Theme - 3

Hazards Identification and Control Measures in Chemical (industrial) Workplaces

industrial Disaster Risk Management

Machine Environment

Man

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January 2010 5.03-0002-2010

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Contents
1. Review Workplace Hazards
1.1. What is a hazard ? 1.2. Why hazards identification? 1.3. Categorising hazards 1.4. How to identify hazards 1.5. Broad categories of hazard 1.6.General understanding about hazards

Hazards Identification and Control Measures in Chemical (industrial) Workplaces

-2 -2 -2 -3 -4 -9 - 10 - 11 - 11 - 12 - 14 - 18 - 19 - 23 - 26 - 33 - 34 - 35 This module is mainly targeted to:Safety auditors Emergency responders Emergency planners and regulators Civil administrators This Module provides the information on various methods of hazards identification and control measures at chemical (industrial) workplaces. At the end of this module, trainees will be able to: understand the philosophy of hazards recognisition; understand the philosophy and methods of control; understand and suggest several methods of preventing and controlling hazards in their own workplaces.

2. Control measures
2.1. Elimination 2.2. Substitution 2.3. Engineering controls 2.4. Administrative controls 2.5. Personal protective equipment 2.6. Other methods of control 2.7. Check lists

1. Workplace Hazards
1.1 What is a hazard ? A hazard is something with the potential to cause harm. According to OHSAS 18001:1999, hazard is a source or situation with a potential for harm in terms of human injury or illness, damage to property, damage to the environment, or a combination of these. 1.2 Why hazards identification? Hazard recognition or hazard identification is vitally important in accident prevention. By recognising hazards' characteristics and properties, we can clearly determine proper controls. Unfortunately, the majority of us sometimes overlook to recognise hazards. There are many reasons why hazard identification has to be updated. We have identified the following top 15 reasons after doing extensive research :Top 15 Reasons I. the identification of workplace hazards is the first step in the risk management process; ii. when a new job, task or activity is introduced\initiated; iii. when the existing process conditions will have to changed;

3. Conclusion 4. Glossary 5. Reference

when current standard operating procedures need to be altered; when we plan to modify plant facility or plant layout; when a new equipment or machine will be installed in the plant site; when new safety equipment is introduced; when replacement of chemical, catalyst or fuel is required; when a new product will be produced; when plant expansion project is scheduled; when after an incident or accident occurred; when a neighbour plant will be built near the existing chemical plant; when safety audit, safety inspection, safety patrol or self-inspection system is being done; xiv. when transportation of the hazardous chemicals is required; xv. when on-site and off-site emergency plans are prepared as per the schedule 11 and 12 of MS and IHC rules 1989 of EPA 1986. In an industry there is interface in between man and machine with various materials through standard operating procedures (SOPs). In diversified working environment any variation in coordination or short cuts or uncomfortability of the man may lead to Machine Man happening of any type of the errors. Environment This error may transform in the bigger accident, if not controlled Error in time. The popular fish bone example is used to show this relationship for error or Method Material accident as shown in fig-1 1.3 Categorising hazards Fig-1

iv. v. vi. vii. Viii. ix. x. xi. xii. xiii.

machinery, when a confined space permit has expired, a sticking safety valve on a boiler, intermittent electrical or and mechanical defect). To make the job of identification of hazards in the workplace easier, it is important to record the following all activities involved in work process and tasks who is involved in those activities details of plant or materials that are used It is important to make a list of all the hazards at the workplace. Once this list of hazards is compiled then each of the hazards should be considered individually for risk management. 1.4 How to identify hazards The first step in the risk management process is the identification of workplace hazards. This means looking for those things at the workplace that have the potential to cause harm. To begin identifying hazards, simply ask the question, 'Does this task/activity/situation/ event has the potential to harm a person, property, environment, and or system?' Another way is to ask the question 'What-if?' For example, when inspecting a construction site, ask 'What if a worker walks without hat in the industrial premises which is either under construction or renovation? Answer may be in absence of hat it is possible that any falling object may cause harm to worker, so falling object is hazard to a worker and hat may protect the workers head. These are proactive ways to identify hazards. Hazards can also be identified from records of past accidents and near misses. What-if. . . ? analysis is a structured approach to identify hazards and improves the chances of identifying all of the hazards in the workplace. Persons can ask themselves: 'Is this activity safe? What if this or that occurs - then - what will happen?' (Please refer module-11 for more information The following are the other most important hazard recognition methods: Pre-Use Analysis can be applied before any new equipment, device, instrumentation, personal protective equipment, machine, tool, plant facility, etc. are used. This method is applied before exposure to hazards. Multi-Step Planning Process is applied before hazard exposure and applied to every task, job and activity. To apply this method simply asks a series of questions before doing the task, job or activity. The question should be similar to:

To assist in identifying hazards, the hazards may be categorised as follows: The obvious hazard is apparent to the senses (e.g. unguarded machinery, building defects, or and faulty electrical equipment). The concealed hazard is not apparent to the senses (e.g. electricity, presence of toxic vapours, or and high frequency noise). The developing hazard cannot be recognised immediately and will develop over the time (e.g. a worn tyre on a mobile crane or and frayed steel cables), and The transient hazard is an intermittent or a temporary hazard (e.g. overload of

a. b. c. d. e.

What am I going to do? What is the purpose of doing this job, task or activity? How will I do that job, task or activity? How could I get hurt doing this job, task or activity? What will I do to prevent accident (injury, illness health)?

roles, such as electricians, office workers or drivers, technicians; tasks, such as working on the lathe, loading the truck, decanting a substance or data processing. Other ways to help identify hazards include: consulting workers about problems they have encountered in doing their work, any near misses or events that have not been reported, symptom, experience, such as pain and discomfort in body parts, or changes to vision, hearing, and skin conditions, conducting a health and safety audit. seeking information by

Work Permit is issued before the job, task or activity done. Some questions asked and a checklist shall be completed to assure that hazards are not overlooked. Generally the checklist includes the analysis of toxic gas (such as carbon monoxide, H2S), oxygen sufficiency, flammable gas concentration, etc. Equipment Inspection is implemented to any equipment before it is used or put into operation. Equipment inspection is planned and organised to check overall equipment conditions, safety protective equipment, guarding, emergency stop, etc. Suggestion Method encourages to propose or suggest potential hazards (and controls) that are contained in a job, task or activity. Workers consider their past time experiences on the shop floor and field to give suggestions. This method can be used for improving current hazard identification list. Safety Patrol can be carried out by every worker in the plant site, not only by persons who are in charge of health and safety matters. Safety patrol may be done during an equipment running, plant operation, plant shut down or whenever it is intended to identify potential hazards. Visual inspection and observation is the most common and simple way to begin to look for hazards by regular walk- through visual inspections of the workplace. Look at each task the workers do, to see if any hazards are present, such as handling loads, using chemicals or equipments. It may also be helpful to observe workers performing their tasks and the activities involved, such as set-up, operation, cleaning, maintenance and inspection. This will provide the opportunity to see whether the documented procedure for performing the task is being followed by the workers, or whether workers are taking short cuts for speeding up work (e.g. by removing guards), etc. Structured approach to improve the chances of identifying all of the hazards in the workplace, it will help to take an additional structured approach. It is done by dividing the workplace into groupings such as: locations, such as offices, grounds, warehouse or wet areas; functions or production processes, such as administration, cooking, washing, cleaning, receiving, forming, or finishing;

undertaking workers surveys (e.g. body maps and discomfort surveys), consulting with Workplace Health and Safety Representatives (WHSRs) and workplace health and safety committees, knowing the industry's experience of common potential hazards, acquiring information from designers, manufacturers, suppliers, and other organisations, such as unions, employer bodies and health and safety consultancies. testing, measuring and sampling by means of analysing records and data covering incidents and near misses, worker complaints, sick leave and staff turnover, maintenance records, results of surveys, audits or inspections. Some workplace activities or arrangements may create or increase hazards, if they are not properly managed or guided, for example, saw dust used by worker in the spillage of Nitric acid releases dangerous fumes of nitrogen oxides which are recognised as brown to yellow colour fumes. Fig-2 demonstrates as discussed.

Mixture of Nitrogen Oxides Nitric Acid

W SA

ST DU

Nitric Acid

Fig-2

When collecting information to identify hazards, consider the following: competency and level of training of workers and its adequacy, how people actually use, clean, service or repair equipment and materials, how suitable the things used for the task are, and how well they are located, how people could be hurt directly and indirectly by the various workplace aspects, how waste materials are or should be disposed off, the life cycles of substances, plant, materials and premises, which may affect their safety, mock drills and reviewing the reports, safety reports and audits, on-site and off-site emergency plans, risk assessment reports, examination and reviewing of HAZOP, FEMA, FTA and ETA, etc. (Refer module 11) Some workplace activities may create or increase hazards, if they are not properly managed. These include: purchasing policies (e.g. if the products, plant, materials and personal protective equipments that are selected are the cheapest one and are not safely designed, not suitable for the job or suited to the workers using it or are of inadequate quality); roles, responsibilities, and account abilities (e.g. if they are not clearly defined, people will not know what they have to do, when or how to do it. It applies especially in emergency situations); excessive physical and mental tasks and job demands which may lead to an inability to keep the worker's mind on the job; organisational arrangements, such as shiftwork and rosters, may lead to fatigue and human error where workers are working for long hours, or are working on more than one job; levels of supervision and ratios of supervisors to workers (e.g. greater levels of supervision are appropriate in some areas; key performance indicators (e.g. when set too high they create unrealistic performance targets, which can increase the workers' tendency to take short cuts and increase risks while trying to achieve the targets); maintenance and servicing programmes for plant to cover wear and tear training programes, where risk management of property is emphasised over the risk management of people and safety; economic drive. In recent years, accidents involving major accident hazards (MAHs) industries in India and overseas have resulted in numerous chemical disasters. Consequently, governments, chemical industries and communities worldwide are determined to prevent further serious accidents and considering the hazards beyond the plant premises to assess the impacts. Major Accidents Hazards (MAH) industries such as oil

refineries, chemical fertilizers, chemical plants and large fuel and chemical storage facilities where large quantities of hazardous materials are stored, handled or processed are governed by the Manufacture, Storage and Import of Hazardous Chemicals (MS and IHC) Rules 1989 and subsequent amendments. Chemical Accidents (Emergency Planning, Preparedness and Response) Rules 1996 under the Environment (Protection) Act 1986 have further advocated to protect people, property and the environment from chemical accidents. This will be achieved by applying safety obligations on everyone involved with the storage, process, transport and handling of hazardous materials. Central Motor Vehicle Rules 1989 also guides to identify and control the hazards, the theme 2 deals with the details about the hazards, risk and control during transportation of hazardous chemicals. These regulations regulates MAH industries to minimise the likelihood of accidents at these sites and to minimise adverse off - site impacts. This is achieved by assisting the operators of such facilities to meet their safety obligations, which includes the provision of: a systematic risk assessment; emergency plans and procedures; a safety management system; a programme of induction, information, education, supervision and training for all persons at the facility; information to, and opportunities for, consultation with the neighbouring community; a safety report and audit. The satisfactory fulfilment of these obligations are monitored and promoted by the Regulatory Weather Conditions: Agencies through a Day-time only Clear and sunny professional review Wind speed 3m/s and audit processes. Release Conditions: The hazards due to release of any chemical is assessed by knowing the impacts zones both on - site and off - site by doing computer modelling
Chlorine drum (920kg) Liquid value release Indoor release
1 ppm No impact

3 ppm Minor impact 20 ppm Significant impact

Fig-3

and dispalying the affected area on map. It requires scientific and technical understanding about the behaviour of the chemical. Impact modelling and assessment, for example, of a toxic gas is shown in the fig-3 and similar are needed for explosion and fire. The information gained is then used to facilitate land use planning decisions and in the emergency services to develop realistic emergency planning, preparedness and response mechanism. (For detail refer module 11 -15) 1.5 Broad categories of hazard To help with the process of identifying hazards it is useful to categorise hazards in different ways for example by topic, for example: a) mechanical; b) electrical; c) radiation; d) substances; e) fire and explosion; f) toxic release; and g) natural calamities. During work activities could the following hazards exist? a) Slips/falls on the floor level; b) Falls of persons from heights; c) Falls of tools, materials, etc, from heights; d) Inadequate headroom; e) Hazards associated with manual lifting/handling of tools, material, etc; f) Hazards from plant and machinery associated with assembly, commissioning, operation, maintenance, modification, repair and dismantling; g) Vehicle hazards, covering both on-site transport and travel by road; h) Fire and explosion; i) Violence to staff; j) Substances that may be inhaled; k) Substances or agents that may damage the eye; l) Substances that may cause harm by coming into contact with, or being absorbed through the skin; m) Substances that may cause harm by being ingested (for example entering the body via mouth); n) Harmful energies (for example, electricity, radiation, noise, vibration, etc.); o) Non-compliance of regulation p) Inadequate thermal environment, for example too hot; q) Lighting levels; r) Slippery, uneven ground/surfaces;

s) Inadequate guard rails or hand rails on stairs; t) Subcontractors' activities. 1.6 General understanding about hazards The following figures/photographs helps in understanding the hazards from control point of views:-

Poor signage fails to convey the message about the hazards and therefore increases the possibilities of damages due to hazards

Poor maintenance and repair of vessels and pipes increases the potential hazards of the release of the chemicals into the workplace surrounding environment

Poor security and broken boundary walls are biggest potential hazards

Poor storage or pile up of the chemical drums or tonners are the potential hazards, falling of drums and consequently the release of the chemicals

10

2. Control measures
To control the hazards there are four principles in general. Elimination of the hazard is the best option, if elimination is not possible then substitution should be considered. Engineering control is applied to control hazards Elimination by engineering modifications in the process. The last principle Substitution advocate the administrative control by making some administrative mechanism in the Engineering controls workplace to keep away hazards . from human and workplace. Administrative
R e d u c t i o n

2.2 Substitution If a particular dangerous chemical or work process cannot be completely eliminated, then try to replace it with a safer substitute. It is not easy to find safer chemical substitutes (in fact, no chemical should be considered completely safe). It is important to review every year or so current reports on the chemicals used in the workplace because chemicals considered to be safer substitutes today may not be considered safe in the future. When one has to look for safer substitutes, try to choose a less volatile (volatile liquids vaporise, or evaporate easily) instead of a highly volatile one, choose a solid instead of a liquid, etc. For example, many dry, dusty powders are also available in brick, pellet, paste, flakes, oil damped powders, and other forms that create less dust when handled, and reduce the chance of inhaling the dust. Many plastics and rubber industry chemicals can also be supplied in dust-suppressed forms. These materials can be more expensive to purchase but they are safer for workers to handle and can be cheaper when other costs are considered, such as the cost of ventilation to control dust, personal protective equipment, etc. Fig - 7A demonstrates the dust/fume of a hazardous chemical, this chemical has been substituted by a chemical which do not have dust/fumes as shown in Fig - 7B . Other examples of substitution include using: less hazardous solvents instead of toxic ones dichloromethane or fluorochlorohydrocarbon instead of carbon tetrachloride; and toluene, cyclohexane or ketones instead of benzene). detergent plus water-cleaning solutions instead of organic solvents; freon instead of methyl bromide chloride as a refrigerant; leadless glasses in the ceramics industry; leadless pigments in paints; ozone in place of chlorine in swimming pools; synthetic grinding wheels (such as aluminum oxide, silicon carbide) instead of sandstone wheels Are substitute materials always safer than the original hazard? No. There are examples where a material that was thought to be safer was found to be as bad as, or worse than, the original hazard. A classic example is asbestos. Fibreglass

DUST

The application of all four control measures with the use of personal protective equipments (PPEs) reduces the hazards significantly in workplace and out side of the unit. It is shown in fig -5. 2.1 Elimination

controls Personal protective equipment Fig-5

H a z a r d s

Fig-7A
WELL, THERE IS NO DUST

The most effective control measure is to control hazards at the source by eliminating the hazard. Eliminate hazards at the development stage it is important to consider health and safety aspects when work processes are still in the planning stages. For example, when purchasing machines, safety should be the first concern, not cost. Machines should conform to national safety standards they should be designed with the correct guard on them to eliminate the danger of a worker getting caught in the machine while using it. Machines that are not produced with the proper guards on them may cost less to purchase, but cost more in terms of accidents, loss of production, compensation, etc. Unfortunately, many used machines that do not meet safety standards are exported to developing countries, causing workers to pay the price with Fig-6 accidents, hearing loss from noise, etc. Fig-6 is the best example for accident when machine guard is eliminated or in other words hazard of accident could be eliminated by providing the machine guard.

Fig-7B

11

12

has been used as a substitute for asbestos; however, it is now known that fibreglass is also a hazardous material and is not a completely safe substitute for asbestos. A substitute may be better than the original hazard, but that does not mean it is safe. Where one can get information on substitute materials? Material Safety Data Sheet (MSDS) is the best source of getting information about the hazardous chemical. As per the Schedule 9 of Manufacture, Storage and Import of Hazardous Chemicals (MS and IHC) Rules 1989 and subsequent amendments. MSDS is also available with other sources are as shown in fig-8. Protective measures are important when working with all chemicals, even if one is using a safer substitute. Can dangerous work processes be substituted with safer processes? Yes. Changing the way of job is another form of substitution. For example, vacuuming up dust instead of sweeping it, or using membrane cell by mercury electrodes to control mercury pollution is safer way in chlor alkali industry .Wet methods mean spraying water over a dusty surface to keep dust down, or mixing water with the material used to prevent dust from being created. These methods reduce the amount of dust in the air. The toxic fumes should be scrubbed by water or dilute chemical solution by spraying through scrubbers as shown in Fig-9. Other examples are: i. electric motors instead of diesel or petrol engines to eliminate hazardous exhaust fumes; ii. dust-free cutting or grinding equipment; iii. dip or brush instead of spray painting; iv. covered containers to carry materials which produce air contaminants.

Use a vacuum cleaning when cleaning up toxic dust. Never sweep toxic dust-sweeping puts the dangerous dust back into the air where you can breathe it. (Fig-10)

Fig-10
Remember 1. If a dangerous chemical or work process cannot be eliminated, then try to replace it with a safer substitute. Not all substitute materials are really safer - they may be better than the original hazard but can still be dangerous. 2. Protective measures are important when working with all chemicals, even if you are using a safer substitute.

2.3 Engineering controls There are a number of common control measures which are called engineering controls. These include enclosure, isolation and ventilation. I). Enclosure If a hazardous substance or work process cannot be eliminated or substituted, then enclose it so workers are not Fig-11A exposed to the hazards . Many hazards can be controlled by partially or totally enclosing the work process. Highly toxic materials that can be released into the air should be totally enclosed, usually by using a mechanical handling device or a closed glove system that can be operated from the outside. Fig-11A shows the total enclosing of hazards while Fig-11B shows the partial enclosure. The Fig- 11C is not a good practice where hazard is not enclosed. In the example the fumes/vapours are considered for giving an example of enclosure.

LOCAL FIRE DEPARTMENT

EMPLOYER

CHEMICAL MANUFACTURER

LOCAL FACTORY OR LABOUR INSPECTORATE TEACHERS AT LOCAL COLLEGES OR UNIVERSITIES

UNION

Fig-11B

LOCAL FIRE DEPARTMENT

LOCAL LIBRARY

ITSs

ILO

OTHER

Fig-11C

Fig-8

Fig-9

13

14

Machine guarding is another form of enclosure that prevents workers from coming into contact with dangerous parts of machines. Workers should receive training on how to use guarded machines safely. Some of the areas of a machine that can injure are: the point of operation (which is the area on a machine where work is actually being performed); pinch-points; sharp areas, such as blades; exposed electrical components, which can cause electrical shock or burns; presses, which can crush; rotating parts; flying chips and sparks. Here are a few examples of types of machine guards: a. Enclosure guards: prevent from coming into contact with the dangerous moving parts of a machine by enclosing the parts or forming a barrier around the dangerous parts. This type of guard also prevents broken and flying machine parts from hitting. b. Interlocking guards: prevent from operating the machine if the guard is not in place, or automatically stop the machine if part of body enters a dangerous area. Photoelectrical or mechanical-sensing devices (such as a photoelectric eye) are examples of interlocking guards. Unguarded machines are hazardous c. Automatic guards: actually pull or Fig-12 push the hands, arms, or body away from the danger zone as the work is being done. d. Remote control, feeding, placement or ejecting guards: these control methods protect from dangerous points of operation. For example, a two-handed control requires both of hands to be on the controls (away from the danger zone) when operating the machine. This is a common method with punch/ stamping presses; a feeding mechanism may use an automatic device to feed material into the machine, so that no need to feed by hand. (ii). Isolation Isolation can be an effective method of control if a hazardous job can be moved to a part of the workplace where fewer people will be exposed, or if a job can be changed to a shift when fewer people are exposed (such as a weekend or midnight shift). The worker can also be isolated from a hazardous job, for example by working in an air-conditioned control booth. It is also important to limit the length of time and the amount of a substance(s) to which workers are exposed if they must work in the hazardous area. For example,

dust-producing work should be isolated from other work areas to prevent other workers from being exposed. At the same time, workers in the dusty areas must be protected and restricted to only a short time working in those areas. Isolation is also possible by using PPEs in the hazardous areas. Isolating the work process or the worker does not eliminate the hazard, which means workers can still be exposed. (Iii). Ventilation Ventilation in the workplace can be used for two reasons: (1) to prevent the work environment from being too hot, cold, dry or humid; (2) to prevent contaminants in the air from getting into the area where workers breathe. Generally there are two categories of ventilation: local exhaust ventilation and general ventilation. Whatever the type, ventilation should be used together with other methods of control. a. Local exhaust ventilation usually uses suction, based on the principle of a vacuum cleaner, to remove pollutants from the air. There are two common types of local exhaust ventilation used in industry today: (i) fumes are sucked into an open tank with side slots and into a closed system, through which they are then transferred to a disposal point away from the workers (a degreasing tank is an example of this); (ii) fumes are sucked into a canopy hood which hangs over a contaminant and forced out through a ventilation duct. This type is Fig-13 very effective where the air pollutants have a high temperature, or if they rise in the air for another reason (for example, the heat from furnaces or ovens causes pollutants to rise). Fig -13 demonstrate the suction at local level Partial enclosure (such as laboratory fume cupboards or screens placed around welders) combined with a local exhaust ventilation system is one of the best solutions for controlling toxic material. This type of system must operate as close as possible to the source of the hazardous agent to reduce it from spreading, yet at the same time allow access to the work process. Fig -14 Demonstrate Fig-14 the partial enclosure.

15

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b. General ventilation generally used for keeping the workplace comfortable, is one of the least effective methods of controlling hazards but one of the most commonly used. The purpose of any general ventilation system is to remove contaminated air and replace it with fresh air. This system does not really remove hazardous agents from the air; it simply reduces the amounts in the air to levels that are considered safe for breathing. The effectiveness of a general ventilation system depends on several things, like: how quickly the hazardous agent is being released into the air; how much and how quickly fresh air is coming in; and how the contaminated air is being removed. Unfortunately, many workplaces use general ventilation as the only source of ventilation. Air-bricks, windows and doors may be opened to increase the general flow of air. However, these openings are often blocked or shut. Doors and windows are sometimes locked for security reasons, air-bricks may be blocked by excess stock being stored across them, etc. Without good general ventilation, hazardous agents in the air can accumulate (sometimes to dangerous levels), and the workplace may become very hot, difficult to work in and dangerous. Are fans a good source of ventilation? No. Fans can only help to remove fumes, dusts, etc., but they should not be used as a primary source of general ventilation and should never be used as a method of . removing toxic materials.

1. Engineering controls include enclosure, isolation and ventilation. 2. If a hazardous substance or work process cannot be eliminated or substituted, then full enclosing is the next best method of control. 3. Isolation can be an effective method of control if a hazardous job can be moved to a part of the workplace where fewer people will be exposed, or if the job can be performed at a time when fewer people will be exposed. Alternatively, the workers can be isolated from a hazardous job. Isolating a work process or a worker does not eliminate the hazard, therefore elimination is always a better choice than isolation. 4. General ventilation can be used for keeping the workplace comfortable, and local exhaust ventilation for removing air pollutants. General ventilation is one of the least effective methods of controlling hazards. Ventilation systems must be checked and serviced regularly. Sprinkle some dust or hold a piece of cloth near the exhaust outlet to see if the air movement in your workplace is adequate.

2.4 Administrative controls Administrative controls limits the duration of working time of the workers at a hazardous place. Some examples of administrative controls include:
Photo-1

Photo-2

Does your workplace have some type of ventilation system in place that you assume is working properly? In many cases, the ventilation system is not effective because of poor design, lack of servicing, etc. Ventilation systems must be checked and serviced regularly. The best way to test how well the ventilation system in your workplace is working, is with special equipment and personnel trained to use it. Unfortunately, the equipment and personnel can be hard to get. However, a simple way to see how well the ventilation extract system in your workplace is working is to sprinkle some dust or hold a piece of cloth near the exhaust outlet. If there is little air movement, then the ventilation system is not working properly and should be repaired. Photo1 and 2 show the ventilation system off and on respectively

changing work schedules (for example, two people may be able to work for four hours each at a job instead of one person working for eight hours at that job); Fire giving workers longer rest periods or shorter work shifts to reduce exposure time; assembly moving a hazardous work process to an area where point fewer people will be exposed; Fig-15 changing a work process to a shift when fewer people are working; clear and readable signage are administrative tool for communication and control of hazards at workplaces (example Fig -15 and16); compliance of regulatory provisions is the best administrative control; 0rganisation of drills for emergency Inclusion of bonus to those who regards safety and Fire exit follow the safety instructions; disclosure of the hazards and risk to civil administration Fig-16 to get help in real emergency; inclusion of safety in Corporate Social Responsibility (CSR) and demonstration with community of nearby.

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An example of administrative controls being used together with engineering controls and personal protective equipment is: a four-hour limit for work in a fully enclosed, high noise area where ear protectors are required.
1. Administrative controls limiting the amount of time working at a hazardous job can be used together with other methods of control to reduce exposure to hazards. 2. Administrative controls do not eliminate exposures; they only reduce exposure time.

Protection against airborne particles, e.g. stone dust. This filter contain mess to filter out dust.

Protection against gases and fumes, e.g. when using paints containing solvents. This filter contains activated carbon. With a combination filter containing both a dust and a gas filter. These masks are examples of the simplest effective respiratory protection. The filter should be replaced when it gets harder to breathe or when it begins to smell. The filter should be replaced frequently. Make sure none of protective gear is made ha asbestosa ofd hlmts,hts e ee

2.5 Personal protective equipment Personal protective equipment (PPE) is the least effective method of controlling occupational hazards and should be used only when Examples of PPE include: other methods cannot control hazards sufficiently. safety glasses PPE can be uncomfortable, can decrease work ear protectors performance and can create new health and safety respirators with filters hazards. For example, ear protectors can prevent dust masks from hearing warning signals, respirators can make it gloves protective suits harder to breathe, earplugs may cause infection, and safety shoes leaky gloves can trap hazardous chemicals against the skin. PPEs should be used in addition to other control hazards methods . However, if it is impossible to reduce hazards inspite of the, elimination, substitution, engineering and administrative controls then PPEs should be used to save lives of workers and even community. PPE puts a barrier between the worker and the hazard. PPE may keep the hazard out, but it also keeps heat and water vapour in the protective clothing, which can cause hot and uncomfortable conditions. When wearing PPE, workers should drink plenty of water and take frequent breaks. In hot or humid working conditions, one should wear PPE for a short time (even as little as ten minutes in very hot conditions) . Heat and humidity can also decrease the effectiveness of some protective equipments; for example, a respirator mask may not have a tight seal if your face is wet with perspiration or water. How do you know what type of PPE to use? The type of PPE you need to use depends on the hazards and, exposure.

Protection for: Type of gear airway respirators, mask goggles, glasses, polarizers

Protection for: Type of gear

head

head

head

helmets, hats

helm hats ets,

helm hats ets,

Helmets, hats Head

skin

Lungs

skin

Eyes

Skin

skChemicalrresistantg inchemicalma eclothing,lo in, c eresistantsista tc th h ic l n aprons resistant clothing, chem ical a os p clothing, aprons skinaprons r nical resistant clothing, chem
aprons
special gloves, rubber finger-

hands

muffs, plugs Ears Hands

hands coats special gloves, rubber fingerfeet hands coats

special gloves, rubber fingeragainst work shoes, boots radiation feet coats metal-lined shields and aprons
against work shoes, boots feet radiation metal-lined shields and aprons

Special gloves, hns ad rubberiag vs,r be finespc finger-coatsr e l loe ubr g ca ots against work shoes,

Feet radiation ok os, o Protective clothing should fit well in order to give the best protection. she bshould aprons aa st wr Careots and be gin metal-lined shields taken while purchasing the PPE and it should be as per the bodytio of the workers r d size a ia n for both men and women. All PPE should be checked for holes or aireleakage.ld a dafor mta e sh Lookpo s l-lind ie s n r n signs of leaks, such as dust near the nose, or dust in the nose hairs. If a worker is having beard or large mustache then it is difficult to get a good seal - if your mask does not have a good seal you cannot breathe in hazards

feboots radiation e t against work shoes, boots

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PPEs should be used according to the chemical composition, for example the pesticides can cause serious poisoning, including nerve damage and skin and eye damage, so SCBA ( Self Contained Breathing Apparatus) should be used. Use of the appropriate safety PPEs is essential to protect from chemical hazards. The following fig- 17 and 18 show the wrong and right PPEs during spray of pesticides respectively.

In Phot-4 both of the employees in this picture bears the SCBA to protect themselves for toxic gas inhalation, in addition to this the safety shoes are better here to the previous case (Photo-3).

Photo-4

In Photo-5 the PPE includes the whole body cover, the yellow cloured full body cover is the best way to work in toxic gases. The adjacent employee don't have full body cover so he is not better protected in comparison to yellow one. Fig-17 Wrong Fig-18 Right
Photo-5

Sometimes workers use barrier creams to prevent hazards from getting through the skin on their hands and arms. Barrier creams are not very effective and can even cause more exposure to hazards by trapping dusts next to the skin or causing chemicals to get through skin. Barrier creams can help to remove dirt when wash the skin, but they are not a substitute for hazard-specific gloves.

Use of PPEs during action of emergency management during toxic gas release which is highly soluble in water is demonstrated in next five photos. In Photo-3 the left side worker is using SCBA (Self Contained Breathing Apparatus) but is devoid of helmet, while right side worker is bearing helmet but is not bearing SCBA so both are having risk, one is having risk of falling object on the head and other is having the risk of getting toxic inhalation (Photo-3).

Photo-6

In Photo-6 both workers are having SCBA and for victim, they are taking care by providing compressed air. The response team members should have full body protection through comprehensive body cover by all PPEs. The best example is shown above where whole team is better protected for any emergency action for toxic releases, because everyone has SCBA, full body cover, helmet, shoes, hand gloves . If we compare Photo-3 to 7 then the PPEs have following orders of betterment i.e. 3 < 4 < 5 < 6 < 7 meaning to say preparedness of the response team is better in Photo-7 and poor in Photo-3.

Photo-3

Photo-7

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Proper training is needed in the use, care, maintenance and to know limitations of PPE.

A few example of best and poor practices of housekeeping are shown below:

SIGN: Caution Hard Hat Area COMMENT: Standardised hard hat SIGNAGE: RECOMMENDATION: None.
Points to remember about personal protective equipment 1. PPE is the least effective method for controlling hazards in the workplace and should be used only when hazards cannot be controlled sufficiently by other methods. 2. PPE can be uncomfortable, decrease work performance, and can create new health and safety hazards. Workers in PPE should take regular breaks. 3. Hot or humid working conditions decrease the effectiveness of PPE. Under these conditions, workers should take frequent breaks and drink plenty of fluids. 4. The type of PPE required depends on the hazard, the way exposure affects the body and the exposure time. 5. If PPE does not fit you well it may not protect you; this is particularly important with respirators. All PPE should be checked for leaks. 6. All workers using PPE should be trained in the proper use, maintenance and limitations of PPE.

SIGN: Danger High Voltage Within Keep Out COMMENT: Standard electrical safety sign with warning symbol. RECOMMENDATION: None.

2.6 Other methods of control General cleanliness Keeping a clean and organised workplace is an important method of controlling hazards. Good housekeeping (keeping a clean workplace) reduces the risk of fire and is cost-effective, since machines and tools that are cleaned regularly need less servicing. At the same time, maintaining a pleasant working environment can produce higher productivity. Good work practices include: proper cleaning at regular intervals (using industrial vacuum cleaner) proper waste disposal proper and immediate clean-up of any spills proper sprinkling of scrubbing agent to absorb or to dilute the toxic gases release into the environment or work place correct storage and labelling of materials.

Proper storage and housekeeping can avoid such sitiuations

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3. Conclusion
Check-list to assess the control measures After having the review of hazards recognistion and control methods in previous pages it can be concluded that hazard control process has following six steps i. Assessment ii. Analysis Assess iii. proper judgement of the right control methods Monitor Analyze iv. Appropriate control methods recommendation v. proper implementation Act Judge vi. Monitoring of the whole process The above six steps have been depicted as Fig-19. for machine guards 1. Are the operators' hands, fingers and bodies kept safely away from the danger areas when a machine is being operated? If no, what type of guard could be installed? 2. Are starting and stopping controls within easy reach of the operator? 3. Are belts, pulleys, chains, spockets, gears and blades properly guarded? 4. Are rotating parts covered or out of reach inside the equipment? 5. Are fans that are located near the floor guarded? 6. Are guards firmly attached so they cannot easily be removed?
Fig -19
Annexure

Recommend

7. Have operators been told about the importance of using guards? Have they been trained in the operation and maintenance of guarded machines? 8. If operators are not within sight or hearing distance of other workers,

It is strongly recommended that please observe the hazards seriously and report to competent persons to control the hazards any type of casual approach can become a disaster to you or your company

is an alarm device provided? 9. Is there an effective system for disconnecting and locking out the machine from its power sources when guards are removed during maintenance? Have workers been trained in lockout procedures and in machine maintenance procedures? 10. Do machine guards restrict workers' productivity, cause discomfort or annoyance to the operator? 11. Does the design or construction of the machine guards create any new dangers? 12. Is the company following all local or national requirements for machine guarding and any special rules for guarding of hand and portable powered tools and machinery?

Check lists To review the control measures for various types of hazards we are providing a few check lists for self assessment in annexure for following: to assess the control measures for machine guards to assess the control measures for local exhaust ventilation to assess the control measures for personal protective equipments (PPEs) to assess the control measures for general cleanliness assess the control measures for personal hygiene assess the control measures for hazards control and emergency planning

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Check-list to assess the control measures for local exhaust ventilation

Annexure

Check-list to assess the control measures for personal hygiene 1. Drink clean, potable water.

Annexure

1. Do you smell chemical odours or see dust building up near the hood or machines? Can you see contaminants in the air? 2. Is the hood close enough to the place where air contaminants are being released? 4. Are any ducts broken or leaking? 5. Check motors and fans. Are any belts broken? Are fans installed correctly ? Are fan blades covered with dirt, grease, etc. and inefficient? 6. Ask the senior management to show the original design of the system. Have extra hoods been added to cover new machines? If any were added, was the system balanced again? Can it handle the new load? 8. Are there many bends, twists or Ys in the duct system? These can slow down the movement of the exhaust air as well as causing increased noise levels. 9. Does the hood pull contaminants in the proper direction away from the worker's face rather than past it? 10. Does the amount of clean air brought into the system equal the amount exhausted? Does monitoring of hazardous gases is efficient and concentration is within prescribed limits. 11. Has the employer used an instrument called a velometer to see if the airflow is strong enough?

2. Never eat in locker rooms, washrooms or where dangerous materials are used. 3. Wash the hands and the exposed parts of your body regularly and take daily baths or showers. 4. Clean your teeth and mouth daily and have periodic dental check-ups if possible. 5. Wear proper clothing and footwear. 6. Do not mix work and street clothes. 7. Clean working clothes, towels, etc. with the help of a special laundry, if possible, particularly when they get contaminated. 8. Keep physically healthy with regular exercise. First-aid and fire-fighting equipment Use this check-list to assess the first-aid and fire-fighting equipment in the workplace. 1. Is adequate first-aid equipment provided and checked regularly? 2. Are trained and adequate first-aid personnel present during all shifts? 3. Is adequate space available in first-aid room ? 4. Is first-aid competence been evaluated during drills? 5. Are locations of first-aid posts visible and within reach ? 6. Have Ambulance been equipped with necessary medical facilities? 7. Are body showers and eye wash available at all points? 7. Are workers encouraged for taking meal at clean dinning places ? 8. Are safety committees recommendations being discussed with workers and supervisors for improving personal hygiene health?

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4. Glossary
Check-list to assess the control measures for general cleanliness
Annexure

1. Is the layout designed to facilitate order and cleanliness? Is there adequate space between machines exists? 2. Are aisles, passageways, transport areas and exits clearly marked and free of obstacles? 3. Are special areas set aside for storage of raw materials, finished products, tools and accessories? 4. Are there racks for hand tools or other necessary items above work tables? 5. Are there underbench slots or other spaces for storage of small personal belongings? 6. Are receptacles for waste and debris in convenient locations? 7. Are floor-covering materials suitable for the work and for cleaning? 8. Are there screens or simple devices to prevent deposits of oil, liquid wastes or water on the floors available? 9. Are there drainage channels for waste water? 10. Are there special groups of people to carry out day-to-day cleaning and weekly or monthly cleaning? 11. Have arrangements been made to remove finished goods and wastes? 12. Is there a clear assignment of duties for maintenance and repair of work premises, particularly stairs, walkways, walls, lights and toilet/ washing facilities exists?

Accident/Incidents: Any unplanned, sudden event which causes or is liable to cause injury to people or damage to building, plant, material or the environment. Consequence: Result of a specific event. Emergency plan: A formal written plan which, on the basis of identified potential accidents together with their consequences, describe how such accidents and their consequences should be handled either on-site or off-site. Evacuation: Evacuate means to move all people from a threatened area to a safer place. To perform an evacuation, there must be enough time for people to be warned, to get ready, and to leave an area. Generally, if there is enough time for evacuation, it is likely to be the best protective action. Hazard: An inherent property of a substance, agent, source of energy or situation having the potential of causing undesirable consequences. Hazardous substances: An element, compound, mixture or preparation which, by virtue of chemical, physical or (eco) toxicological properties constitutes a hazard. In-place protection: In-place protection means to direct people to quickly go inside a building and remain inside until the danger passes. When protecting people inside, direct them to close all doors and windows and to shut off all ventilating, heating and cooling systems. In-place protection is used when evacuating the public would cause greater risk than directing them to stay where they are, or when an evacuation cannot be performed. When inside, people must keep all windows and doors closed. In-place protection may not be the best option if the vapours are explosive, if it will take a long time for the gas to clear the area, or if the buildings cannot be tightly closed. Isolation: Isolate Hazard Area and Deny Entry means to keep everybody away from the area if they are not directly involved in emergency response operations. Unprotected emergency responders should not be allowed within the isolation area. This Isolation task is done first, to get control of a place to work. This is the first step for any protective action that follow. Major accidents: Any unplanned, sudden event which causes or is liable to cause serious injury to people or damage to buildings, plant, material or the environment. Probability: The likelihood that a considered occurrence will take place. Risk: The combination of a consequence and the probability of its occurrence.

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5. Reference
1. Feyer, A.M. and Williamson, A.M. (1998): Human factors in accident modelling. In: Stellman, J.M. (Ed.). 2. Encyclopaedia of Occupational Health and Safety, Fourth Edition. Geneva: International Labour Organision. 3. Guidence Note QGN 17, Development of effecive Job Safety Analysis, Queenland Government, 2010. 4. www.hrdp-idrm.in 5. Incident Response System: National Disaster Management GuidelinesIncident Response System, National Disaster Management Authority, Government of India July 2010. 6. Emergency Response Manual, Guidelines for WHO Representatives and Country Offices in the Western Pacific Region Provisional Version, October 2003. 7. Andereassen, M.; Bakken, B.; Danielsen, U.; Haanes, H.; Solum, G.; Stenssas, J.; Thon, H.; Wighus, R., (1992). Handbook for fire calculations and fire risk assessment in the process industry. Scandpower A/S. 8. Hazard Identification and Risk Analysis Code of Practice, BIS IS 15656: 2006, Bureau of Indian Standards. 9. Khan, F.; Abbasi, S., (1998). MAXCRED-a new software package for rapid risk assessment in chemical process industries. Environ. Modell. Softw.. 10. Khan, F.; Abbasi, S., (1999). HAZDIG: a new software package for assessing the risks of accidental release of toxic chemicals. J. Loss. Prevent. Proc. 11. Roberts, B., (1982). Thermal radiation hazards from release of LPG from pressurized storage. Fire Safety J. 12. Simmons, J.; Erdmann, R.; Naft, B., (1973). The risk of ctastrophic spill of toxic chemicals. Rep. UCLA-ENG-7425. Unv. of California, Los Angeles, California.

Notes

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