causes and the recommendations to avoid the recurrence of such accidents. The investigation report is sent to the management and the HODs concerned for further action. The recommendations are followed up for implementation. All near miss incidents including those which have environmental impact are reported, investigated and analyzed. 31. Warning Label System : All portable chemical containers have been pasted/painted with suitable hazard warning symbols for easy identification. During the procurement of chemicals hazard warning labeling, instructions for use, emergency action procedure are also ensured. 31 32. Colour Coding System : All pipes have been color coded and the direction of flow of fluid has been marked. The colors are easily identifiable and the legend has been displayed in prominent places. The control valves are marked with the direction of closure. 33. Training : The necessary information are furnished to all employees by the way of training. This includes a) Basic Training, b) Refresher training, c) In plant training d) External training and e) Specialized Training. The training needs are identified through head of the departmentsby consultations and feedback system. First aid training is imparted to the employees through St.John’s ambulance association and Tamil Nadu Apex Skill Development Centre and the presence of atleast 5% of the first aiders in each shift is ensured. 34. Employee Consultation : In our industry participative safety management is ensured by having plant level safety committees, central safety committee, and safety steward’s committee in which the 32 employees of various disciplines participate and discuss about safety related matters. The recommendations are implemented without fail. SAFETY COMMITTEES a. Central Safety Council: The Central Safety Council is the apex body to lay down safety concepts and policies. WTD(Greenstar) is the Chairman of the Council and AGM (Safety and Environment) is the Secretary. All the Head of Departments and Trade Union representatives are members of the Council. The Council meets every month, and issues such as review of accidents, Modifications adherence to legal and statutory requirements and other safety aspects are discussed. The recommendations of the council are implemented immediately. b. Plant Safety Committees: We have Plant Safety Committees with the Plant Manager as the Chairman, officers, staff of all discipline and Assistant Manager (Safety) as members of the Committee. These Committees meet every month and various issues relating to Safety such as unsafe conditions, modifications required, personal protective compliance requirement etc. are discussed. There are seven such committees functioning in the factory. c. Safety Steward’s Committee: To promote safety consciousness, good housekeeping habits and to maintain a communication link between the Safety Department and individual Departments, representatives from various departments at the shop floor level meet every month to discuss the safety related problems in their areas, under the chairmanship of the AGM (Safety & Environment). There are totally 15 safety Stewards representing various departments. Various case studies and "Best Practices" in safety are discussed in the meeting. d. Contractor Safety Committee: Various problems related to safety of contractors are discussed in this committee with AGM (Safety & Environment) as Chairman, JM (Planning), Executive and officer (H.R.), Sr.Engineer (Civil), Security Inspector and Assistant Manager (Safety) and Contractors as members. 33 35. Safety Promotional System: To create awareness among employees and to motivate them to work safely, various Safety Promotional activities are carried out. i. Safety slogan, Safety essay, drawing and quiz competitions during National Safety Day Celebration. on 4th March and quiz competitions for World Environment Day Celebration, on 5th June. ii. Safety Ambassador"PEP Talk" iii. Publishing safety beacons on various topics, every month. iv. Safety award scheme for 2 million accident free man-hours and one year accident free period. v. Provision of safety library having safety and fire books, national and international magazines from reputed organizations. vi. National Safety Day and world Environments Day Celebration. Employees Quiz Competition Good House Keeping Award SPIC SCHOOL Safety & Fire Exhibition Our safety management programme is an on-going system of activities so structured to fitinto the day to day management functions. We, in SPIC and Greenstar, have identified the key areas, set realistic, attainable goals and provided ways and means to achieve the objective of safe production. By measuring our performance against established standards, evaluating the deviations and correcting the deficiencies, SPIC and Greenstar is not only maintaining high standards of safety but also improving further to reach new peaks. The five-star safety management system makes the employees feel proud of their contributionin improving the performance of the company towards Health, Safety and Environment. 34  ACCIDENT PREVENTION Presently, there is rapid growth in the field of Petrochemicals, Heavy chemicals and Fertilizers. The peculiar phenomena with accidents occurring in chemical industries is that the risks involved are invisible and silent in nature. To make it more clear, the process materials are handled in closed systems and as such nothing is visible. Also, because of the effect of the toxic gases and vapors on the human system, one may riot be able to identify when an accident happens to him. In view of the above, there is no necessity to emphasize the importance of safety and accident prevention in industries. If safety precautions and safe procedures are practiced, it will definitely result in accidents prevention and will save the lives of many people. PREVENTIVE STEPS: MANAGEMENT CONTROL Eliminating unsafe Discovering Eliminating unsafe condition causes acts By means of By means of By means of 1. Safe guarding all machines 1. Investigation of 1. Safe gaurding and equipment. accidents all machines and 2. Job Safety analysis 2. Accident Analysis equipment. 3. Rectifying or reventing 3. Recording and 2. Job Safety analysis defective conditions. reporting data 3. Rectifying or 4. Risk Assessment preventing 5. Inspection of Plants' and defective equipment conditions. 6. Suitable, safe design and construction. 4. Risk Assessment 7. Safe arrangements and work 5. Inspection of methods. Plants' and 8. Adequate Ventilation and equipment illumination. 9. Safe dress and personal protective equipment. 35 In Accident prevention, the following four E’s play a prominent role. 1. Engineering Revision : It is a method of removing unsafe mechanical or physical conditions by changing manual work to mechanised work. Unguarded machines are adequately guarded. New devices are introduced in the work. Modern technique, revised procedure are adopted by rectifying the unsafe process or system of work. 2. Education and Training : It is to be ensured that the worker is qualified to do the job safely and efficiently. It is also important to see that he understands the work methods thoroughly. He should be further educated, by giving him job instructions with necessary emphasis on the safety aspects. New employees should be given basic training, orientation training which will be helpful in doing the job safely. Periodical refresher training is to be imparted to the regular employees on Health, Safety, Environment and Firefighting. Safety talks, Safety films, Safety courses, Safety booklets, Safety bulletins and Newsletters and Safety Posters, are the important methods of Safety education and training. 3. Enthusiasm : It is a positive approach for Safety promotion. Workers are motivated by introducing Safety awards or Safety incentive schemes. This helps to prevent accidents. Employees can be made to participate in Safety promotional activities such as Safety Slogan competitions, Safety suggestions, Safety Quiz and Elocution competitions. Safety consciousness and safety attitude of an employee are considered for his promotion. 4. Enforcement : Enforcement is the last resort to improve safety. To restore and achieve the safety performance, a minimum of discipline is required. Violation of safety rules should be viewed seriously, taking disciplinary action, if necessary. Accident prevention is a team effort, so Safety is everybody's business and not a one man show. Personal adjustment, persuasion and appeal to workers will help in improving safety. Considering the skill and experience on the job, job rotation among the workers can be given. It is one way of fixing proper man for proper job. In spite of every precaution on the part of the manufacturers of equipment, suppliers of the materials, and supervision by the safety personnel, accidents do happen. The reason is the human error. With the most modern engineering know- how, the process and machinery can be designed safe, and materials can also be handled safely. It is only by religiously following the safety regulations and procedures the accidents due to human failures can be prevented. Accidents severely limit production and efficiency. Needless destruction of life and health of people is a moral evil, and every individual has a moral obligation to human society to prevent accidents. 36  OUT OF THIS NETTLE, DANGER, WE PLUCK THIS FLOWER, SAFETY --- HENRY IV ACCIDENT REPORTING AND INVESTIGATION Accident Reporting System Classification of incidents Reportable Accident: An accident which involving an employee or contract work men causes bodily injury by reason of which the injured person sustained major injury typically not able to resume his duties within 48 hours, immediately following the accident and shall be reported to factory inspectorate in prescribed format. (Form –18) Additionally  “Accident” is an Electrical Accident as per rule 44A of the Indian Electricity Act, 2003  “Accident” as under section 27 of the Petroleum Act, 1934  “Accident” involves Boiler or Steam Pipe under Indian Boiler Act, 1923 as amended.  Any other accident as defined under relevant applicable Act and Rules. Non reportable accident: Accident involving an employee or contract workmen sustained with minor injury causing less than 48 hours of absence from the work which requires medical treatment either in occupational health center as inpatient or in other hospitals outside. 37 First aid Accident: Accident involving an employee or contract workmen sustained with an injury and getting first aid treatment in occupational health centre which may not have any loss of work days. Near Miss incident: An unintended / unplanned event that has not resulted in Injury, Illness or Damage of any nature but has the potential to do so. Fire Incident: Any incident involving fire which has an open flame. Spark produced from electrical systems melting of cable, generation of smoke, which is early stages of fire, shall not be reported as fire and shall be reported as near miss incident Other incident: Any incident, which is not covered under all other categories and having potential HSE related issues such as spill /release of chemical etc Employee Transport Vehicle accident: Any accident happened while travelling in company-arranged vehicle while commuting to duty or on other official work Dangerous Occurrence: Any Dangerous occurrence as prescribed in Rule 96 of Tamilnadu Factory rules 1950. (Reportable in form – 18)  Bursting of a plant used for containing or supplying steam under pressure greater than atmospheric pressure.  Collapses or failure of a crane, derrick, winch, hoist or other appliances used in raising or lowering persons or goods, or any part thereof, or overturning of a crane.  Explosion or fire or bursting out, leakage or escape of any hot molten metal, liquid or gas causing damage to any person or any room of place in which persons are employed ,or fire in rooms of cotton pressing factories when a cotton opener is in use.  Explosion of a receiver or container used for the storage ata a pressure greater than atmospheric pressure of any gas or gases (including air) or any liquid or solid resulting from the compression of gas.  Collapse or subsidence of any floor, gallery, roof, bridge, tunnel, chimney, wall, building or any other structure. 38 Procedure: Reporting of injury incidents:  Upon occurrence of an “Accident” the injured person / witness immediately informs the Area Operator / Shift In charge of the plant. Shift In charge/Area operator immediately meets the injured person to assess the nature of injury and arranges for first aid / medical help by calling ambulance from fire station.  Injured person or persons have to be moved to medical Centre through ambulance only to avoid further injury or to avoid increasing intensity of damage to the injured part of the body.  Shift in charge has to fill in the first information report (FIR) and send it along with ambulance or otherwise it is the responsibility of the shift in charge to hand over the FIR to medical centre.  Contractor /plant personnel should not use their vehicle for shifting injured person to medical center.  In case the ambulance is not available due to any reason alternate vehicle will be arranged by safety head to station at fire department.  Within 10 minutes the Shift In charge informs his Department Head and Head of Safety about the accident.  The safety Head reports the accident to the WTD(SPIC) & WTD (Greenstar) either orally or through messages.  Safety Head arrange to send one safety officer to medical centre to get preliminary information from the injured or witness and then safety officer moves to the scene of accident site to assess the nature of the incident and collect the basic information.  Within in the shift Accident Report shall be prepared by the Shift in charge describing the incident and forward to department head and then to safety department.  If the injured is by any reason report directly to Occupational Health Centre, it is the duty of the OHC attendant to intimate the information to head of safety for further course of action.  If the Injured person directly visits the Occupational Health Centre (OHC), the attendant has to collect the following information after rendering First aid/medical help.  Name of the person injured  Department/contract  Location  Date and time of accident  Nature of injury,  Part of the body affected  Details of treatment given.  The OHC attendant has to inform the Shift In charge, Fire station and Duty medical officer immediately. 39  If the injured has to be given immediate external treatment as decided by the OHC attendant/medical officer, he informs fire station to mobilise Ambulance and shift the injured immediately to the Hospital based on nature and extend of injury.  Injury report will be prepared by OHC attendant and sent to Head – HR, concerned department HOD and to Safety HOD.  If the injured leaves the gate without the knowledge of safety department on his own vehicle or his contractor vehicle it is the duty of the gate security officer has to inform head of safety for further course of action  Shift In charge has to fill the information in Incident report within his shift and submitted to Safety Department for analysis.  The following information has to be collected while reporting investigation report  Name and age of the person injured  Department/contract  Location of the accident  Date and time of accident  What exactly the injured person was doing at the time of incident.  PPE used or not.  The injured person or the witness description of the incident  Nature of injury,  Part of the body affected  The agency causing the incident such as equipment and its tag number.  List of reasons for incident such as unsafe act/unsafe condition or any other cause.  Immediate Corrective action taken and the proposed preventive action.  Details of treatment given. Statutory Reporting : HR Department reports and maintains the acknowledgement on the  “Accident” report submitted to the office of the Directorate of Industrial safety andHealth  “Accident” report submitted to the nearest ESIC local officer and nearest insurance medical office  “Accident” report submitted to the medical insurance company Head of Electrical has to report and maintains the acknowledgement on the  Electrical accident report submitted to the office of the Electrical Inspectorate and State Electricity Board / Supplier of the electricity  “Accident” report under petroleum rules, Gas cylinder rules shall be submitted to the office of the PESO by E&I department  Accident” report under Indian Boiler Act, 1923 shall be submitted to the office of Boiler Inspector by E&I department. 40 Reporting of Near Miss:  The person who is involved or witnesses the near miss shall inform to the concerned area officer who in turn informs to Shift in charge/Department head/safety head immediately.  The Area officer has to take corrective action immediately in consultation with theshift in charge or the Department Head.  The Shift in charge/department head has to collect and fill in the information as requiredin the near miss report form and forward to safety department.  The Head of safety informs the near miss to WTD(GREENSTAR)and decides on a course of actionin consultation with the Department head. Reporting of Dangerous Occurrences:  The witness immediately informs the Area Officer/Shift In charge  The Area Officer/Shift In charge immediately reaches the site to assess the nature of damage and initiates control procedure in consultation with the department head.  He informs the department head and safety head immediately.  Safety head immediately visits the site and assesses the nature of the “Dangerous Occurrence”.  HR department is responsible for reporting and maintaining the records of the dangerous occurrences to the Directorate of Industrial safety and Health as per the relevant Act and rules. Reporting of Fire Incident:  The person who notices the fire has to break the Manual fire call point immediately and /or informs the fire station by using the nearest intercom/PA system.  Fire Shift In charge informs the Head Safety and mobilize fire tender with fire crew to the incident site  The Shift in charge has to collect and fill the information as required in the Fire incident report form and forward to safety department.  Head of safety is responsible for investigating and maintaining records of the fire incidents.. Investigation of Incidents:  After getting preliminary information on the incident, safety head decides on the investigation requirement on the incident.  Safety Head in discussion with WTD(GREENSTAR) will constitute a committee for detailed investigation based on the nature and severity of the incident.  Head of safety will be the coordinator- three more cross functional members of safety stewards committee and other non-managerial category will be a part of the investigation team from Maintenance and/or Process.  The team identifies the root cause / causes which lead to the occurrence of the incident. 41  The investigation team proposes Corrective Action to address the root cause / causes in order to prevent recurrence of such incident and the investigation report shall be submitted within a week. Corrective actions mainly focus three actions:  Action requiring elimination of Hazards  Action requiring substitution to reduce Hazard and risk  Actions requiring better engineering control  Actions requiring better administrative controls  Action requiring better PPE controls  Department Head is responsible for the implementation of the corrective actions including the recommendations suggested by the investigation team.  Safety Head identify the requirement of horizontal deployment of corrective action in similar work situations /equipment in other areas of the plant and carry out survey and send the findings to the concerned department for implementing the recommendations.  The effectiveness of the system is verified by the investigation team once the recommendations are implemented. Review of Risk Assessment:  As a part of the investigation process, the investigation team reviews existing Hazard Identification and Risk Assessment of the activity or equipment or facility involving the incident, assesses existing engineering, administrative and PPE controls, recalculates the risk number / risk factor as per procedure determines the acceptability of risk and time frame to mitigate the risk.  Head Safety confirms that the reviewed Risk Assessment Rating is in line with actual hazards present for the activity or equipment or facility involving the incident.  The investigation team, after implementation of the Corrective and preventive action again reviews and update the Hazard Identification and Risk Assessment of the activity or equipment or facility involving the incident, and recalculate the risk factor. 42  ACCIDENT ROOT CAUSE ANALYSIS PURPOSE : 1. To identify the causative factors. 2. To locate the hazards involved in the procedures. 3. To evaluate the suitable corrective actions. 4. To design the suitable engineering revisions. METHODOLOGY: 1. By studying the type of incident occurred.  Reportable  Non Reportable  First aid  Occupational illness  Property damage  Fire or Explosion  Environmental incident  Near miss  Dangerous occurrence or  Others 2. By studying the property damage occurred.  Property / Material damaged  Nature of Damage  Object/substance inflicting damage  Cost of Damage 3. By enquiring the injured person.  Name of Injured  Department  Employee No.  Contract  Age Body part affected:  Ear(s)  Neck  Chest / Shoulder(s)  Back 43   Abdomen  Trunk / Torso  Hands / Wrists  Fingers  Arms(s)  Hip / Pelvis  Legs  Knee(s)  Foot / Ankle(s) / Toe(s)  Body System(s)  Multiple Parts  Non-Personal Damage Nature of Injury:  Bruising / Bumps  Burns  Crushing Injury  Ear / Hearing Condition  Eye / Vision Condition  Fracture / Dislocation  Heart/Circulatory Diseases  Infectious Diseases  Needle stick  Open Wound / Laceration  Dermatitis  Electric Shock  Embedded Foreign Bodies  Nerve Damage  Infectious Diseases  Inhalation  Splash  Sprain/strain Type of Contact:  Bites / Scratch / Kicks  Bio hazardous Material  Bodily Reaction / Exertion  Contact with Objects – in, on, under  Electricity  Fire 44  Exposure to Extreme temperature  Fall from Elevation  Hazardous Materials  Motor Vehicle Accident  Needles / Sharps  Noise  Overexertion  RMI (Repetitive Motion Injury)  Slip, Trip or Fall  Struck by Object 4. By studying the statement of the witness. 5. By collecting information from the other persons involved in the incident 6. By studying the Severity potential  Minor  Major  Severe 7. By studying the equipment/material which caused the injury.  MOC specified correctly  Preventive maintenance followed or not  Management of change followed or not  Any other further deviations  Rules/ regulations  Standards  Operating conditions 8. By analyzing the frequency of the occurrence of the incident.  Appropriate PPE used (As per HIRA)  Unsafe condition  Unsafe act  Any further deviation 9. By studying the method, which is used to do the job.  SOP specified correctly  Procedure followed  Whether work permit taken  Management of change followed  Any other further deviations  Rules/ regulations  Standards  Operating conditions 45 TYPE OF ANALYSIS : a) Individual Analysis is used to find out the root causes. b) Group analysis is used to know about the company's Accident record. INDIVIDUAL ANALYSIS GROUP ANALYSIS a) Accident description a) Nature of injury b) Immediate Causes b) Part of body c) Root Causes c) Type of contact d) Lack of Control d) Accident type e) Department wise e) Agency of the accident f) Age and time wise f) Unsafe condition g) Conclusion g) Unsafe Act h) Recommendation IMMIDIATE CAUSES: SUBSTANDARD ACTS: SUBSTANDARD CONDITIONS:  Operating without authority.  Inadequate Guards/ Barriers.  Failure to warn.  Inadequate/Improper PPE.  Failure to secure.  Defective tools/Equipment or Materials.  Failure to follow Procedure.  Congestion or Restricted action.  Disabling/Removing safety devices.  Inadequate warning system.  Using defective equipment.  Fire or explosion hazards.  Using equipment improperly.  Poor housekeeping.  Failure to use PPE Properly.  Slippery surface.  Improper loading.  Noise Exposure.  Operating at improper speed.  Radiation exposure.  Improper position for Task.  Extreme Temperature Exposure.  Improper placement.  Extreme pressure exposure.  Servicing equipment in operation.  Inadequate or excessive illumination.  Horseplay  Inadequate ventilation.  Under influence of Alcohol.  Weather condition  Others (specify).  Others (specify). 46 ROOT CAUSES: PERSONAL FACTORS: JOB FACTORS:  Inadequate physical /Physiological Capability.  Inadequate Leadership and/  Inadequate Mental/ Psychological capability. or Supervision.  Mental or psychological stress.  Inadequate engineering.  Lack of knowledge.  Inadequate purchasing.  Lack of skill.  Inadequate Maintenance.  Improper Motivation.  Inadequate tools and  assignment equipment.  Responsibility and accountability undefined  Inadequate work standards.  Wear and Tear.  Abuse or misuse. LACK OF CONTROL:  Under pressure to complete  Leadership and Administration the job  Planned inspection and maintenance.  Personal selection and  Accident/ Incident Investigation. assignment  Emergency Preparedness.  Responsibility and  Rules and Work permits. accountability undefined USE OF CAUSE ANALYSIS: 1. To carry out suitable accident prevention programme to avoid recurrence of accidents. 2. To impart suitable training. 3. To revise the safety standards and rules suitably. Review of Risk assessment and comparing with the current risk assessment:  Activity  Personal Protective equipment.  Hazard  Health and Hygiene Control.  Controls considered  Personal Communications.  Risk rating  Group Communications.  Deviation  Knowledge and skills Training. Corrective and preventive actions:  Engineering control  Administrative control (SOP, Work permit, training, instructions, job change etc.,)  Personal protective equipment 47  ACCIDENT CAUSE ANALYSIS (INDIVIDUAL) (Model case study) Brief description of the accident: On 04.12.2018 at 17:30 hrs, Mr. S. Antony Satheesh was cleaning the End shied of the Urea plant Ammonia Booster pump’s 75 KW motor kept in the trolley. While cleaning the end shield of the motor, unfortunately his hand got slipped when he tilts the end shield and his left hand middle finger got struck between end shield and trolley. He was immediately taken to Medical center by Ambulance and he returned to the work after treatment. Immediate cause:  Substandard Acts: Failure to warn. Basic cause:  Lack of knowledge Lack of control:  Knowledge and skills Training Review of risk assessment: Whether risk assessment carried out earlier: No Current risk assessment –As per HIRA procedure: Activity : Cleaning the end shield of motor kept at trolley Hazard : Fall of object Controls Administrative : Training to be given Engineering Controls : NA PPE : Safety gloves Corrective and preventive actions: Engineering control : NA Administrative control : Training has to be given then and there before work by the electrical supervisor persons Personal protective Equipment : NA 48 Conclusion: The accident happened due to the lack of training and because of the individual’s carelessness. Hence adequate training is required to prevent any accidents further. ACCIDENT CAUSE ANALYSIS (GROUP) (Model case study) 1. Brief description of the accident: On 28.02.2019 Mr.Nitesh kumar had come to work at 8:45hrs in General shift. He was assigned the job of urea solution tank level indicator since it was showing erratic readings. The tank was drained and the pad type indicator was flushed with hot water to release choke if any. At 11:45 hrs. The drain had got choked and hot condensate was held up in tank. While removing the bolts of the indicator and hot condensate inside the tank splashed over his left leg, causing scalds on his left foot. He was sent to medical Centre in ambulance and treatment was given. 2. Analysis: 1. Incident type --- Reportable 2. Body Part Affected --- Foot 3. Nature of Injury --- Splash 4. Type of Contact --- Contact with Objects 5. Unsafe condition --- No He was removing the bolts of pad 6. Unsafe Act --- type level indicator when hot condensate splashed over his legs. 49 3. Conclusion of Analysis : The tank wasn’t properly drained as the drain has some choke, the level indicator was flushed with hot water to release choke and the bolts of the indicator was removed releasing the condensate. Before handing over the job to other department, operation department should have ensured that the equipment is safe for use. This accident happened due the unsafe act, as the individual did not use appropriate PPE and due to the carelessness of the operation Dept. 4. Recommendation : 1. As per the HIRA, appropriate PPE must be ensured, before carrying out the job. 2. SOP should be modified and instruction should be included as, before handing over the job to other department, operation department should have ensured that the equipment is safe for use. 50  ACCIDENT CAUSE ANALYSIS (GROUP) CASE STUDY-1: On 02.12.2017, the bagging of DAP was being carried out in bagging plant. The even number chutes are used for wagon loading, whereas the odd number chutes are used for truck loading. From chute no:9, the materials were bagged and loaded to the trucks. Shift in-charge did not give a PEP talk and work procedure to contract workers before starting a job. Around 14:55 hours, a piece of small lump stuck up in chute number 9’s shutter and as there was no proper casing for the entire chute parts above the packer scale, Mr. Karrnan, the supervisor of M/s. Vasikaran & Co., instructed the workers to remove the lump. There is no proper procedure in SOP for this particular activity and PPEs were not worn by the workers. The workers were not able to remove the lump, and so Mr.Karnan himself got engaged in the work at 15:10 Hrs. While removing the lump with his bare hands, the chute’s shutter hit the injurer’s right hand ring finger, causing cut injury. 1. Analyze the accident. 2. Find the cause of this accident. 3. Give your recommendations to prevent such accidents. CASE STUDY-2: On 29.11.2018, Mr. M. Esakky, Senior technician was doing his routine motor checkup job in the SA plant. After he checkup the motor in DT pump tank, while stepping down DT pump tank staircase, steps in the staircase was in the corroded condition and when he step down it got broken and he fell down injuring his right leg. He got a little abrasion in his right leg. He went to Medical Centre and treatment was given. 1. Analyze the accident. 2. What was the cause of the accident? 3. Give your recommendations to prevent such accidents. CASE STUDY-3: Mr. A. Karthik, JE came in second shift. He was allotted to do work in the rock unloading area. He was carrying out his regular duty of supervising the contract worker’s job. He was asked to check the exhaust fan condition by his higher official. He checked the exhaust fan condition. While checking he tried to free rotate the exhaust fan belt with bare hands instead of using F Keys and so his hand got caught between the belt and wheel as it rotated freely. And his right hand index finger got a cut injury. He was sent to Medical Centre by Ambulance and treatment was given. 1. Analyze the accident. 2. What was the cause of the accident? 3. Give your recommendations to prevent such accidents. 51 CASE STUDY-4: On 04.05.2018, Mr.Ashikul Islam came to shift at 18:00 Hrs and the job was allocated to him at the over size conveyor area. He was removing the spilled material near the running conveyor using shovel. While removing the spilled materials he left his shovel in between the conveyor belts near the tail drum of the conveyor. Accidently the shovel was pulled in by the conveyor, he tried to remove the shovel, due to inadequate training, supervision and got a crushing injury in his hands/wrist. Immediately he was taken to medical Centre by ambulance for treatment. Analyze this accident and recommend suitable remedial actions. CASE STUDY-5: On 12.07.2018, Mr. Dinesh Kumar came to work at general shift hours (08:45 Hrs). Work permit was not taken. He started to change the lye hose in the sulphur melting zone at 15:30 Hrs, without wearing PVC Hood or PVC Coverall. The lye hose was a temporary arrangement. One side of the hose was connected and while connecting the other side of the hose, accidently a minute drop of lye present in the hose, fell on the right eye of the injurer. Immediately he washed his eyes. Immediately he was taken to medical centre by ambulance, first aid was given and was further referred to Agarwal eye Hospital. After treatment he returned back to duty at 18:15 Hrs. Analyze this accident and recommend suitable remedial actions. CASE STUDY-6: Mr. Forikul Islam of M/s Gopal Contract, in PA plant was cleaning the sludge in the ground floor area. While he was cleaning the sludge in reactor side, he unfortunately hit his head against the scaffolding pipe in the nearby area and had a cut injury. At the time of incident, as he did not wear PPE properly, that is, he wore his helmet without chinstrap, and hence it fell down, and when he took the helmet and lift up, he hit his head against the scaffolding pipe. He was immediately sent to Medical Centre by Ambulance, treatment was given and returned. CASE STUDY-7: On 30.09.2018, at 14:30 hrs Mr. Lalit Mermu of Hari Contract was doing his routine jobof cleaning the spilled rock in the running conveyor. At the time of incident, he was cleaning the spilled rock in CR2 conveyor tail drum area. While he used the shovel to put spilled rock in the CR2 conveyor, the shovel got struck in-between the conveyor and tail drum, since the tail drum was not guarded. He tried to pull out the shovel and got cut injuryin his right hand ring finger and middle finger. He was immediately taken to Medical Centre by Ambulance and treatment was given. 52 CASE STUDY-8: On 19.12.2018, at 16:30 hrs Mr. Manika raj of Johnson Engineering Contract was working in SPA sump area. An additional SPA line was provided and it was extended with rubber hose, he tried to remove the hose from the line after closing the valve but at that time accidentally, the holdup acid in the hose was splashed over his eyes,as he did not wear safety goggles. He immediately washed his eyes and was taken to Medical Centre by Ambulance and treatment was given. CASE STUDY-9: Mr.Muthupandi was working in the Reactor area. He was removing the drain line of R1 reactor in order to clean the hose (which is suction line for Pump P2031 A). While he was removing the drain line, due to poor communication, the operator opens the wash water line without giving prior information to him. He got scared and while trying to escape, he accidentally immersed his legs inside the acid sludge drain sump near the reactor, as the illumination in the area was inadequate and there is no proper working platform nor a escape route. He got chemical burns in the right leg. He was sent to Medical Centre by Ambulance and treatment was given. CASE STUDY-10: On 10.08.2018, Mr.Nagaraj, supervisor of M/s EDAC came to work in his day shift (12 hrs) to the Sulphuric acid unloading area. In the SA unloading area, we can unload three tankers simultaneously and at around 15:45 hrs, two SA tankers were connected for unloading the acid and the job was done without taking any work permits. Suddenly Sulphuric Acid got splashed on the injured who was standing, without wearing PPEs, near the unloading pump, switch operating area, due to the damaged valve in that unloading point. Immediately he used the emergency shower and was taken to medical centre by ambulance. After treatment he returned back to duty. CASE STUDY-11: Mr. R.Sankar, rigger of M/s Johnson Contract was cleaning the spool in the SA plant area. He lifted the knife edge of valve body (Spool) himself, without using proper lifting equipment. While doing so, unfortunately it got slipped off and fell on his left leg ankle, causing minor cut injury. He was sent to Medical Centre by Ambulance and treatment was given. CASE STUDY-12: The job in lye tank was carried out by getting proper vessel entry permit vide No:44309 and Hot work Hazardous permit vide no- 60642. Mr.Shanmugaraj of M/s GP Engg came to work at general shift hours and was involved in the grinding job. At around 15:30 hrs, he was grinding the bur in the 2” drain nozzle of the NaOH(Lye) tank. Unfortunately the 53 grinding wheel got broken and stuck Mr.Shanmugaraj in his left hand wrist causing cut injury, as the grinding machine does not had machine guards. Immediately he was taken to medical centre and treatment was given. Analyze the above accidents and recommend suitable remedial actions. ALL OUR KNOWLEDGE COME THROUGH CORRECTING OUR MISTAKES - KARL POWER MAINTENANCE SAFETY Definition: It is to adopt safe procedures and follow precautionary steps while carrying out maintenance work of preventive, break down, routine or on-line nature. Purpose: 1. Decreases potential for accidents 2. Reduces the risk of equipment failure 3. Decreases a facility's downtime 4. Increases a facility's efficiency SAFETY IN MAINTENANCE WORKS: I. CIVIL MAINTENANCE: 1. Excavation: It is carried out inside the factory premises for making foundations to erect equipment and building, for providing trenches, for laying cables/ pipe lines and for making sumps. 54 Safety Precautions: a. Before starting any excavation work or road cutting, get clearance from Safety and Electrical Departments. Ensure that work is started with safety permit. b. Prevent dislodgment of loose or unstable earth rock or other materials from falling into the excavation by proper timbering. c. Dump away excavated materials from the point of excavation. Ensure that they do not slip and fall back. d. No unauthorized entry is permitted. Place warning signals. e. During night, display a danger light to warn traffic and men. f. Excavation pit or opening on the ground more than 6' deep must have a cover or a barring of 2 ft. height. g. During excavation if a cable or pipe line is visible, inform Electrical, Safety and Operation Departments. h. Before closing the excavation get clearance from electrical department to ensure that cables are not disturbed / damaged i. Use pickaxes or spade for excavation and do not use crow-bar. Inadvertent damage to buried cables can lead to electrical shocks, if a crow-bar is used. j. Wear PVC gumboot and gloves to protect against electrical shock, in case any power cable is damaged during excavation. 2. Sand Blasting: a. As far as possible avoid blasting operation for surface cleaning. Use buffing and manual brushing. b. If it is absolutely necessary to sand blast, check the sand, blasting equipment / nozzle thoroughly. c. Sand blasting is to be done inside an enclosure with proper ventilation. 55 d. The person carrying out the job should wear dust mask or breathing hood, eye protection, etc. e. Sand blasting is not permitted in open area and road sides. f. Rubber hoses should have been properly clamped. g. Check the unloading pressure of the compressor and compressor relief valve popping pressure. 3. Scaffolding: Tubular scaffolding is to be erected as per norms/standards/job requirement by following all safety precautions. Safety belt and life line is to be used during scaffolding erection work.  Ensure that footing and anchorage are sound and rigid.  Guard rails and toe boards must be provided on all open sides of a platform.  Scaffolds and all component parts must be capable of supporting four times the maximum intended load.  Overlap all platforms and planking a minimum of l ft.  Ensure that all poles, legs and uprights are securely and rigidly fixed.  Do not work on scaffolds during storm and high winds.  Remove tools, materials and debris as soon as possible.  For scaffolding use 2" OD steel tubing.  Ensure that in the case of swinging scaffolds, the size must between 20 and 30 inches wide overall.  Ensure that the scaffold suspended by wire or fibre rope is capable of supporting atleast 6 times the intended load.  Inspect all wire ropes, fibre ropes, slings, hangers, platforms etc. before each installation. Do not permit more than 2 men to work at one time on scaffolds designed for a working load of 500 kg. In case of 750 kg. not more than 3 men are allowed. 56 4. Roof Repairs: During asbestos roof repairing / sheet replacing / 'J' bolts changing, following precautions are to be taken a. Obtain class - I permit. - Higher Elevation b. Ensure proper supervision. c. Use safe roof walk ladder or crawl board. d. Wear safety belt and life line, tied to the ladder or in the cross wire rope, if provided on the roof. e. Use scaffolding if necessary. f. For very high elevation jobs, if the approach is not proper, use crane with jula for repair work. g. Do not put sand bags on the roof. Do not put vertical ladder / scaffolding on the roof. II. INSTRUMENT MAINTENANCE: The following jobs require adequate care a. Cabling b. Supporting c. Control valve positioning d. Bleeding/flushing e. Lifting and Shifting of materials NOTE: 1. Safety precautions are to be taken as per the job requirements. 2. Close and continuous supervision and instructions by a responsible person is essential. 57 MECHANICAL MAINTENANCE: 1. Fabrication:  Safe location is to be selected for fabrication either in the work shop or in the field.  If the fabrication work is by the road side, it should not be of any hindrance to vehicular traffic, Fire Tender and Ambulance.  Ensure that proper support is provided, while doing the fit up in the piping or sheet metal.  Power cables should not be routed on the ground to connect the hand drilling machine, grinding machine. Use ELCB while using electrical hand appliances.  Safe method is to be used while lifting / placing pipes / channels / metal sheets. 2. Grinding: To be done using tested standard wheel with safe electrical connection through ELCB. Ensure proper earthing and speed. 58 3. Cutting: Cutting can be done safely using standard hacksaw, wheel, gas torch or arc, adopting standard safe procedure. 4. Welding: Gas welding / arc welding, TIG welding can be done safely using tested welding machines / gas torches and cylinders, cables / hoses etc.  The welder must wear only least inflammable material for clothing.  Leather gloves, aprons, hip leggings, shock resistance footwear and goggles or face shield must be used while working.  Ensure that suitable and sound working platforms are provided wherever necessary.  Flash back arrestor must be fitted in the LPG and oxygen hose leading to the torch  Do not use electrical conduits as earth conductors. 59  Ensure that all connections are clamped or bolted secure and tight to avoid arcing.  Do not drag or pull welding cables along the floor. While cutting or welding is done at elevations, ensure that materials at the bottom floors are protected.  Ensure adequate ventilation while working in confined areas.  Do not use compressed air to blow out or clean, welding or cutting equipment. 5. Piping: Provide proper supports and fix flanges with standard gasket / bolts and nuts. 6. Lifting and Shifting: Engineering materials from stores to workshop or to field, are to be properly handled using proper devices, lifting equipment, adopting safe methods and procedures. Special care is to be taken for sheet metal and heavy materials. 7. Chiselling and Hammering: a. Standard tools are to be selected from standard vendors. b. Mushroom head of chisel and hammer is to be trimmed periodically. c. Magnetic particle test is to be carried out for hammer and chisel. d. Eye protection is to be ensured during chiselling and hammering. e. Proper handle is to be provided for the hammer. 60 ELECTRICAL MAINTENANCE: 1. Cable / Wiring Overhead cabling should be routed safely in a duct/ tray with fire resistant coating. 2. Excavation and underground cabling a. Underground cabling can be routed through trenches or through earth sands with brick coverage. b. The cable trenches should be filled with sand. Dewatering devices should be provided. c. If the cables are laid underground, it should be covered with brick. d. Routing is to be marked and underground cabling drawing is to be kept updated always. e. Underground, damaged or unused cables are to be removed to avoid misleading. f. Welding generators and grinding machines should be tested once in 3 months. g. Grinding wheel is to be checked before fixing it in the machine. ACTION FOR SOME HAZARDS S.No. Activities Hazards Preventive Action 1 Adjusting sway of running belts Caught in between Stop the conveyor. conveyor / adjusting of rollers the belt and pulley Take EC and get and pulleys while conveying or nip in the rollers class-II permit. Carry out the job by following the instructions. 2 Touching the bare wire, Electrocution Check for proper cabling insulation damaged cable / Electrical bum / wiring / earthing, Use unearthed or improperly ELCB for hand earthed electrical hand tools appliance circuit. Carry out periodic testing of electrical equipment. 61  3 Contact with hot surface Thermal burn Provide proper insulation. Use PPE. 4 Contact with chemicals Chemical burn Wear PPE while opening flange. 5 Fall of persons while working on Severe injury or Wear safety belt and heights fatal life line is to be tied to a rigid support. 6 Fall of person while working in Severe injury Ensure proper the same level, due to trip or flooring, stacking slip and cleaning, good house keeping in the work area. 7 While working underneath Severe injury Do not leave loose equipment, loose material will materials on the fall from height platform. Always wear helmet 8 While walking /working person Multiple injury Watch your steps will fall into the while walking. trenches/manholes/ Platform should be ditch/pit/unguarded walkway provided with hand rails, mid rails and toe boards. Pit/trenches and ditches are to be fenced or covered with proper size of slab covers. GUIDELINES FOR GOOD MAINTENANCE: 1. Install the NRV and rupture disc in the correct direction. 2. Use correct, standard bolts and gaskets in flanges. 3. Maintain proper slope on lines. 4. Use standard, level gauges. 5. Don't paint on valve, stem and metal hoses. 6. Fix all trays in columns. 7. Ensure by checking the adequacy and soundness of the scaffolding for work. 8. Do not leave welding slags / welding rod bit inside the pipe line which may jam in the control valves. 9. Fix the block valves in an operable accessibility. 10. Do not allow to mix impurities in the system. 11. Do not fix the insulation in such a way that it will restrict the proper pipe movement, due to expansion. 62  12. Do not forget to put back the machine guard in position after maintenance. 13. Provide proper hand rails / mid rails and toe board with approach ladder to a platform. 14. Hot bolting is to be done after commissioning. 15. Check the welding and do not use odd size bolts. 16. Provide proper support for pipe lines including the branch lines. 17. Ensure that pipe line is resting on the supports. 18. Protect the expansion joints and bellows. 19. Proper spring supports with scale is to be provided at the required places. 20. Slip plate is to be removed before starting and drain is to be provided at the low point and vent at the high elevation. EXPECTED HAZARDS DURING MAINTENANCE OF AN EQUIPMENT: 1. Caught in between rollers / belts while adjusting sway in belt conveyors. 2. Contact with electricity / hot surface / chemicals. 3. Fall of persons a. from heights b. in same levels due to slipping and tripping. 4. Falling of materials from height a. loose materials b. broken materials 5. Unguarded walkway. 6. Tripping hazards due to materials/protrusions. 7. Open manholes / trenches. 8. Inadequate lighting / ventilation. 9. Poor housekeeping. The requirement of safety systems in chemical process industry is of two types. 1. Protection of operating equipments. 2. Safety for operation and maintenance personnel. The aim of safety systems are 1. To detect and provide audio visual alarm regarding abnormal or dangerous condition leading to the failure of equipment. 2. To detect and automatically provide signals or alarms on audio visual devices regarding change in process variable from the desired limit and thus approaching a hazardous condition. Safety in process encompasses the safe environment wherein the persons engaged in any physical activity are able to work safely. 63 To achieve this goal, following are to be ensured. 1. Safe working practice for personal safety. 2. Safe working condition to ensure personal safety. Many chemicals handled in the process industry are hazardous in nature. Leakage of hazardous chemicals clubbed with high pressure and temperature poses a biggest threat. A process industry basically consists of three major mechanical items. 1. Static equipment : Storage tanks, vessels, heat exchangers, and columns 2. Rotating equipment :Pumps, compressor, blower and turbines. 3. Bulk material handling :Piping, valves, traps, flanges and couplings. a. Leakages in Static Equipment The following factors mainly influence the leakage from any static equipment. 1. Aging 2. Corrosion 3. Human error 4. Poor design details 5. Improper materiel of construction 6. Faulty operation 7. Flying object hitting the equipment b. Leakages in Rotating Equipment 1. Leakage from moving parts 2. Leakage from connected pipes 3. Leakage from the casing c. Piping and bulk material leakage 1. Pipes 2. Valves 3. Flanges 64  MACHINE GUARDING Introduction: Safeguarding dangerous parts of machinery is considered as an important aspect in accident prevention. The high severity rate of accidents caused by dangerous parts of machinery justify the importance attached to machine guarding. Principles of Machine Guarding : Guards are to be provided to the following 1. Moving parts of prime movers including wheels. 2. Transmission machinery and 3. Every dangerous parts of any other machinery. Basic requirements of guards: Guards should PINCH (NIP) POINTS 1. Protect the human beings 2. Not interfere with efficiency 3. Be fire-proof 4. Allow repairs 5. Allow lubrication 6. Be well constructed 7. Be well secured 8. Not create new hazards 65 Types of machine guards: 1. Safety by construction 2. Fixed Guards 3. Automatic guards 4. Interlock guards 5. Trip guards 6. Positional or distance guards 7. Safety by position of machinery 8. Other types. 1. Safety by construction: This is an important aspect of machine guarding which needs the attention of the machine designer. Good fencing by design is found in the gear boxes of the capstan turret lathes, milling machines and radial drills, all of which have materially contributed to safety. 2. Fixed guards: 66 The fixed guard is considered in preference to all other types as it always prevents access to the dangerous parts of the machine. The advantages of the fixed guards are a. They are stationary b. They are not having moving parts and c. Very little maintenance is required. Fixed guards are adjustable to accommodate different set of tools for various kinds of work. The fixed guards are found on a. Power press b. Flattening machine c. Milling machine d. Drilling machine etc. e. Pumps and compressors 3. Automatic guard: Automatic guard may be used where neither a fixed guard nor an interlocking guard is practicable. The types of automatic guards are a. Sweep away device b. Pull away device It is actuated by a moving member of the machine to which it is fitted. All automatic guards require careful designing when a rapid motion is required for efficiency in action. The type of guard is fitted in stroke machines, power presses, paper cutting machines and hand fed machines. 67 4. Interlock guard: The principle of the interlock guard is that the control gear to start the machine cannot be operated until the guard is moved by hand into such a position that the operator cannot reach the position of danger. When the machine is in motion the guard cannot be opened. Interlocking guards may be mechanical, electrical, pneumatic or a combination of above types. 5. Trip Guard: Whenever the guard is disturbed from its usual position, the power is cut off and the machine gets tripped. The mechanism itself must be of sufficiently sensitive character to disconnect the power quickly. It is used in laundry, ironing machine, planten printing machine, conveyors etc. 6. Position Guard: a. Two hand controls are those which work on a principle of providing multiple control such as twin push buttons or levers. The worker has to use both his hands to operate the twin controls to operate the machine. b. Distance Guard is one in which a bar or bars are so placed to prevent the fingers of the operator reaching he danger zone. The distance between the danger point and guard has to be varied according to the dimensions of the opening. 7. Safety by position of machinery: This is not a guard at all. The machinery, by virtue of its position is considered as safe. Fixed guard should be provided in such cases as it cannot be taken out under any circumstances. Only during maintenance or repair the worker will go near the machine after stopping and electrically disconnecting the supply. 68 8. Colour coding : The machine guards are painted in red orange colour so that they are clearly visible when they are in position. ACCIDENTS ARE RARE WHEN MACHINE GUARDS ARE THERE MACHINE GUARDS ON STAY ALIVE  STOP ACCIDENT 69  SAFETY IN THE USE OF HAND TOOLS I. Screw Driver: 1. Do not use a blunt screw driver, since, this requires more energy to work and it damages the screw also. 2. Do not use a screw driver as a chisel and do not hammer on the handle. 3. Do not use a screw driver for matching the flange holes. Use a hole-bar. 4. Do not keep the job on your palm and use the screw driver. Use a table because the screw driver may cause injury to your palm. 5. Do not bring the job close to your body while using the screw driver because the slipping screw driver may pierce your body. 6. When the screw driver is used as a connector, ensure that the metal portion is sleeved. II. Chisel: 1. Do not use a chisel with mushroom head. Trim the mushrooms and use