INDUSTRIAL SAFETY BY CDR ALOK MOHAN

1. PDOECL celebrates world quality week commencing 10 Nov 2014 Theme of the day “Connecting people with healthy & safe work environment” INDUSTRIAL SAFETY BY CDR ALOK MOHAN

2. I NDUSTRIAL SAFETY

3. Industrial Safety Various industrial safety surveys carried out all over the world reveal that this is not only the cost of injuries in terms of productivity, time off the job and workers’ compensation, but the industrial accidents had also resulted in pain, family distress in addition to long term economic losses to the workers families

4. How to prevent these accidents ? A combination of training and communication can eliminate or reduce incidents & Create a Safe Culture Using Communication

5. Six guiding standards Plan the work, work the plan, Seek and Accept responsibility, Work in Teams, Exchange Safety Information, Share Best Practices

6. Building LIFE. LIFE stands for ‘Living Injury Free Every day.’ It is a culture that promotes living injury-free every day, & provides the safest workplace possible for our employees

7. Implementing the Right Programs and Procedures Everyone should have safety-conscious behavior. “BASS program” Behaviors Assuring Site Safety to promote safe culture and behavioral attitudes of responsibility Emphasize from the executive suite to the job site the message:- “Every day, every job safely.” “Target Zero” means we want zero injuries Refocus for the Target Zero principle. This is applicable if you see a problem or a hazard that might endanger you or a fellow worker

8. The Value of Safety if we’re evaluating some worker in Industrial safety & they’ve been training on the task and now they’re doing it, working in an electrical cabinet. Even if they’re simulating it, they better not have any jewelry on that could come in contact with anything. We enforce safety and human performance through the evaluation phase.”

9. SAFETY PRECAUTIONS FOR WELDING AND CUTTING CONTAINERS THAT HAVE HELD COMBUSTIBLES EXPLOSION HAZARDS a. Severe explosions and fires can result from heating, welding, and cutting containers which are not free of combustible solids, liquids, vapors, dusts, and gases. Make these Containers safe. Cleaning of all containers is necessary in all cases before welding or cutting.

10. SAFETY PRECAUTIONS WARNING Do not assume that a container that has held combustibles is clean and safe until proven so by proper tests. Do not weld in places where dust or other combustible particles are suspended in air or where explosive vapors are present. Removal of flammable material from vessels and/or containers may be done either by steaming out or boiling.

11. SAFETY PRECAUTIONS Flammable and explosive substances may be present in a container (1) Gasoline, light oil, or other volatile liquid that releases potentially hazardous vapors at atmospheric pressure. (2) An acid that reacts with metals to produce hydrogen. (3) A non volatile oil or a solid that will not release hazardous vapors at ordinary temperatures, but will release such vapors when exposed to heat. (4) A combustible solid; i. e., finely divided particles which may be present in the form of an explosive dust cloud.

12. SAFETY PRECAUTIONS Any container of hollow body such as a can, tank, hollow compartment in a welding, or a hollow area on a casting, should be given special attention prior to welding. Even though it may contain only air, heat from welding the metal can raise the temperature of the enclosed air or gas to a dangerously high pressure, causing the container to explode. Hollow areas can also contain oxygen-enriched air or fuel gases, which can be hazardous when heated exposed to an arc or flame. Cleaning the container is necessary in all cases before cutting or welding

13. METHODS OF PRECLEANING CONTAINERS 1 STEAM METHOD OF CLEANING 2WATER METHOD OF CLEANING 3 HOT CHEMICAL SOLUTION METHOD OF CLEANING

14. MARKING OF SAFE CONTAINERS After cleaning and testing to ensure that a container is safe for welding and cutting, stencil or tag it. The stencil or tag to include a phrase, such as “safe for welding and cutting,” the signature of the person so certifying, and date.

15. INERT GAS TREATMENT ( Which include carbon dioxide and nitrogen) When carbon dioxide is used, a minimum concentration of 50 percent is required, except when the flammable vapor is principally hydrogen, carbon monoxide, or acetylene. In these cases, a minimum concentration of 80 percent carbon dioxide is required. Carbon dioxide is heavier than air, and during welding or cutting operations will tend to remain in containers having a top opening. (2) When nitrogen is used, the concentrations should be at least 10 percent greater than those specified for carbon dioxide

16. PAINT SAFETY Most interior paint, stain and stripper fumes can be flammable and hazardous to health. Always open several windows or provide better-than-adequate ventilation when painting, paint stripping, staining or cleaning up. NEVER paint or use solvents, solvent-based paints, strippers, stains, caulking or clean-up supplies near an open flame or pilot light including furnace, and water heater. When working with solvent-based materials it is best to wear a respirator (type of clean air mask) which will be available at major paint stores. Do not sleep in a freshly painted dwelling for at least two days if at all possible. When sanding, wear a proper dust mask to prevent particles from entering the lungs and, if possible, use a power sander with a sawdust collection bag. Lead-based paint is hazardous to your health

17. General Safety Precautions 1. Always read and follow all the instructions and safety precautions on the label. Do not assume you already know how to use the product. The hazards may be different from one product to another, and the ingredients in individual products often change over time. The label tells you what actions you should take to reduce hazards and the first aid measures to use. 2. Wear chemical-resistant gloves appropriate to the type of stripper being used (see manufacturer's instructions). Common kitchen latex gloves do not provide enough protection. 3. Avoid getting the paint stripper on your skin or in your eyes. Wear protective clothing and goggles appropriate for the project and type of stripper.

18. GENERAL SAFETY PRECAUTIOS 4. Use paint strippers outdoors if possible. If you must use them indoors, cross-ventilate by opening all doors and windows. Make sure there is fresh air movement throughout the room. Ventilate the area before, during, and after applying and stripping. Never use any paint stripper in a poorly ventilated area. If work must be done indoors under low ventilation conditions, consider having the work done professionally instead of attempting it yourself. 5. If you must work indoors, always work so the stripper fumes are blowing away from you and to the outside. A fan can be used to improve cross-ventilation and to ensure fresh air movement. A fan is particularly important for nonflammable products that evaporate quickly, such as methylene chloride. Electrical sparks from fans may increase the chance of flammable paint stripper's fumes to catch fire. 6. Do not use flammable paint strippers near any source of sparks, flame, or high heat. Do not work near gas stoves, kerosene heaters, gas or electric water heaters, gas or electric clothes dryers, gas or electric furnaces, gas or electric space heaters, sanders, buffers, or other electric hand tools. Open flames, cigarettes, matches, lighters, pilot lights, or electric sparks can cause the chemicals in the paint strippers to suddenly catch fire

19. GENERAL SAFETY PRECAUTIONS Only strip paint with chemicals that are marketed as paint strippers. Never use gasoline, lighter fluid, or kerosene to strip paint. Dispose of paint strippers according to the instructions on the label. If you have any questions, ask your local environmental sanitation department about proper disposal.

20. Painting Operations Safety Do not perform work in a heavily populated area, including building air intake areas, until appropriate warnings are posted and occupants notified. If possible, rope off the immediate work area to prevent injury to bystanders. Protect your working area with warning flags and traffic cones when working road and traffic lines. When spraying roofs or building exteriors, have adequate barricades and signs to detour traffic. Eye protection is required whenever rust or loose paint is removed from surfaces with a wire brush. A hard hat is required if the work area is exposed to falling objects.

21. Painting Operations Safety To avoid splinters, always observe the condition of the wood before sanding. Store and dispense flammable solvents from approved safety cans only. Follow the manufacturer's instructions for handling all epoxy materials, thinners, catalysts, paint removers, etc. Gloves and respirators may be required. Clean all working areas after each job and/or shift. Make sure that you wash your hands thoroughly with soap and water before handling food. Inspect all ladders and scaffolds before you begin work

22. Painting Operations Safety Make a safety check of all equipment such as staging tools, spray pots, hoses, fitting hooks, etc. An approved life line, independently fastened to the building above the worker, is required for each worker on a swinging scaffold, boatswain's chair, or unguarded slope 20 feet or more above ground level. Make sure that planks or ladder stages are long enough to extend well beyond the supports. Do not climb onto or use rolling-type scaffolds unless wheels are fully locked. Inspect all rope before use. Rope used around acid or caustics should be inspected frequently during use. Do not use fibre rope that cannot easily be bent or worked, or if fibres seem to be dry or brittle. Do not use fibre rope near sandblasting, or where there is exposure to chemical washing solutions

23. Spraying Safety An approved respirator should be worn when spray painting is being done. Do not paint in shops, chemical laboratories, chemical storage rooms, or similar locations without specific instructions from the supervisor of such locations. Do not perform spray painting in tanks, tunnels, or other confined spaces without specific permission from your supervisor. Appropriate breathing equipment, and/or controls are required for such work to assure that the atmosphere is safe. Do not break connections in pressurized air hose lines. Airless spraying with flammable materials should not be performed in confined areas unless there is sufficient ventilation to keep the atmosphere below the lower explosive limit of the material. Airless spraying with flammable materials may cause generation of static electricity. This will require grounding of both the spraying equipment and the object to be sprayed. Do not point an airless spray gun at any part of the body. Do not clean airless spray guns while there is pressure in the system.

24. Spray Safety Inspect and clean all gauges, gaskets, and valves on all spray equipment to ensure that they are in good working order. Do not interfere with the mechanical operation of safety devices designed to protect you from contact with the spray under pressure. Do not leave rags saturated with paint or thinner lying around in a pile. In order to avoid a fire, see that these rags are left unfolded until they are properly aired out and then discard them in approved containers. Storage in a water filled container is recommended. Spontaneous ignition can occur if certain types of spray paint residues are permitted to mix or accumulate. Dispose of surplus paints and solvents by approved methods only. Removal of lead based requires additional personal protective equipment and air sampling to determine lead exposure.

25. Manager Safety Responsibilities 1. Ensure that sufficient employee time, supervisor support, and funds are budgeted for safety equipment, training and to carry out the safety program. 2. Evaluate supervisors each year to make sure they are carrying out their responsibilities as described in this program. 3. Ensure that all incidents are fully investigated and corrective action taken to prevent the hazardous conditions or behaviors from happening again. 4. Ensure that a record of injuries and illnesses is maintained and posted as described in this program. 5. Set a good example by following established safety rules and attending required training. 6. Report unsafe practices or conditions to the supervisor of the area where the hazard was observed

26. Supervisor Responsibilities 1. Ensure that each employee you supervise has received an initial orientation before beginning work. 2. Ensure that each employee you supervise is competent or receives training on safe operation of equipment or tasks before starting work on that equipment or project. 3. Ensure that each employee receives required personal protective equipment (PPE) before starting work on a project requiring PPE. 4. Do a daily walk-around safety-check of the work area. Promptly correct any hazards you find. 5. Observe the employees you supervise working. Promptly correct any unsafe behavior. Provide training and take corrective action as necessary. Document employee evaluations. 6. Set a good example for employees by following safety rules and attending required training. 7. Investigate all incidents in your area and report your findings to management. 8. Talk to management about changes to work practices or equipment that will improve employee safety

27. Employee Responsibilities 1. Follow safety rules described in this program, WISHA safety standards and training you receive. 2. Report unsafe conditions or actions to your supervisor or manager promptly. 3. Report all injuries to your supervisor promptly regardless of how serious. 4. Report all near-miss incidents to your supervisor promptly. 5. Always use personal protective equipment (PPE) in good working condition where it is required. 6. Do not remove or defeat any safety device or safeguard provided for employee protection. 7. Encourage co-workers by your words and example to use safe work practices on the job. 8. Make suggestions to your supervisor, safety committee representatives or management about changes you believe will improve employee safety.

28. Safety Rules Do not remove or disable any safety device! Keep guards in place at all times on operating machinery. • Never operate a piece of equipment unless you have been trained and are authorized. • Use your personal protective equipment whenever it is required. • Obey all safety warning signs. • Working under the influence of alcohol or illegal drugs or using them at work is prohibited. • Do not bring firearms or explosives onto company property. • Smoking is only permitted outside the building away from any entry or ventilation intake. • Horseplay, running and fighting are prohibited • Clean up spills immediately. Replace all tools and supplies after use. Do not allow scraps to accumulate where they will become a hazard. Good housekeeping helps prevent injuries