Module -1: Introduction to Safety

Safety is a crucial aspect of industrial operations, particularly in process industries, where

hazardous chemicals, high temperatures, and high-pressure systems are commonly used. The
objective of industrial safety is to prevent accidents, protect human life, minimize environmental
impact, and ensure smooth and efficient operations.

Importance of Safety in Process Industries:

 Protects workers from injuries and fatalities.
 Reduces economic losses due to downtime, equipment damage, and legal liabilities.
 Ensures compliance with government regulations and industry standards.
 Enhances productivity by maintaining a safe work environment.
 Prevents environmental hazards and public health risks.

Major Causes of Accidents in Process Industries:

Accidents in process industries can be caused by several factors, including:
 Human Errors: Lack of training, negligence, fatigue, and violation of safety protocols.
 Equipment Failure: Poor maintenance, mechanical failure, and design flaws.
 Chemical Hazards: Leakage, spills, and unintended reactions of hazardous chemicals.
 Fire and Explosions: Presence of flammable substances and inadequate safety controls.
 Process Deviations: Improper operating conditions such as high temperature and
pressure variations.
 Lack of Safety Culture: Inadequate safety training, poor risk assessment, and
insufficient emergency preparedness.

Major Industrial Accidents:

Several catastrophic accidents have occurred in process industries, leading to loss of life,
environmental damage, and economic losses. Some notable incidents include:
a) Bhopal Gas Tragedy (1984, India)
 Industry: Pesticide manufacturing (Union Carbide)
 Cause: Methyl isocyanate (MIC) gas leak due to poor maintenance and safety
negligence.
 Impact: Over 15,000 deaths, long-term health issues, and severe environmental
pollution.
b) Texas City Refinery Explosion (2005, USA)
 Industry: Oil refinery (BP)
 Cause: Over-pressurization of a distillation tower leading to a massive explosion.
  Impact: 15 deaths, over 170 injuries, and extensive property damage.
c) Chernobyl Nuclear Disaster (1986, USSR - now Ukraine)
 Industry: Nuclear power plant
 Cause: Reactor design flaws and operator errors leading to an uncontrolled reaction.
 Impact: Massive radiation release, deaths, long-term health issues, and environmental
contamination.
d) Deepwater Horizon Oil Spill (2010, Gulf of Mexico, USA)
 Industry: Offshore oil drilling (BP)
 Cause: Blowout due to failure of the blowout preventer.
 Impact: 11 deaths, severe marine pollution, and an economic impact on the fishing and
tourism industries.
e) Seveso Disaster (1976, Italy)
 Industry: Chemical manufacturing (ICMESA)
 Cause: Accidental release of dioxin, a highly toxic chemical.
 Impact: Widespread environmental contamination and long-term health consequences.

Lessons Learned from Industrial Accidents

 Implement stringent safety protocols and regular risk assessments.
 Ensure proper training and awareness programs for workers.
 Invest in advanced monitoring and safety control systems.
 Conduct routine maintenance and equipment inspections.
 Strengthen regulatory frameworks and enforce compliance with safety laws.
 Develop and practice emergency response and evacuation plans.

Occupational Toxicology and Occupational Diseases

1. Occupational Toxicology
Occupational toxicology is the study of the effects of workplace chemicals and hazardous
substances on human health. It helps in assessing risks and implementing control measures to
minimize worker exposure.

2. Toxicity
Toxicity refers to the ability of a substance to cause harm to biological systems. It depends on
factors such as dose, duration of exposure, route of entry, and individual susceptibility.

3. Threshold Limit Value (TLV) and Types of TLV

Threshold Limit Value (TLV) represents the maximum concentration of a substance to which a
worker can be exposed without adverse effects.
 TLV-TWA (Time-Weighted Average): The average exposure limit for a normal 8-hour
workday and 40-hour workweek.
 TLV-STEL (Short-Term Exposure Limit): The maximum exposure limit for a short
duration (15 minutes), provided it does not occur frequently.
 TLV-C (Ceiling Limit): The concentration that should never be exceeded at any time.
4. Routes of Entry of Toxic Substances
Toxic substances can enter the human body through various routes:
 Inhalation: Breathing in gases, vapors, fumes, or dust.
 Ingestion: Consuming contaminated food, water, or hands.
 Dermal Absorption: Absorption through the skin due to direct contact.
 Injection: Accidental punctures from sharp objects containing toxic substances.
5. Lethal Dose (LD50) and Lethal Concentration (LC50)
 LD50 (Lethal Dose 50%): The dose required to kill 50% of a test population when
administered via ingestion or injection.
 LC50 (Lethal Concentration 50%): The concentration of a substance in air or water
required to kill 50% of a test population via inhalation or aquatic exposure.
6. Intrinsic and Extrinsic Safety
 Intrinsic Safety: Safety measures designed within equipment to prevent hazardous
conditions (e.g., intrinsically safe electrical circuits in explosive environments).
 Extrinsic Safety: External measures taken to prevent accidents (e.g., use of personal
protective equipment, safety barriers, and ventilation systems).
7. Behavioral Safety
Behavioral safety focuses on human behavior and its role in workplace safety. It includes:
 Training and awareness programs.
 Encouraging safe work practices.
 Observation and feedback mechanisms to improve safety compliance.

8. Occupational Diseases
Occupational diseases are illnesses caused by exposure to harmful substances or work
conditions.
9. Notifiable Diseases
These are diseases that employers must report to regulatory authorities. Examples include:
 Occupational asthma
 Occupational dermatitis
  Pneumoconiosis
 Lead poisoning
10. Pneumoconiosis
A group of lung diseases caused by inhalation of dust particles that lead to lung fibrosis.
 Cause: Chronic exposure to mineral dust such as silica, asbestos, or coal.
 Symptoms: Shortness of breath, chronic cough, and lung impairment.
11. Silicosis
A type of pneumoconiosis caused by inhalation of crystalline silica dust.
 Affected Workers: Miners, sandblasters, stonecutters, and construction workers.
 Prevention: Proper ventilation, dust suppression, and use of respirators.
12. Asbestosis
A chronic lung disease caused by inhalation of asbestos fibers.
 Symptoms: Shortness of breath, persistent cough, and lung scarring.
 Health Risks: Increased risk of lung cancer and mesothelioma.
 Control Measures: Banning asbestos use, providing protective equipment, and regular
medical check-ups.
13. Lead and Its Compounds
Lead exposure can cause severe health problems, particularly affecting the nervous system,
kidneys, and reproductive system.
 Sources: Battery manufacturing, smelting, and lead-based paints.
 Health Effects: Anemia, neurological disorders, abdominal pain, and developmental
issues in children.
 Prevention: Proper ventilation, PPE use, and regular blood lead level monitoring.
14. Chromium and Its Compounds
 Types: Hexavalent chromium (Cr(VI)) and trivalent chromium (Cr(III)).
 Health Effects: Skin irritation, lung cancer, and respiratory diseases.
 Industries at Risk: Electroplating, welding, and pigment manufacturing.
 Control Measures: Engineering controls, PPE, and exposure monitoring.
Module: 2
Hazard and Risk Assessment Techniques
1. Introduction to Hazard and Risk Assessment
Hazard and risk assessment techniques are essential for identifying potential dangers in
industrial settings and implementing control measures to minimize risks. These techniques help
in preventing accidents, ensuring workplace safety, and complying with regulatory standards.
2. Definitions
 Hazard: A potential source of harm or adverse health effect on a person or the
environment.
 Risk: The likelihood of a hazard causing harm, combined with the severity of the
potential consequences.
3. Types of Hazards
 Physical Hazards: Noise, radiation, vibration, temperature extremes.
 Chemical Hazards: Toxic chemicals, flammable substances, corrosive materials.
 Biological Hazards: Bacteria, viruses, fungi, and other pathogens.
 Ergonomic Hazards: Poor workstation design, repetitive movements, improper lifting.
 Psychosocial Hazards: Work stress, harassment, fatigue, and violence.
4. Risk Assessment Process
The risk assessment process involves:
1. Hazard Identification: Recognizing potential hazards in the workplace.
2. Risk Analysis: Evaluating the likelihood and severity of harm.
3. Risk Evaluation: Determining whether risks are acceptable or require mitigation.
4. Risk Control: Implementing safety measures to reduce risks.
5. Monitoring and Review: Regularly reassessing risks to ensure continued safety.
5. Hazard and Risk Analysis Techniques
a) Hazard Analysis (HAZAN)
 Systematic approach to identifying hazards and assessing their potential risks.
 Helps in understanding the nature of hazards and prioritizing risk control measures.
b) Hazard and Operability (HAZOP) Study
 A structured technique used to analyze processes for potential deviations and their
consequences.
 Conducted in multidisciplinary teams to identify hazards and suggest corrective actions.
c) Fault Tree Analysis (FTA)
 A top-down deductive approach to identify the root causes of system failures.
 Uses logic diagrams to map out failure pathways.
d) Event Tree Analysis (ETA)
 A forward-looking technique that evaluates potential outcomes of an initiating event.
 Helps in understanding possible accident scenarios and preventive measures.
6. Safety Checklists and Checklist Analysis
 Safety Checklists: Predefined lists used to ensure all safety requirements are met.
 Checklist Analysis: Systematic review of potential hazards using a checklist to ensure
workplace safety.
7. Case Studies: Major Industrial Accidents
a) Bhopal Gas Tragedy (1984, India)
 Cause: Leakage of methyl isocyanate (MIC) gas due to poor maintenance and safety
failures.
 Impact: Over 15,000 deaths, long-term health issues, and environmental contamination.
 Lessons Learned: Need for stringent safety regulations, proper maintenance, and
emergency preparedness.
b) Chernobyl Disaster (1986, USSR - now Ukraine)
 Cause: Nuclear reactor explosion due to design flaws and operator errors.
 Impact: Massive radiation exposure, fatalities, long-term health issues, and
environmental damage.
 Lessons Learned: Importance of safety culture, regulatory compliance, and risk
assessment in nuclear facilities.
8. Safety Signs and Symbols
 Mandatory Signs: Indicate required actions (e.g., wear safety goggles, helmets).
 Prohibition Signs: Indicate forbidden actions (e.g., no smoking, no entry for
unauthorized personnel).
 Warning Signs: Indicate potential hazards (e.g., high voltage, toxic chemicals).
 Emergency Signs: Indicate emergency exits, first aid stations, and fire extinguishers.
Module 3:
Emergency Preparation and Biological Disaster Management
1. Introduction to Emergency Preparation
Emergency preparation involves planning and implementing measures to respond effectively to
unforeseen disasters, accidents, or hazardous situations. It aims to minimize risks, ensure safety,
and facilitate quick recovery.
2. Concept of Emergency Preparation
Emergency preparation includes:
 Identifying potential hazards.
 Developing emergency response plans.
 Training personnel on emergency procedures.
 Conducting drills and simulations.
 Ensuring the availability of emergency equipment and resources.
3. Identification and Assessment of Hazards
 Physical Hazards: Fires, explosions, structural collapse.
 Chemical Hazards: Toxic spills, gas leaks, hazardous chemical reactions.
 Biological Hazards: Pandemics, bacterial and viral outbreaks.
 Natural Hazards: Earthquakes, floods, hurricanes.
 Technological Hazards: Power failures, industrial malfunctions.
4. On-Site Emergency Plan
 Definition: A plan that deals with emergencies occurring within an industrial facility or
workplace.
 Key Components:
o Emergency response team formation.
o Evacuation procedures.
o Firefighting measures.
o First aid and medical assistance.
o Communication and coordination protocols.
5. Infrastructure for Emergency Preparedness
 Fire alarms and sprinkler systems
 Emergency exits and evacuation routes
 First aid stations and medical facilities
 Emergency response vehicles
  Protective equipment and safety gear
6. Off-Site Emergency Plan
 Definition: A plan for managing emergencies that impact areas outside an industrial
facility.
 Key Elements:
o Coordination with local authorities and emergency services.
o Public warning and communication strategies.
o Shelter and evacuation procedures for surrounding communities.
o Environmental impact assessment and mitigation.
7. Fire Extinguishers and Their Types
Fire extinguishers are classified based on the type of fire they combat:
 Class A: For solid combustibles (wood, paper, textiles) – Water-based extinguishers.
 Class B: For flammable liquids (oil, gasoline) – Foam or CO₂ extinguishers.
 Class C: For electrical fires – CO₂ or dry chemical extinguishers.
 Class D: For metal fires (magnesium, sodium) – Dry powder extinguishers.
 Class K: For kitchen fires (cooking oils) – Wet chemical extinguishers.

Biological Disaster Management

8. Definition of Biological Disaster
A biological disaster refers to a catastrophic event caused by exposure to biological agents such
as viruses, bacteria, or toxins, leading to widespread illness, fatalities, and environmental
contamination.
9. Classification of Biological Disasters
 Natural Biological Disasters: Epidemics and pandemics (e.g., COVID-19, cholera
outbreaks).
 Man-Made Biological Disasters: Bioterrorism, accidental laboratory releases.
10. Biohazards
Biohazards refer to biological substances that pose risks to human health and the environment.
They include:
 Bacteria (e.g., Anthrax, Tuberculosis, Salmonella)
 Viruses (e.g., Influenza, Ebola, COVID-19)
 Fungi (e.g., Aspergillus, Candida infections)
 Toxins (e.g., Botulinum, Ricin)
11. Corona Virus (COVID-19) Pandemic
 Cause: SARS-CoV-2 virus.
 Transmission: Airborne droplets, surface contact.
  Symptoms: Fever, cough, breathing difficulty, fatigue.
 Impact: Global health crisis, economic disruptions.
 Prevention:
o Vaccination campaigns.
o Social distancing and mask-wearing.
o Hygiene measures (handwashing, sanitization).
12. Prevention of Biological Disasters
 Surveillance and Early Detection: Monitoring disease outbreaks and rapid response.
 Public Health Measures: Vaccination programs, sanitation improvements.
 Personal Protective Measures: Use of masks, gloves, and personal hygiene practices.
 Emergency Response Planning: Quick mobilization of medical and support teams.
 Legislation and Biosecurity: Enforcement of health regulations and control of
biological hazards.
Module 4: Personal Protective Equipment (PPE)
1. Introduction to Personal Protective Equipment (PPE)
Personal Protective Equipment (PPE) refers to safety gear designed to protect workers from
hazards in the workplace. PPE serves as a last line of defense against injuries and health risks
when engineering and administrative controls are insufficient.
2. Legal Requirements for PPE
 Occupational Safety and Health Administration (OSHA) (USA): Enforces PPE
regulations under 29 CFR 1910 Subpart I.
 Indian Standards (BIS - Bureau of Indian Standards): Defines PPE standards under
IS codes.
 Factories Act, 1948 (India): Mandates the use of PPE in hazardous work environments.
 Employer Responsibilities:
o Provide appropriate PPE at no cost.
o Ensure PPE is maintained and replaced as needed.
o Train employees on proper PPE use.
o Conduct workplace hazard assessments.
3. Limitations of PPE
 Does not eliminate hazards but only minimizes exposure.
 Can cause discomfort, fatigue, or mobility restrictions.
 Requires proper maintenance and storage.
 Ineffective if improperly worn or selected.
4. PPE Selection Guidelines
 Identify workplace hazards (physical, chemical, biological, ergonomic).
 Choose PPE based on risk assessment.
 Ensure proper fit, comfort, and usability.
 Comply with regulatory standards.
5. Types of PPE and Their Uses
a) Head Protection
 Purpose: Protects against impact, falling objects, and electrical hazards.
 Examples: Hard hats, bump caps.
 Standards: IS 2925:1984 (Industrial Safety Helmets).
b) Eye and Face Protection
  Purpose: Shields against chemical splashes, flying debris, radiation, and intense light.
 Examples: Safety goggles, face shields, welding helmets.
 Standards: IS 5983:1980 (Eye Protectors), ANSI Z87.1.
c) Hand Protection
 Purpose: Prevents injuries from chemicals, cuts, burns, and abrasions.
 Examples: Rubber gloves, cut-resistant gloves, heat-resistant gloves.
 Standards: IS 4770:1991 (Rubber Gloves for Electrical Purposes).
d) Foot and Leg Protection
 Purpose: Protects from impact, punctures, electrical hazards, and chemical exposure.
 Examples: Steel-toe boots, metatarsal guards, rubber boots.
 Standards: IS 15298:2002 (Safety Footwear).
e) Body Protection
 Purpose: Shields from heat, chemicals, biological agents, and mechanical hazards.
 Examples: Fire-resistant suits, chemical-resistant suits, aprons.
 Standards: IS 15758:2007 (Protective Clothing).
f) Respiratory Protection
 Purpose: Prevents inhalation of toxic gases, vapors, dust, and infectious agents.
 Examples: N95 masks, self-contained breathing apparatus (SCBA), air-purifying
respirators.
 Standards: IS 9473:2002 (Respiratory Protective Devices).
6. PPE Training and Usage
 Proper selection and fitting of PPE.
 Instructions on correct usage and limitations.
 Maintenance, inspection, and storage practices.
 Emergency response procedures while using PPE.
7. Indian Standards on PPE
 IS 2925:1984 – Industrial safety helmets.
 IS 5983:1980 – Eye protectors.
 IS 4770:1991 – Rubber gloves for electrical work.
 IS 15298:2002 – Safety footwear.
 IS 15758:2007 – Protective clothing.
 IS 9473:2002 – Respiratory protective devices.
8. Housekeeping and PPE
 Ensures a clean and hazard-free environment.
 Prevents slips, trips, and falls.
 Facilitates proper storage and maintenance of PPE.
  Reduces risks of fire and chemical exposure.
9. Material Safety Data Sheet (MSDS) and Its Applications
 Definition: A document that provides safety information about chemicals used in
workplaces.
 Key Components:
o Chemical identity and properties.
o Hazard identification.
o Safe handling and storage guidelines.
o First-aid and emergency response measures.
 Applications:
o Helps in selecting appropriate PPE.
o Guides safe chemical handling.
o Assists in emergency preparedness.
10. Case Studies
a) Bhopal Gas Tragedy (1984, India)
 Cause: Methyl isocyanate (MIC) gas leak due to inadequate safety measures.
 PPE Failure: Lack of proper respiratory protection and emergency equipment.
 Lessons Learned: Need for proper PPE, emergency preparedness, and regular safety
audits.
b) Chernobyl Disaster (1986, Ukraine)
 Cause: Nuclear reactor explosion and radiation leak.
 PPE Failure: Insufficient protective suits and respiratory gear for emergency responders.
 Lessons Learned: Importance of radiation-protective PPE, proper risk assessment, and
training.
Module 5: Safety Audit and Legislations
1. Introduction to Safety Audit and Legislations
Safety audits and legislations play a critical role in ensuring industrial safety, environmental
protection, and compliance with legal requirements. Safety audits help in identifying workplace
hazards, improving safety practices, and minimizing risks.

2. Key Legislations Related to Safety and Environmental Protection

a) Environmental Protection Act, 1986
 Purpose: Provides a framework for environmental conservation and pollution control.
 Key Provisions:
o Regulates air, water, and soil pollution.
o Empowers the government to take measures for environmental protection.
o Establishes penalties for non-compliance.
o Promotes sustainable industrial practices.
b) Manufacture, Storage & Import of Hazardous Chemicals Rules, 1989
 Purpose: Regulates the handling of hazardous chemicals to prevent industrial accidents.
 Key Provisions:
o Classifies hazardous chemicals and their permissible limits.
o Requires industries to maintain Material Safety Data Sheets (MSDS).
o Mandates on-site and off-site emergency plans.
o Ensures proper labeling, packaging, and safe handling of chemicals.
c) The Industrial Disputes Act, 1947
 Purpose: Governs industrial relations and dispute resolution.
 Key Provisions:
o Defines unfair labor practices.
o Provides mechanisms for conciliation, arbitration, and adjudication of disputes.
o Establishes provisions for layoffs, retrenchment, and strikes.
o Aims to maintain industrial peace and worker welfare.
d) The Factories Act, 1948
 Purpose: Ensures the health, safety, and welfare of workers in factories.
  Key Provisions:
o Regulates working hours and employment conditions.
o Requires industries to maintain proper ventilation, lighting, and sanitation.
o Mandates the use of protective equipment and safety measures.
o Enforces periodic inspections and compliance checks.

3. Essentials of Safety Audit

 Systematic evaluation of workplace safety practices.
 Identification of potential hazards and non-compliance issues.
 Assessment of effectiveness of safety policies and programs.
 Recommendations for improvements and corrective actions.

4. Auditing Programs in Classified Areas

 High-Risk Industries: Chemical plants, refineries, power plants, construction sites.
 Workplace Safety Audits: Assessment of fire safety, PPE compliance, emergency
preparedness.
 Environmental Audits: Evaluation of waste management, pollution control measures.
 Health and Hygiene Audits: Monitoring worker exposure to hazardous substances.

5. Audit Procedures
1. Planning and Preparation: Define objectives, scope, and audit criteria.
2. Data Collection: Review safety records, policies, and incident reports.
3. Site Inspection: Physical examination of workplace conditions and practices.
4. Interviews: Discussion with employees and management regarding safety practices.
5. Analysis and Reporting: Identify gaps and recommend corrective actions.
6. Follow-up and Monitoring: Ensure implementation of safety improvements.

6. Audit Team
 Lead Auditor: Oversees the audit process and ensures compliance.
 Safety Officers: Assess workplace hazards and emergency procedures.
 Engineers and Technicians: Inspect equipment and operational safety.
 Health Experts: Evaluate hygiene and worker health conditions.

7. Benefits of Safety Audits

 Improves workplace safety and reduces accident risks.
  Enhances compliance with legal and regulatory requirements.
 Identifies areas for continuous improvement.
 Boosts employee awareness and involvement in safety programs.
 Reduces financial losses due to workplace incidents.

8. Safety Report
 Contents:
o Summary of audit findings.
o Identified risks and hazards.
o Compliance status with safety regulations.
o Corrective and preventive actions.
o Recommendations for improving safety measures.
 Purpose:
o Provides a structured overview of workplace safety conditions.
o Acts as a reference for regulatory compliance and future audits.
o Helps management in decision-making for safety improvements.