ADU

Chemical Engineering Department

Industrial safety and Maintenance(Cheg5212)

Industrial safety and maintenance
Introduction
What is safety?
o Accident free operations

o Being protected from any failure, breakage and accidental harm.

o Continuing of healthful living without injury.

o Refers to the precautions people take to prevent accident, harm, danger,

loss, pollution (air/water/environment).
Cont…
Safety, hazard, and risk are frequently-used terms in chemical process
safety. Their definitions are

 Safety or loss prevention: the prevention of accidents through the use

of appropriate technologies to identify the hazards of a chemical plant
and eliminate them before an accident occurs.

 Hazard: a chemical or physical condition that has the potential to

cause damage to people, property, or the environment.
Cont…

Risk: a measure of human injury, environmental damage, or economic

loss in terms of both the incident likelihood and the magnitude of the
loss or injury.
 Disaster:
 A risk of hazard which has the potential to cause significant personal,
social, property and damage to the environment
Cont…
 Is a natural or man-made hazard resulting in an event of substantial
extent causing significant physical damage or destruction, loss of life,
or drastic change to the environment.

Accident:

• Is a condition of something going wrong due to various contradictions

• Is unforeseen and unplanned event or circumstance, often lack of

intention
Cont…
How accident happened?
Accident occur because of:
o lack of knowledge
odiscrepancies (difference, inconsistent)
odeviations (from normal conditions or operations)
oindividual behavior
oUnsafe operations
Cont…
Today safety is an integral part of any industry. Developing any process
industries from concept stage the following stages are required,
o Designing
o Erection
oTesting
o Operations
oMaintenance

 Neglecting safety actions at any of the above stages can result into disaster
leading to loss of human life and desired plant production.
Cont…
In process industries unsafe conditions reduces:

 production rate

 Quality of the product

 Good working condition for employees

Therefore, it is essential to design and incorporate complete safety

system in all stages (Process plant design development)
Integration of safety, health & environment
 Apart from safety there are two interrelated aspects i.e. Health (well-being

of employee) & environment are also attached equal importance and

considerations.

 For instance, if the health of employee is not given due regard, may lead to

accident.

 If the industry pollutes the environment around workplace it will ultimately

affect health of employee which may ultimately affect production.

Cont…
N.B. Checking the pollution in the industry should be implemented
because in the long run it is not only affect the performance of the
industry but also the life of everybody will became miserable due to poor
health which in turn will affect safety.

Overview of industrial safety management

Safety management : is an act and science of setting safety objectives of
the industrial company and related activities of planning, organizing,
directing, executing, supervision, monitoring, improving various functions
to achieve the safety objectives.
Cont…
Objectives of safety managements
• To prevent accidents, personal injuries and death
• To minimize unsafe situations and unsafe acts by personal by applying
management techniques.
 Functions of safety management
Humanitarian

Commercial Morale

Functions of
safety
managements

Mandatory
Social & Legal

Organizational
Cont…
Humanitarian
o Providing fast medical treatment and financial assistance and
compensations
o Provide healthful environment and surrounding
o Continuous following/watching and improvement
Morale
oThe reduction of injuries and death by keeping up the moral of the
worker and organizations
Legal
o Implementation of acts and rules formulated by legal, government
standards…etc
Cont…
Organizational

 To reduce downtime, expenditure on worker compensations, legal

expenditure and improve productivity and profits.

 Sometimes safety is the question of Survival of the company, some

accidents (disasters) result in closure of the company.
Cont…
Commercial

 To enhance company’s image and respect,

 Improve public relations there may improve commercial competitiveness.

Social

• To help society by improving environment, minimizing pollutants and

leading a happy human life.
Cont…

Safety symbols

 Are used across the world and in different sectors. Let it be industrial,
construction, school or any workplace, these symbols can be understood
in any part of the world.

 Safety signs and color are useful tools to help protect the health and
safety of employees and workplace visitors.
Cont…
Safety signs are used to:
 Draw attention to health and safety hazards
 Point out hazards that may not be obvious
 Provide general information and directions
 Remind employees where personal protective
 Show where emergency equipment is located
 Indicate where certain actions are prohibited
Cont…
o Colour attracts attention and can be used extensively for safety
purposes. For example, colour can be used as an additional safety
measure to identify the contents of pipes and the nature of the hazard.

o The choice of colour also draws attention to the probability of a hazard

causing harm. For example, the colour red is used to indicate a definite
hazard. A potential hazard is communicated by the colour yellow. When
employees are aware of the hazards around them and take the necessary
precautions, the possibility of an injury, illness or other loss is
minimized.
Cont…
Sign Categories
There are three basic sign categories used in the workplace:
 Regulatory
 Warning
 information

Each category is distinguished by its shape. These categories are divided

into sub-categories that can be recognized by their colour
Cont…
Cont…
Sign Types

One of three sign types should be used to communicate a message:

 symbol signs
 symbol signs with text
 text signs
Cont…
Cont…
CLASS A: COMPRESSED GAS

This class includes compressed gases, dissolved gases, and gases liquefied
by compression or refrigeration.

CLASS B: FLAMMABLE AND COMBUSTIBLE MATERIAL

This class includes solids, liquids, and gases capable of catching fire in the
presence of a spark or open flame under normal working conditions.

CLASS C: OXIDIZING MATERIAL

These materials increase the risk of fire if they come in contact with flammable
or combustible materials.

CLASS D: POISONOUS AND INFECTIOUS MATERIAL

Division 1: Materials Causing Immediate and Serious Toxic Effects

These materials can cause death or immediate injury when a person is

exposed to small amounts. Examples: sodium cyanide, hydrogen sulphide

CLASS D: POISONOUS AND INFECTIOUS MATERIAL

Division 2: Materials Causing Other Toxic EFFECTS

These materials can cause life-threatening and serious long-term health

problems as well as less severe but immediate reactions in a person who is
repeatedly exposed to small amounts.
Cont…
Caution Symbol

Also called a warning sign, the caution symbol is placed to make people aware of possible dangers or
hazards ahead.
Thermal Safety

Thermal sign basically suggests that there may be objects or materials in a particular
area. These materials can be too cold or extremely hot to touch with bare hands. As it can
cause the skin to burn, wearing protective gloves over your hands, while handling these
materials, is mandatory at all times.
First Aid Symbol

A square box with a green + sign, usually indicates medical emergency

Cont…
Eye Safety

The sign shows a pair of snow goggles. This suggests that there may be hazardous materials which
can cause irritation to the eyes. Hence, wearing protective eye goggles is necessary in that particular
vicinity.
Electrical Safety

It is used to tell people there may be certain electrical machines and/or equipment in the vicinity.
Which is why, keeping utmost care is necessary as there can be danger of getting an electric shock.
After a particular capacity of voltage, if you come in contact with the energy, you can suffer sever
injuries or even death.
Classification of accidents
Accidents can be classified in various ways such as,

 classification based on the magnitude of the danger of life and property,

these are:

a. Minor: where there is no loss of life

b. Moderate: where there is injury but no loss of life and property

c. Major: where there is loss of life

d. Disaster: There is extensive loss of property and /or life.

Cont…
 Classification based on cause and effects
oFire and explosions

oElectrical Accidents –shock

 Fire and explosion initiated by spark and short circuiting currents

o Chemical accident and explosion

 Emission of gases, flames, dust, chemical fluids
 Nuclear disaster, radiation of radioactive rays
Cont…
oAccident with machinery, plant, tools
 Due to human error
 Due to failure of plant accessories
 Due to process hazard (eye injury due to laser, welding light)

oFalling of object on body

 During construction work
 During operation of plant (ex, overhead crane)
Cont…
oFalling of person from height (ex, ladder)
 Accident from civil works
• During construction
• During service life of plant

oHuman made accidents

 Deliberate damage in parts
 Thefts of critical parts
Cont…
oNatural disasters
 Flooding
 lightning
 Landslide
 Earthquake and volcano
Summary of industrial accidents
Fire and
explosion
Chemical
Accident & Electrical
Accidents
Explosion

Accidents
Accident
with
from civil
machinery ,
Industrial works
plant, tools
Accident

falling of
Human made
object on
accidents
body

Falling of
Natural
Object from
Disasters
height
Accident investigation Approaches (Strategies)
There are three basic approaches/ strategies

1. Pre-Accident Strategy

2. Post-Accident Strategy

1. Pre-Accident (Pre-Risk) Accident investigation

 Is the activities taken before the occurrence of an accident (Prevention methods)

This can be divided in to Two parts

• Safe place strategy
• Safe Person strategy
Cont…
Safe place Strategy
oSafe Workplace
oSafe Equipments
oSafe Process
oSafe Transportation
oGenerally Safe Environment
Cont…
Safe Person Strategy

Protecting the workers by giving protective equipments (PPE, like

gloves, helmets,..) or protective facilities, if the working environment
is not safe.

Note: Usually the safe place strategy is preferable than the safe person
strategy, if the place is safe, the safe person strategy is unnecessary
Cont…
2. Post Accident Strategy (post risk assessment)

 Is a strategy after the accident had occurred

 The post accident strategy is used as a feedback for the pre-

accident strategy by assuming the cause and effect of the accident

occurred.
Types of industrial accident (on workers)
o Slipping

oWorker may be caught b/n two objects

oElectric shock

oPoisoning (exposed in toxic, acidic matter)

When and why accident happened?
I. Unsafe act (practice) :- this includes
 Operation without authority
• (when you operate with out authority, you need to inform other
workers)
 Operating at unsafe speed
• (driving too fast, ex, forklift)
 Using unsafe equipments
 Using not properly maintained equipment
Cont…
 Working on unguarded or dangerous equipments

 Misbehaving at working place

• (laughing and joking with other workers)

 Failure to use personal protective materials

II. Unsafe human (personnel) cause

oConcerned with mental/physical characteristics of personal unsafe

act, this includes
Cont…
oImproper attitude (deliberate violation of safety acts)

oLack of knowledge /skill

oPhysical/ mental defects

III. Unsafe mechanical (Physical) causes(Also called unsafe condition)

oImproper guarding :
 Unguarding
 Removing the guards
Cont…
oDefective agencies
 Breakage
 Decayed equipments and places
 Slippery/ smoothness

oHazardous arrangement
 Process line /layout
 material storages
Cont…
IV. Unsafe procedure

oCaused by managerial acts

V. Unsafe house keeping

o General cleanness of the house

o Waste disposal methods

Cont…
Generally accident occurred due to
a) Human Error
o Due to unsafe practice
o Lack of foresight
o wrong attitude …etc
 This accident cover about 88 % of the total industrial accident
b) Mechanical failure
o Due to plant condition, equipment or tool failure
 This cover about 10% of the total industrial accident
c) Act of Nature
o Due to whether, flood, lightning …
 This covers only 2% of the accident occurred in most of the industry.
Cont…
Main cause of accident

 Incorrect design, construction, installation, testing and commissioning

 Incorrect use of machinery and industrial facility

 Lack of inspection and maintenance

 Incorrect plant layout ,(improperly set)

 Incorrect functioning of equipments

Cont…
 Poor maintenance practice

 Lack of skill, instruction and poor supervisions

 Incorrect working materials (ex, improper raw material

substitution)
Cont…
Consequence of accidents:

o Production interruption

o Economic and social loss

o Damage and distraction of material

o Distraction of human life

o Damage the moral of the employee

Cont…
Chemical plant accidents follow typical patterns. It is important to study
these patterns in order to anticipate the types of accidents that will occur.

Accidents follow a three-step process/sequence

1. Initiation - the event that starts the accidents

2. Propagation - the event or events that maintain or expand the accident

3. Termination - the event or events that stop the accident or diminish it

in size
Cont…
Example 1:
A worker walking across a high walkway in a process plant stumbles and
falls toward the edge. To prevent the fall, he grabs a nearby valve stem.
Unfortunately, the valve stem shears off and flammable liquid begins to
spew out. A cloud of flammable vapor rapidly forms and is ignited by a
nearby truck. The explosion and fire quickly spread to nearby equipment.
The resulting fire lasts for six days until all flammable materials in the
plant are consumed, and the plant is completely destroyed.
Cont…
Ans.

oWorker tripped to initiate the accident

o Accident propagated by shearing of valve and resulting explosion

and growing fire

oTermination by consumption of all flammable materials

Objective and goals
 Objectives cover a shorter term and are always measurable

 While Goals are more long range than objectives and they may or may
not be quantitatively measurable.

 Most often, objectives are goals that have been broken into small,
progressive pieces.
Establishing Effective Safety Goals
 Establishing goals for the safety performance program provides a vital
blueprint for implementing and directing the organization’s resources
in order to achieve desired outcomes.

 The most commonly found goals in any safety and health program
include lost-time injury rate, lost workdays, recordable injury rate, and
total injury rates.
Cont…
poorly constructed safety well constructed safety goals and objectives:

goals and objectives: oOver the next five years, the organization

o Improve the safety record of will reduce OSHA recordable injuries by 10

the organization percent.’’

oThe organization will oDuring this fiscal year, the organization will

increase employee safety provide twelve monthly safety-training

training offerings.’’ programs at which 90 percent of the

employees shall attend.’’

Cont…
Accountability

oManagers particularly at senior levels, must take proactive responsibility

for controlling issues that could lead to ill-health, injury or loss.

oA nominated senior manager at the top of the organization needs to

oversee policy implementation and monitoring.

oThe nominated person will need to report regularly to the most senior
management team and will be a director or principal of the organization.
Employers’ responsibilities
The general duties of employers under the HSW Act relate to:
oThe health, safety and welfare at work of employees and other workers,
whether part-time, temporary, homeworkers, Government Training Schemes
or on site as contractors – i.e. anyone working under their control or direction
oThe health and safety of anyone who visits or uses the workplace
o The H&S of anyone who is allowed to use the organization’s equipment.
o The H&S of those affected by the work activity, for eg. neighbours, and the
general public.
Cont…
Duties of employers to employees

 To ensure the health, safety and welfare of all employees. In particular:

o safe plant and systems of work

o safe use, handling, transport and storage of substances

oprovision of information, instruction, training and supervision

o safe place of work and access.

Cont…
o Safe working environment with adequate welfare facilities

oDevelop suitable emergency procedures. Ensure that employees and others

are aware of these procedures and can apply them

oProvide employees with adequate and relevant health and safety training

o Provide health and safety information to employees and others, such as other
employers, the self-employed and their employees who are sharing the same
workplace and parents of child employees
Cont…
Employees’ responsibilities

Employees have specific responsibilities under the HSW Act, which are:

o To take reasonable care for the health and safety of themselves and of other
persons who may be affected by their acts or omissions at work.

o To co-operate with the employer and others to enable them to fulfil their
legal obligations.

oThe responsibilities cover directors, senior managers, site managers,

department managers, supervisors and employees.
Cont…
oUse any equipment or substance in accordance with any training or
instruction given by the employer

oReport to the employer any serious or imminent danger

o Report any shortcomings in the employer’s protective health and safety

arrangements.

oAre alert to observe and correct, or report, unsafe practices and conditions.
Cont…
oMaintain a healthy and safe place to work and cooperate with managers in the
implementation of health and safety matters.

oLearn and follow the operating procedures and health and safety rules and
procedures for safe performance of the job.

oFollow the established procedures if accidents occur.

Cont…
 Continuity of organization
o Bench marking(BM)

oBM is an ongoing process of measuring one company’s safety performance

against that of competitors or organizations that are recognized as industry
leaders.

o In other words, BM is simply learning what other programs and organizations

are doing to be successful and using some of those successes in one’s own
program or organization.
Cont…
o BM can also be used to identify areas of weakness and assist in prioritizing
program improvements.

An optimum benchmark can be characterized by the following

1. should be measurable in terms of cost, time, value, or some other quantitative

parameter.

2. should be meaningful and relevant.

3. Should be available in external and competitive environments.

Cont…
These following four perspectives are all tied to the organizational mission
and vision. Within each perspective, goals can be developed and the
appropriate metrics can be identified.

o Financial perspective

o Customer perspective

o Internal perspective

o Innovation and learning perspective

 Marketing mix
Price
List price
Discounts Promotion
Allowances Sales promotion
Payment Advertising
period sales force
Product credit terms Public relations
Product variety Direct marketing
Quality
Features
Brand name Place
Marketing Channels
Packaging
Sizes
mix Coverage
Services Assortments
warraties Locations
returns Inventory
Transport
Cont…
Product

o Products have both tangible and intangible benefits.

oTangible benefits include benefits, which can be measured such as the top
speed of a car. Intangible benefits are benefits that cannot be measured such
as the enjoyment the customer will get from the product.

o It is important that the product is changed as necessary to bring it up to date

and prevent it from being overtaken by competitor.
Cont…
Price
oIt is very important that the correct price is charged for a product.

o If the price is too high consumers will avoid the product, as they will believe
it to be too expensive yet.

o If the product is priced too low they may believe that there is something
wrong with the product for it to be so cheap.

oAlso, if the company charges too low a price, it may not cover its costs
Cont…
Promotion
oOnce the product has been made and the price set, it is important that
potential customers are told about the product.

o Promotion can also be used for reassuring the consumer that the
product is of good quality and persuading them to purchase the product.

o Promotional methods include: advertising, direct selling, point of sale

and incentives.
Cont…
Place
oPlace decides where the product is to be sold. There are three main
distribution channels to choose from:

oTraditional - selling the product to wholesalers who will then sell the
product on to retail outlets.

oModern - producers selling the product directly to the retail outlet.

oDirect - the producer selling directly to the consumer such as door-to-

door sales or over the Internet.
Cont…
o Customer value and customer satisfaction theory explain how to create a
good relationship with a customers and why it is so essential to find loyal
customers and also retain the old ones.
Cont…
Customer Value

o Marketing-orientated companies attempt to create customer value in order to

attract and retain customers. Their aim is to deliver superior value to their
target customers. In doing so, they implement the marketing concept by
meeting and exceeding customer needs better than the competition.
Customer Satisfaction

o Customer satisfaction is a measure of how an organization's total product

performs in relation to set of customer’s expectations.

Cont…
o Customer satisfaction depends on the product’s perceived performance
relative to a buyer’s expectations.

o If the product’s performance falls short of expectations, the customer is

dissatisfied. If performance matches expectations, the customer is satisfied.

o If performance exceeds expectations, the customer is highly satisfied and

delighted.
Cont…
o Companies should: take into account the need to protect the
environment, health and safety and generally conduct their business in
such a way as to contribute to sustainable development.

o Companies should establish and maintain environmental management

systems that can properly gather and evaluate information about the
environmental, health and safety-related consequences of company
operations.
Cont…
Quality process

Total quality management(TQM): the company’s focus on its customers

o Quality is defined as meeting or exceeding customer expectations.

oTQM recognizes that a perfectly produced product has little value if it is

not what the customer wants.

o Therefore, we can say that quality is customer driven.

Cont…
oHowever, it is not always easy to determine what the customer wants,
because tastes and preferences change. Also, customer expectations often
vary from one customer to the next.

oCompanies need to continually gather information by means of focus

groups, market surveys, and customer interviews in order to stay in tune
with what customers want.

oThey must always remember that they would not be in business if it were
not for their customers.
Cont…
oAccording to TQM a quality product comes from a quality process. This
means that quality should be built into the process.

o Quality at the source is the belief that it is far better to uncover the
source of quality problems and correct it than to discard defective items
after production.

o If the source of the problem is not corrected, the problem will continue.

For ex., if you are baking cookies you might find that some of the cookies
are burned.
Cont…
oSimply throwing away the burned cookies will not correct the problem.
You will continue to have burned cookies and will lose money when you
throw them away. It will be far more effective to see where the problem
is and correct it.

o For example, the temperature setting may be too high; the pan may be
curved, placing some cookies closer to the heating element; or the oven
may not be distributing heat evenly.
Cont…
oThe old concept focused on inspecting goods after they were produced or after
a particular stage of production.

o If an inspection revealed defects, the defective products were either discarded

or sent back for reworking. All this cost the company money, and these costs
were passed on to the customer.

o The new concept of quality focuses on identifying quality problems at the

source and correcting them.
Cont…
Service quality depends on quality of each three dimensions

o Input quality refers to e.g. equipment that is up-to-date, waiting areas are
clean and comfortable, service personnel has skills and knowledge and is
appropriately attired.
o Next, process quality is a quality of interaction between provider and
customer.
Cont…
o Output quality refers to the result of service provision and includes
both tangible results and intangible benefits; it means changes in the
customer’s physical/mental state or a change in something that the
customer possesses. By testing systems approach
Cont…
Accessibility, communications and company expectations.

communication
oGiving your employees information about the general duties under the
Health and Safety at Work Act and specific legal requirements relating to
their work.

oGiving employees necessary information about substances, plant,

machinery, and equipment with which they come into contact.
Cont…
o Discussing with contractors, before they come on site, how they plan to do
their job, whether they need any equipment from your organization to help
them, whether they can operate either in a segregated area or only when part
of the plant is shut down and, if not, what hazards they may create for your
employees and vice versa.
Cont…
Clear Leadership & Expectations?

OBJECTIVE: A work environment where there is effective leadership and

support that helps employees know what they need to do, how their work
contributes to the organization, and whether there are impending changes.

oThe most widely accepted types of leadership are instrumental and

transformational.
Cont…
o Instrumental leadership focuses primarily on producing outcomes, with
little attention paid to the ‘big picture,’ the psychosocial dynamics
within the organization, and, unfortunately, the individual employees.

oTransformational leaders are seen as change agents who motivate their

followers to do more than what is expected.

oThey are concerned with long-term objectives and transmit a sense of

mission, vision and purpose.
Cont…
oThey have charisma, give individualized consideration to their
employees, stimulate intellectual capabilities in others, and inspire
employees.
Cont…
Why is clear leadership and expectations important?

 Effective leadership increases employee morale, resiliency and trust, and

decreases employee frustration and conflict.

 Good leadership leads to individuals being 40% more likely to be in the

highest category of job well-being, a 27% reduction of sick leave, and a
46% reduction in early retirements with disability pensions.
Cont…
What happens when clear leadership and expectations are lacking
in the workplace?

o leaders who do not demonstrate visible concern for their own

physical and psychological health set a negative example for their
staff and can undermine the legitimacy of any organizational
program, policy and/or service intended to support employees.
Cont…
o Middle managers are at greater risk due to the fact that they must be
leaders and be led simultaneously. This role conflict can lead to feelings of
powerlessness and stress.
Cont…
End