Like manufacturers in all industries, pharmaceutical manufacturers and their employees face real and serious health and safety issues. In some cases, the hazards are the same ones we find in most manufacturing facilities. In other cases, the hazards are more specific to pharmaceutical manufacturing. Likewise, pharmaceutical manufacturers use hazard controls and risk mitigations that are common to many industries as well as more specific to pharmaceutical manufacturing, including all levels of the hierarchy of controls, from elimination down to administrative controls such as training for pharmaceutical safety and the use of PPE.

1. 1
INDUSTRIAL HAZARDS AND
PLANT SAFETY
PRESENTED BY:
SANJAY PATEL

2. 2
• Introduction
• Chemical Hazards and Management of
Over-exposure to Chemicals
• Gas Hazards and Handling of Gases
• Dust Explosion and Control
• Fire and Explosion Hazards
• Control of Fire and Explosion
• Safety Management

3. 3
HAZARD
ANYTHING WITH POTENTIAL FOR
PRODUCING AN ACCIDENT.

4. 4
• Hazard is a term associated with a
substance that is likelihood to cause an
injury in a given environment or
situation.
OR
• Hazards was defined as any substance
(raw material), machinery or equipment
that could cause simple or serious injury
leading to absence from work.
• Industrial hazard may be defined as any
condition produced by industries that
may cause injury or death to personnel
or loss of product or property.

5. 5
Industrial Safety
• Safety in simple terms means freedom from
the occurrence of risk or injury or loss.
• Industrial safety or employee safety refers to
the protection of workers from the danger of
industrial accidents.
• Toxic and corrosive chemicals, fire,
explosions and personnel falling into
accidents are the major health and safety
hazards encountered in the operations of
chemical and pharmaceutical related
industries.

6. Building Configurations (Design, Lay-out)
Building in which explosives are handled or
stored should be separated
Spatial organization of building depends on
• Circulation of people and materials
 The health and safety issues – concern with
emergency access to the building by
emergency personnel – Firemen and police.
 Special attention should be given
a) To ease of access and emergency evacuation
for handicapped persons.
b) Avoid barriers at main entrance, doorways,
Public toilet/telephones, & elevators. 6

7. Building Configurations (Design, Lay-out)
c) Less floor load, i.e. More moving area for
workers.
d) Enough facility for entry and exit in ordinary
and emergency condition. Exit doors –
outside.
e) Number of exit doors depends upon the size
and capacity of establishment, but at least 2
there should be 2 exit.
f) Where fire hazards are likely to occur no exit
should be away from any point by 75 ft.
g) Wide passage on sides of laboratories.
h) Floor must be slip-proof under wet condition.
7

8. • Laboratory module
a) Provide separate storage for flammable
gases & liquids (Toxic and reactive liquids).
b) Safe distance from mail plant & fire-proof.
c) Ventilation – Air enters near the floor level
and leaves the room near the ceiling.
d) Drum – air-tight to prevent any leakage. Not
be stored one over other.
e) Inflammable substance is advisable to store
at top floor. If it’s stored at ground level
then vapors move up via leakage and there
are all possibilities of electrical accident.
f) Ceiling – provide with automatic showers.
8

9. EQUIPMENTS
a) Located to provide adequate working areas,
aisles and light (near windows).
b) Properly guarded.
c) Quick stopping devices either automatically or
manually controlled.
d) High instruments then high platform should
be provided.
• Utilities and Services
Basic utilities are: Power, water supply,
gas supply, Air/Vacuum line, Heating, Ventilating
and AC, Exhaust duct & drainage systems.
9

10. SERVICES
a) Fire alarm services,
b) Fire pump/Fire suspension systems,
c) Emergency communication system, Lighting,
smoke detection/evacuation system, Cabinet,
Showers, Eye-wash.
d) Make-up air system.
e) Master electrical disconnect switch.
f) Electrical, gas, steam, air and vacuum lines
are grouped so that it can be reached easily.
10

11. 11
Hazard Categories:
Chemical Hazards
Mechanical Hazards
Electrical Hazards
Fire and Explosion Hazards
Pressure Hazards
Biological Hazards

12. 12
CHEMICAL HAZARDS
• Chemical exposure may cause or contribute to
many serious health effects such as heart
diseases, central nervous system damage,
kidney and lung damage, sterility, cancer,
burns, and rashes.
• Some chemicals may also be safety hazards
and have the potential to cause fires and
explosions and other serious accidents.
• Chemicals may be found in solid, liquid,
aerosol, or gas and vapor form.
• The degree of danger varies according to the
form of the chemical and the factors like,
– Its physical properties
– Its toxicity
– The way it is used
– The environment in which it is encountered.

13. 13
• Routes of entry - Inhalation, Ingestion, skin
absorption. (inhalation is the main route of
entry)
Chemical agents can be classified into-
1) Metals - Lead, TEL, As, Hg, Cd, Ni
2) Aromatic Hydrocarbons - Benzene, Toluene,
Phenol
3) Aliphatic Hydrocarbons - Methyl alcohol
4) Gases –
* Simple asphyxiates : N2, CH4, CO2
* Chemical asphyxiates : CO, H2S, HCN
* Irritant gases : Ammonia, SO2, Cl2,
* Systemic poison : CS2

14. 14
• Not all forms of a chemical poses a health
hazard. Example, a lead pipe is not a
significant health hazard.
• However, the lead can become a human
health hazard if the pipe is sanded or
welded, producing lead dust or fumes.
• The dust or fumes can become inhaled, or
it can leach into water and be ingested.
• A chemical may be hazardous even in solid
form. Example, individuals who are
sensitized to Nickel may develop dermatitis
from skin contact with the metal.
• Fuming solids emit toxic vapors that may
be inhaled. Some materials, such as
pesticides, can evaporate directly from
solid form.

15. • Some solids are not a hazard alone but
become hazardous when they come into
contact with other chemicals (e.g., Acid in
contact with iron can release hydrogen gas).
• Many liquids are hazardous in contact with
the skin. They either damage the skin or they
are easily absorbed through the skin.
• It is important to remember that chemicals
that can damage or be absorbed through the
skin will have this effect on all skin, not just
the hands.
15

16. 16
• For example, inhalation is the primary route
for a chemical to enter the body. Its vapor
pressure is important in determining the
liquid degree of hazard.
• Liquids with a low vapor pressure may create
a low airborne concentration.
• Liquids with a high vapor pressure may
produce high airborne concentrations.

17. 17
MANAGEMENT OF OVER-EXPOSURE
TO CHEMICALS
1. Removal from Exposure:
 Prompt removal of the person from the
exposure site is the first step.
 Air respirators and lifelines are mandatory
first aid.
2. Resuscitation:
 Resuscitation means restoration of life of one
who is apparently dead (collapsed or
shocked).
 Further supportive care should be provided
as with any other medical emergency.

18. 3.Decontamination:
 A victim whose skin or clothing has been
contaminated requires immediate removal of
garments and shoes. Then vigorous showering
with soap and water, including attention to the
fingernails and scalp is advised.
4.Symptomatic Treatment:
 Acute over-exposure may result in a variety of
signs and symptoms that require general
supportive medical management regardless of
the specific agent. Examples include the control
of convulsive seizures, treatment of broncho-
spasms, dehydration & arrhythmias.
18
MANAGEMENT OF OVER-EXPOSURE
TO CHEMICALS

19. 19
CHEMICAL SAFETY SYMBOLS
Poisonous
Environmental hazard
Corrosive
Flammable
Irritant or Harmful
Explosive
Oxidizing chemical
Spontaneously Combustible
Stow away from foodstuffs
Dangerous when wet
Flammable Gas
Non flammable gas
Inhalation Hazard
Poisonous Gas
Flammable Solid

20. 20
TLV CONCEPT
 The Threshold Limit Value - Time Weighted
Average (TLV-TWA) : Time-weighted average
concentration for a normal 8-hour working
day and a 40-hour working week, to which
nearly all workers may be repeatedly exposed
day after day, without adverse effect.
 The Threshold Limit Value - Short Term
Exposure Limit (TLV-STEL) is defined as a 15-
minute, time-weighted average which should
not be exceeded at any time During a
working day, even if the 8-hour time-weighted
average is within the TLV.

21. Preventing accidents involving chemical
& reagents
• Maintain up-to-date inventory & information sheets
on each chemical.
• Before opening a chemical, always read the safety
& risk phrases written on label. Know the hazard
symbol for chemicals.
• Making sure chemicals that can react dangerously
together. i.e. incompatible chemicals.
• Keep chemicals & reagents out of direct sunlight
and don’t allow them to overheat.
• Ensure the caps of containers are airtight and
tightly closed – volatile, flammable, hygroscopic
or have toxic/irritating vapor.
21

22. Preventing accidents involving chemical
& reagents
• Don’t use rubber liners in the caps of bottles
containing Iodine, ether, xylene etc.
• Don’t use ground glass stoppers – KOH and NaOH
that absorbs CO2 from the air.
• Keep the laboratory well ventilated when using
hazardous chemicals (flammable / irritating vapor).
• When preparing reagents, wear appropriate dress.
• Ensure an eye-wash bottle is available.
• Never mouth pipette, taste or inhale chemical.
• Always wash the hands immediately after handling
chemicals.
22

23. 23

24. 24
MECHANICAL HAZARDS
• MHs associated with powers-driven machine, whether
automated or manually operated machine driven by
steam, hydraulic or electric power..
• Mechanical injuries – Cutting, tearing, shearing,
crushing, breaking, straining and puncturing.
• Shearing – Such tragedies would occur when operators
reached under the shearing blade to make an
adjustment.
• Crushing – Part of body is caught between two hard
surface that progressively move together. Very painful
and difficult to heal.
• Breaking – Machine used to deform engineering
materials in variety of ways also cause fracture.
• Puncturing – A puncture results when an object
penetrates straight into the body & pull straight out.
• Straining and spraining – Muscles are overstretched
and joint strains – cause swelling and pain.

25. 25
Prevention of MHs (Safeguarding)
• Safeguarding is to minimize the risk of accidents of
machine-operator contact.
Requirements of safeguards
1. Prevent contact
2. Be secure and durable
3. Protect against falling object
4. Don’t create new hazard
5. Don’t create interference
6. Allow safe maintenance
Types of safeguards
1. Point of operation guards
2. Point of operation devices
3. Feeding/ejection method
4. Robot safeguards

26. 26
• It is the point where hazards to human exist.
• Single purpose - only one hazard (Fixed & non-
adjustable).
• Multiple-safeguard - guard against more than one
hazard (adjustable).
• There are three types
1. Fixed guard – provide permanent barrier b/w workers
and operation point
Merits – Suitable for many applications,
Require little maintenance,
Suitable for high and repetitive operations.
Limitations – Limited to specific operations,
Inhibit normal cleaning and maintenance.
1. Point of Operation Guards

27. 27
2. Interlocked Guard – They shut-down the machine
when guard is not securely in place.
Merit – Allow safe access for removing jams or for
maintenance.
Limitation – Require careful adjustment &
maintenance.
3. Adjustable Guard – Provide barrier against a variety
of different hazards associated with different
operations.
Merit – Flexible
Limitations - Require careful adjustment &
maintenance
1. Point of Operation Guards

28. 28
Photoelectric – Optical device that shut-down the
machine any time the light field is broken.
Limitation – Require frequent calibration.
Don’t protect against mechanical failure.
Radio-frequency – Capacitance devices that brake the
machine. (capacitance field – interrupt by body).
Electromechanical devices – contact bars allow only a
specified movement b/w worker & hazard.
Limitations - Require careful adjustment & frequent
maintenance
Pull back devices- Pull the operators hand out of the
danger zone when machine start working
2. Point of Operation Devices

29. 29
Automatic feed – It eliminate the need for operators to
enter the danger zone.
Semiautomatic feed – Use for variety of approaches
for feeding stock to the machine. Like Dial feeds,
plunger, movable dies and sliding bolsters.
Automatic Ejection- Eject the work pneumatically or
mechanically.
Advantages – Operators don’t have to reach into the
danger zone to retrieve work pieces.
Restricted to use with relatively small stock.
3. Feeding & Ejection Systems

30. 30
Main hazards associated with robots are:
1. Entrapment of a worker between a robot and a
solid surface.
2. Impact with a moving robot arm.
3. Impact with objects ejected or dropped by the
robot.
Best Guard – To erect a physical barrier around the
entire perimeter of a robot’s work envelop.
- A guard containing a sensing device that
automatically shuts down the robot any person or
object enter into work envelop.
4. Robot Safeguards

31. 31
All the operators should be trained
 In the safe operations & maintenance of their
machine.
 In the emergency procedures to take when
accidents.
 In co-ordination techniques and proper use of
devices.
 Supervised to ensure that they dress properly.
 Know how to activate emergency shut down
controls.
 Inspection, maintenance, adjustment repair and
calibration of safeguards should be carried out
regularly.
 Short-cuts that violate safety principle and
practices should be avoided.
GENERAL PRECAUTIONS

32. Fire hazards are conditions that favors fire
development or growth.
Three elements are required to sustain or start
fire.
Oxygen # Fuel # Heat
Sources of Fire Hazards
 Without fuel, there is no fire hazard (Solids,
liquids, vapors & gases).
 Spontaneous combustion and non-explosion
proof electrical equipment is the potential
ignition source.
32
FIRE & EXPLOSION HAZARDS

33. Sources of Fire Hazards
33

34. 1. Filter paper soaked with Nitrophenol deposited
in a waste.
2. Active carbon with Amm. Nitrate.
3. Cotton & Cellulose soaked with H2SO4.
4. Oxygen and org. matter.
5. Disposal of inflammable liquids in drainage.
6. Oil-bath flash point of oil reaches easily.
DETECTION OF FIRE HAZARDS
Many automatic fire detection are used – Smoke
radiation, Thermal expansion detectors, Heat
sensitive insulation, Photoelectric fire, Radiation
sensors and Ultraviolet or I.R. Detectors.
34
List of dangerous substance

35. 35
• The effects of fire on people take
the form of skin burns due to
explosion to thermal radiation.
• The severity of the burns depends
on the intensity of the fire and the
explosion time.
• Fire occurs in the industry more
frequently than explosions and
toxic release, although the
consequences in terms of loss of
life are generally less. Therefore,
fire might be less hazardous. Fire
can take several different forms
including jet fires, pool fires and
boiling liquid expanding vapor
explosion.

36. 36
Prevention of Fire & Explosion
1. Careful plant layout and judicious choice of constructional
materials can reduce fire hazards.
2. Hazardous operations should be isolated by conducting
them in separate buildings.
3. Fire resistance brick-walls can limit the effects of an
explosion.
4. The roof is designed to lift easily under an explosive force.
5. Possible sources of fire are reduced by eliminating the
unnecessary ignition sources such as flames, spark,
heated materials, matches, smoking, welding, static
electricity.
6. The installation of sufficient fire alarms, temperature
alarms, fire-fighting equipment and sprinkler systems
must be specified.
7. Proper storage of inflammable liquids.
8. Smoking should be prohibited near any possible fuels.

37. Fire Suspension
 It includes water sprinkler and fire extinguishers.
 All fire suspension systems – connected to the
building central alarm system.
37

38. Water Sprinkler (Showers)
• The vertical standpipes used for the sprinkler
system also serve fire cabinets
• on each floor.
• Hose size – 1.5 inch diameter
• Maximum length – 50 ft
• Longer hose – difficult to turn on and use by persons
lacking hands – on fire training.
Manually Hydrant – A pump set has to be started
manually, when a hydrant valve is opened.
Semi-automatic Hydrant – pump will start
automatically, hydrant valve is opened.
Automatic Sprinkler- Containing water under pressure
and connected to a water supply. Water falls vertically
in an umbrella like pattern.
38

39. 39
Fire extinguishers are installed inside hose.
These are designed for extinguishing the initial
fires. The early fires are divided into three
categories,
• Class A fires: These fires are originated from
ordinary combustible materials. These fires are
controlled using water which produces
quenching and cooling effects.
• Class B fires: These fires are originated from
oil’s, greases, flammable liquids etc. The
extinguishing agent should produce a
blanketing or smoothening effect.
• Class C fires: These fires are originated in
electrical equipment. The extinguishing agent
produces a non-conducting property.

40. 40

41. 1. Water Filled Fire Extinguisher
Here due to reaction between acid
(H2SO4) and dissolved Na.
Bicarbonate produced CO2.
Due to high pressure of CO2 in the
container containing water, water
pushes out through pipe.
Due to high heat of evaporation, it
exert powerful cooling effect, so
water vapor displaces oxygen
from the site burning.
Modification – Water fog
More droplets – more surface area.
Cooling & deatmosphering.
Use – Electrical installations &
inflammable solvents.
41

42. 2. Foam Extinguisher
It contains 2-6% liquid fluoroprotein in water.
Foam is mixed with air or N2 - foam discharge from
nozzle.
Foam flows easily over the surface of liquid and
thus separates the flammable liquid from air supply.
It has cooling and deatmosphering action.
42

43. 2. Foam Extinguisher
Unsuitable for mechanical & electrical
equipments.
Most flammable liquid are lighter than water
so, water can’t be used to put the fire out.
Crude oils fires will burn even floating on
fresh or sea water, so foam extinguisher are
preferred over water system.
USE – Hydrocarbon fires, flammable liquids
(oils, Gasoline)
43

44. 3. Carbon-Dioxide Extinguisher
When water is contraindicated for fire suspension
b’cos of the presence of large materials like Sodium
that react with water violently. Other system must
be used like CO2, Halon and Dry chemicals
extinguisher.
CO2 - Clean, Non-combustible, non-corrosive,
effective and easy to maintain gas.
Many materials don’t burn – When O2 less than 16%
or air is diluted with carbon dioxide.
Two types
1) High pressure liquid CO2 at atmospheric pressure – gas foam
2) Low pressure containers kept 1t 0°F.
Unsuitable – Cellulose nitrate and Na/K derivatives. It
decompose with Na/K derivatives
44

45. 3. Carbon-Dioxide Extinguisher
When valve is open CO2 expanded – called snow.
Due to Sudden expansion solidifies a part of CO2
(30%) into dry ice (-79°C), which do not conduct
electricity.
The snow- lowering of temperature of the burning
material below ignition point. At the same time it
displaces the Oxygen of the surrounding.
45

46. 4. Halon Extinguisher
It contain halogenated hydrocarbons as an agent.
When the hydrogen of methane or ethane are
replaced by halogen (Fluorine, Chlorine, Bromine)
they change from inflammable gases to
extinguisher agent.
Fluorine atom increase the inertness & stability of
hydrocarbons.
Halon – 1301® - non-toxic at conc. used, but avoid
unnecessary exposure.
Less expensive than CO2 or H20 system.
CCl4 vapor are highly toxic.
USE – Electronic, high-voltage, or computer lab.
46

47. 4. Halon Extinguisher
Halon cylinders are pressurised to 360-600 PSI
with nitrogen or CO2. It keep halon in liquid state.
Halon (CCl4) vaporizes at 77°C, producing non-
combustible vapor , which puts out fire by
smothering.
47

48. 5. Dry-chemical Extinguisher
 It contain two cyinder, one – for NaHCO3 in dry foam,
another – Liquid CO2 or N2 as expellant gas.
 When valve open expellent gas rush to another cylinder
containing NaHCO3. Sodabicarb expelled out, which
gets decomposed by flame into soda vapors and CO2.
 Soda foam an air-excluding crust over the burning
surface. CO2 displaces O2 and smothers fire.
Ammonium phosphate may be used- more Effective.
48

49.  A Shock is caused by electrical current passing
through human body.
 The quantity and path of this current determines the
level of damage.
 Electrical hazards occurs when a person makes
contact with a conductor carrying a current &
simultaneously contacts the ground.
Short circuits are one of many potential electrical
hazards than can cause electrical shock. Another
hazard is water – decrease the resistivity of material
Major sources of electrical shock are:
Working with electrical equipments on damp floors,
Lighting strikes, Using matel ladders & contact with a
base wire carrying current. 49
ELECTRICAL HAZARDS

50. 50
Hazardous Gases
• Several volatile and flammable liquids are
employed in chemical industries.
• These liquids get vaporized when exposed
to at or above room temperature causing air
pollution.
• The vapour gets ignited causing fire
accidents and explosions. Further, they tend
to spread rapidly into the surrounding area.
• Result in loss of life and property. Hence,
storage and handling of these hazardous
gases need special attention to avoid
hazards.

51. 51
Hazardous Gases
• Combustible Gases
 Explosion hazard.
 Must maintain below lower explosive limit.
• Toxic Gases
 Hazardous to human health.
 Employee exposure must be limited.
• Oxygen Displacing Gases
 Indirect human health hazard.
 Deficiency of breathing oxygen.

52. 52
Hazardous Gases

53. 53
Hydrogen Sulfide
H2S in Air Toxic Symptoms
• 1 ppm Odor detected, irritation of
respiratory tract
• 10 ppm Allowable for 8 hours
exposure
• 20 ppm Protective equipment is necessary
• 100 ppm Smell killed in 5 to 15 minutes.
May burn eyes and throat;
coughing
• 500 ppm Respiratory disturbances in 2 to
15 minutes. Coughing, collapse &
unconsciousness
• 1,000 ppm Immediate unconsciousness.
Brain damage may result unless
rescued promptly. Death in 3 to 5
minutes.

54. 54
Carbon Monoxide
CO in Air Toxic Symptoms
• 400 ppm Headache within 1-2 hrs.,
widespread in 2.5 - 3.5 hrs.
• 500 ppm Dizziness, nausea, convulsions
within 45 min.
• 1,600 ppm Headache, dizziness, nausea
within 20 min. Death in 2 hours.
• 3,200 ppm Headache, nausea within 5-10
min. Death within 30 min.
• 6,400 ppm Headache, dizziness within 1-
2 min. Death within 10-15 min.
• 12,800 ppm Death within 1-3 minutes.

55. 55
Chlorine
Cl2 in Air Toxic Symptoms
• 3.5 ppm Minimum concentration
detectable by odor
• 15 ppm Causes throat irritation,
smarting of eyes
• 30 ppm Coughing, more severe throat
irritation, general feeling of
discomfort in the chest
• 40-60 ppm Respiratory reflexes,
coughing, burning of eyes,
nausea,vomiting. Possible
death within 30 minutes
• 1000 ppm Death within a few breaths

56. 56
Ammonia
NH3 in Air Toxic Symptoms
• 20 ppm First perceptible odor
• 40 ppm Slight eye irritation
• 100 ppm Irritation of eyes and nasal
passages
• 400 ppm Severe irritation of throat,
nose, upper respiratory tract
• 700 ppm Severe eye irritation
• 1700 ppm Serious coughing, bronchial
spasms, death within 30 min.
• 5000 ppm Serious edema, strangulation,
asphyxia, death immediate

57. 57
Nitrogen Dioxide
NO2 in Air Toxic Symptoms
• 60 - 100 ppm Immediate irritation of
the nose and throat,
coughing,nausea,
choking, headache,
shortness of breath and
restlessness. Edema may
develop within 6 - 24
hours after exposure
• 100 - 150 ppm Exposure for 30 - 60
minutes can cause death
• 200 - 700 ppm Death within minutes

58. 58
Nitric Oxide
NO in Air Toxic Symptoms
• 50 ppm Does not cause irritation nor
is it easily noticed but can
chronic respiratory problems
and possibly edema
• 60 - 150 ppm Irritation of throat, coughing,
burning of chest Can cause
tightness/ burning of chest 6 -
24 hours after exposure and
possibly shortness of breath
and sleeplessness. Air hunger
will increase rapidly leading to
loss of consciousness and
then death.
• 200 - 700 ppm Fatal after a few minutes

59. 59
Sulfur Dioxide
SO2 in Air Toxic Symptoms
• 3 - 5 ppm Detectable by irritation
• 8 - 12 ppm Throat irritation, coughing,
constriction of the chest,
tearing and smarting of eyes
• 150 ppm Extreme irritation and can be
tolerated only for a few
minutes
• 500 ppm Acutely irritating and causes a
sense of suffocation

60. 60
Oxygen Deficiency
Oxygen Symptoms Developed,
• 20.9% Normal oxygen concentration in
air
• 15 - 19% Decreased ability to work
strenuously.
• 12 - 14% Respiration increases in exertion,
pulse up, impaired coordination,
perception & judgment
• 8 - 10% Mental failure, fainting,
unconsciousness, blueness of
lips, nausea & vomiting
• 6 - 8% 8 minutes, 100% fatal; 6
minutes, 50% fatal, 4 - 5
minutes, recovery with treatment
• 4 - 6% Coma in 40 seconds, convulsions,
respiration ceases, death

61. 61
Hazardous Gases Management
Compressed gases are filled in cylinders and
transported to the place of use. The important
precautions to be followed are given below:
1. Cylinders should not be dropped or permitted to strike
against each other.
2. Safety devices fitted to the cylinders should not be
tampered.
3. Special and standard tools should be used on valves.
Normally these are provided by manufacturers.
4. Cylinders should be protected against extremities of
weather, particularly against excessive rise in the
temperature.
5. Cylinders (received) should bear a conspicuous
standard label indicating the kind of gas. The colour of
the label shows whether gas is inflammable, corrosive
or inert.
6. Full cylinders should be separated from empty
cylinders.

62. 62
Gas Sensor Placement
 Place sensors close to
possible gas source.
 Place sensors in areas where
gas might accumulate.
 Place toxic gas and oxygen
deficiency sensors in the
“breathing zone”.
 Consider accessibility and
maintenance issues.

63. 63
Gas Weight in Relation to Air
• Ammonia Lighter
• Butane Heavier
• Carbon Monoxide Slightly Lighter
• Methane Lighter
• Chlorine Heavier
• Ethane Slightly Heavier
• Ethylene Slightly Lighter
• Heptane Heavier
• Hydrogen Lighter

64. 64
TYPE OF MATERIAL UNITS OF MEASURE
• Dusts Millions of Particles per
cubic foot
• Mineral – Sand Mass per unit of air
• Organic - grains (Milligram/cubic meter
of air - mg/m3)
• Mists Mass per unit of air
• Acid Mist Milligram/cubic meter
of air - mg/m3
• Fumes Mass per unit of air
• Welding Milligram/cubic meter
of air - mg/m3
• Fibers Mass per unit of air
• Cotton Dust Milligram/cubic meter
of air - mg/m3
• Asbestos Fibers per unit of air
fibers/cubic centimeter
of air - f/cc
• Gases Parts per million parts of
air - ppm
• Carbon Monoxide ppm
• Vapors Parts per million parts of
air - ppm
• Solvent mass per unit of air
(milligrams/cubic meter
of air - mg/m3)

65. 65
DUSTS EXPLOSION
• Dust means, if the maximum particle size of the
solids in the mixture is 500 mm.
• Dust explosion is a rapid combustion of a dust cloud.
During the process, heat and reaction products are
evolved. The flame is propagated in a confined space.
The required oxygen for combustion is mostly
supplied by air.
• In pharmaceutical industry, a number of grinding
operations are employed.
• If iron or stone pieces get into the disintegrator or
grinding mill, sparks are emitted, which may bring
about explosion with some easily combustible
materials. Therefore, suitable precautions should be
taken against accumulation of dust. It has been
found that in pharmaceutical and ancillary factories,
dust of starch and dextrin besides organic substances
are extremely hazardous.

66. 66
FACTORS IMPACTING A DUST
EXPLOSION
1. Particle size
2. Chemical properties of a dust
3. Moisture content
4. Cloud dispersion

67. 67
COMBUSTION PRINCIPLES
• Fire is a rapid oxidation process with
the evolution of light and heat in
varying intensities.
2C + O2 2CO
• Deflagration is a combustion
reaction in which the velocity of the
reaction front through the unreacted
fuel medium is less than the speed
of sound.

68. 68
DUSTS (Pneumoconiosis)
Inorganic Dust
 Coal Dust - Anthracosis
 Silica - Silicosis
 Asbestos - Asbestosis
Organic Dusts
 Cane Fiber - Bagassosis
(Bronchi gets
affected)
 Cotton dust - Byssinosis (In
Textile industries)
 Tobacco - Tobaccosis,
Lung Cancer

69. 69
DUSTS MANAGEMENT
1. Avoiding the development of explosive
mixtures : Dust should not be accumulated at a
place. Removed from the site as soon as it forms.
2. Replacing the atmospheric oxygen by inert gas,
working in a vacuum or using inert dust : This
process is also known as inerting. Explosion dusts
can be changed into mixture by the addition of inert
dust such as rock salt and sodium sulphate, so that
dust is diluted to a level less than its lower limit of
explosive range.
3. Preventing the occurrence of effective ignition
source : Some of the ignition sources are welding,
smoking, cutting, mechanically generated sparks
and the resulting hot sources. Electric discharges are
brush discharge, bulk surface discharge, spark
discharge and propagating brush discharge. The
premises must be kept very clean, eliminating all
sources of ignition.

70. 70
PROCESS EQUIPMENT AT RISK IN
DUST MANAGEMENT
• DUST COLLECTORS
• Storage Enclosures (e.g., silos, bins,
hoppers,etc.)
• Pneumatic Conveying Systems
• Air-Material Separators
• Size Reduction (e.g., hammermills,
granulators, grinders, etc.)
• Material Feeding Devices (bucket
elevators)
• Heating Equipment

71. 71
Biological Hazards
Bacteria- Tetanus,Tuberculosis, Anthrax,
Brucellosis(Milkmen),
Gonorrhea(Sex-workers-Genital
organs get affected).
Virus - Hepatitis, AIDS
Protozoal&Parasitic- Malaria,Hydatid(Dog
handlers),Hookworms, tapeworms (Agri-
workers), etc.
Fungi-(Agri-workers)- Tinea-infections,
Coccidiomycosis,

72. 72
Plant Safety
• Identification of the hazards and employing the
protective measures to control the hazards are
important to protect the people from their
consequences. Accident prevention needs systematic
and technical study of every aspect of the plant
design and operation.
• Plant safety differs from the traditional approach of
prevention of accidents in a number of ways:
1.There is more concern with accidents that arise out of
technology.
2.There is more emphasis on foreseeing hazards and
taking action before accidents occur.
3.There is more emphasis on systematic methods of
identifying hazards and estimating the probability that
they will occur and their consequences.
4.There is concern with accidents that cause damage to
plants and loss of profit.
5.Traditional practices and standards are looked at
more critically.

73. 73
Objectives- Safety Management
• Safety Management planning is done for,
Total Prevention or Safe Management of
hazards.
Safety of men at work and in the vicinity of
hazards.
Effective rescue and treatment of casualties.
Mitigating the severness of Disaster first and
ultimately to control the whole situation.
Casualty identification, classification and
safe transportation to Trauma Centre or
Hospital.
Providing factual information to authorities
coordinating the operations to avoid
contradiction and confusion.

74. 74
• The primary step in any Safety planning
is the identification and assessment of
the principal hazards. The hazard can be
fire, explosion, toxic release, failure of
structure or vessel holding hazardous
substances, sudden heavy toxic
emissions from exhausts/ vents/
chimneys etc.
• Identification of vulnerable points likely
to result in Disaster are essential
through :
• Operational experience
• Past history/ experience
• Criteria review

75. 75
THE FIRST STAGE OF SAFETY
ASSESSMENT
In a process plant essentially consists
of three steps:
1. Identifying the hazard.
2. Estimating the effects or
consequences of the hazard.
3. Determining probability or
likelihood of occurrence of
hazardous event.

76. 76
THE NEXT STEP OF SAFETY
ASSESSMENT
To determine whether effects of the
consequence and the probability of
occurrence of the hazard is within the
acceptable limit or not.

77. 77
HAZARD IDENTIFICATION
METHODOLOGY
Hazards in process plants are primarily
identified based on following information:
1. HAZARDOUS PROPERTIES OF MATERIALS
2. TYPE OF UNIT PROCESS/ OPERATION
3. OPERATING PARAMETERS
4. ANY OTHER RELEVENT DATA
5. CHECK-LIST
6. DOW INDEX

78. 78
COMMONLY USED STRUCTURED
HAZARD IDENTIFICATION
TECHNIQUES
1. WHAT IF ? ANALYSIS:
 What if the Raw Material contains
impurities?
 What if Cooling Water is Lost?
 What if the Vessel Agitation Stops?
 What if Power Supply Fails?
 What if the Temp./ Press. Sensor Fail?
 What if the Pump Stops? etc.

79. 79
2. HAZARD STUDY
GUIDE WORDS
• NO
• MORE
• LESS
• AS WELL AS
• PART OF
• REVERSE
• OTHER THAN, etc.

80. 80
3. FAILURE MODE AND EFFECTS
ANALYSIS (FMEA)
• FMEA evaluates the ways in which an
Equipment can Fail and the Effects of
such Failures on an Installation
4. FAULT TREE ANALYSIS (FTA)
• Deductive Reasoning Process
5. EVENT TREE ANALYSIS (ETA)
• Inductive Process

81. 81
HAZARD CONTROL
MEASURES
1. Physical Protection
2. Procedural Protection
3. Educational Protection

82. 82
Physical Protection
 Strict & Rigorous approach in following the
Relevant Standards , Codes & Practices.
 Built in Safety Devices and Safety System.
 Field Monitors for Different Toxic Gases.
 Burning Waste gases in a Flare System.
 Provision of Wind Cones.
 Fire Proofing of Steel Structures.
 Passive Protection System.
 Active Protection system.
 Automatic Protection system.
 Improved Waste Water Management.

83. 83
PROCEDURAL PROTECTION
 Fire Emergency Procedure
 Disaster Preparedness Plan
 Mutual Aid Scheme
 No Smoking Policy
 Investigation of All Accidents
 Hazard Identification through Safety Committee, House
Keeping Committee, Safety audit Committee
 Conducting Plant Survey, safety survey
 Work Permit System
 Statutory Requirement
 Safety Promotional Activities
 Information notes on Unsafe conditions
 Annual Medical Check up of Employees
 Safe Start up & Shut Down Procedure
 Regular and Preventive Maintenance
 Periodic testing of Fire Fighting Appliances

84. 84
EDUCATIONAL PROTECTION
Periodic Training Programme on
Safety, Fire Safety and Hazardous
properties of materials.
Mock Fire Drill.
Safety Manuals.
Health & Safety News Bulletins.
Safety Motivation schemes.
Plant Operating Manual.
Educating the Public Living nearby
about the activities in the industry.

85. 85
GROWING IMPORTANCE OF
SAFETY MANAGEMENT DUE TO
1. LEGISLATION.
2. CUSTOMER ATTITUDE.
3. SOCIETAL EXPECTATIONS.
4. MANAGEMENT ATTITUDES.

86. 86
EMPLOYER RESPONSIBILITIES
 Identify and list hazardous chemicals in
their workplaces.
 Obtain Material Safety Data Sheets
(MSDSs) and labels for each hazardous
chemical, if not provided by the
manufacturer, importer, or distributor.
 Implement a written Hazard program,
including labels, MSDSs, and employee
training.
 Communicate hazard information to
employees through labels, MSDSs, and
formal training programs.

87. 87
HOW CAN WORKPLACE HAZARDS
BE MINIMIZED?
 The first step in minimizing workplace
hazards is to perform a thorough hazard
assessment.
 Employers can rely on the evaluations
performed by the manufacturers or
importers to establish the hazards of the
chemicals they use.
This information is obtained from
MSDSs and labels.

88. 88
WHY IS A WRITTEN PROGRAM
REQUIRED?
• Ensures that all
employers receive
the information they
need to inform and
train their
employees
• Provides necessary
hazard information
to employees
(f) "Labels and other
forms of warning."
(g) "Material safety data
sheets."
(h) "Employee
information and
training."
Safety Program

89. 89
Container
Labeling
Material Safety
Data Sheet
MSDS
Label
Hazard
Communication
Program
Program
To ensure that employers and employees
know about work hazards and how to
protect themselves so that the incidence of
illnesses and injuries due to hazardous
chemicals is reduced.

90. 90
HOW MUST CHEMICALS BE
LABELED?
Each container of Hazardous
chemical entering the
workshop must be labeled or
marked with:
• Identity of the chemical
• Appropriate hazard warnings
• Name and address of the
responsible party

91. 91
Container Labeling in the
Workplace
• The hazard warning can be
any type of message, picture,
or symbol that provides
information on the hazards of
the chemical(s) and the
targeted organs affected, if
applicable.
• Labels must be legible, in
English (plus other languages,
if desired), and prominently
displayed.

92. 92
Material Safety Data Sheets
Prepared by the chemical manufacturer or
importer and describes:
• Physical hazards, such as fire and
explosion.
• Health hazards, such as signs of exposure.
• Routes of exposure.
• Precautions for safe handling and use.
• Emergency and first-aid procedures.
• Control measures.

93. 93
Material Safety Data Sheets
(cont’d)
• Must be in English and include information
regarding the specific chemical identity and
common names.
• Must provide information about the:
– Physical and chemical characteristics
– Health effects
– Exposure limits
– Carcinogenicity (cancer-causing)
– Identification (name, address, and telephone number) of
the organization responsible for preparing the sheet
• Must be readily accessible to employees in their
work area.
• MSDSs have no prescribed format.
• If no MSDS has been received for a hazardous
chemical, employer must contact the supplier,
manufacturer, or importer to obtain one and
maintain a record of the contact.

94. 94
TRAINING
Training is required for
employees who are exposed
to hazardous chemicals in
their work area:
• At the time of initial
assignment.
• Whenever a new hazard is
introduced into their work
area.

95. 95
WHAT TRAINING IS NEEDED
TO PROTECT WORKERS?
• Explanation of the Safety program,
including information on labels, MSDSs,
and how to obtain and use available
hazard information.
• Hazards of chemicals.
• Protective measures such as engineering
controls, work practices.
• How to detect the presence or release of a
hazardous chemical (using monitoring
devices, observation, or smell).

96. 96
RETENTION OF RISK IS
BUSINESS
&
RETENTION OF CUSTOMER IS
PROGRESS