Elements of Safety Management

Elements of Safety Management MEEG721
M.Tech in Health, Safety & Environment Engineering
Educational Qualification Improvement Programme

(EQUIP)
Indian School of Petroleum & Energy

in association with
University of Petroleum & Energy Studies
S.NO. CHAPTER NAME PAGE NO.
UNIT-I Introduction to SHE aspects 3
1
UNIT-II 29
Types and Severity of Accidents
Cost of Accidents
UNIT-III Safety Policy, Organization, Monitoring and 41

Reporting
UNIT-IV Emergency/Disaster Plans 64
UNIT -V Process safety management 51
UNIT-VI First Aid 73
UNIT-VII Safety officer role & responsibility 80
UNIT-VIII Major disaster 88
UNIT-IX 106
Personnel Risk in Industrial Operations
Mineral Exploitation
Material Handling Processes
Manufacturing Plant
Chemical Industry
UNIT-1
INTRODUCTION TO SHE ASPECTS
2
INTRODUCTION:
The industrial operations have been constantly developing, upgrading and improving their
design and operating techniques in terms of economy of scale, high quality products and
energy optimization to meet the stiff market competition. All this has increased the
potential of major risks. Major accidents like Bhopal , Mexico city ,Seveso , Flexiobro and
others in the last two decades or so have shaken the confidence of general public about
they safety of the people, property and environment. In fact, some companies have been
closed down on account of poor safety and environmental performance. After these major
disastrous government authorities, human activist groups and corporate houses in many
countries including have taken a number of steps to evolve a strategy to avert major
mishaps in the installations which have the potential to cause loss of human life, property
and environmental damage. No doubt, health, safety and environment issues are very
critical in the industrial operations in the current scenario.
HSE MODEL AND ITS INTEGRATION WITH BUISNESS:
HSE is an integrated management comprising discipline of occupational, health and

environment and fire protection. What ever way you look at these functions, industrial
hazards- unsafe acts and situations are the basic problems to be managed. When an
industrial hazards leads to an immediate or sudden accidents like an injury, fire, explosion
or toxic release. It becomes a safety issues and safety management comes in the picture.
When the hazards have chronic health effects like stress, musco-skeltal disorders and other
industrial diseases, it becomes occupational health problems. On the other hand, when the
effect on the unsafe situations is long term and spread over larger areas beyond the
boundary limit it becomes an environmental problem.
No doubt, HSE efforts of many organizations are driven by statutory requirements and they
do whatever minimum is required to avoid litigation and fines. However an efficient and
enlightened corporate see HSE in much broader perspective. For them good HSE
performance is an integral part of efficient and profitable business management. They are
committed to improve their health, safety and environment and fire protection performance
on a continuous basis and on the sustainable way, i.e. meeting the needs of present without
compromising the ability of future generations to meet their needs. The compulsion of
3
integrating HSE functions with business can be well appreciated by looking in to the cost of
an accident/ incident. Consider the following direct or indirect costs of major accidents/
incidents:
Injury/ loss of life to self or co-workers

Workman compensation
Cost of injury/ investigation
Loss of property and material
Loss of profits
Punitive sanctions and fines
Closure/ shutdown of the installation
Public litigation
Environmental pollution
Ecological damage
Loss of business
Shareholders wrath
The above does not include the cost of psychological and social factors associated with major
accidents. Considering all these it is sensible to integrate HSE as an important
management functions like production, maintenance, finance marketing and human
resources etc.
HSE MANAGEMENT FRAME WORK:
As said earlier, many organizations try to meet only the minimum regulatory requirements.
But this is not enough in todays business and social requirement. Regulations alone can
not guarantee the safety of industrial complex. Most of the regulatory agencies lay down
rules and regulations, which are the minimum basic requirements for the safe design and
operation of an installation. Sound and safe engineering practices are equally important
but are not adequately addressed in their requirements. The statutory and law enforcing
agencies are generally slow in updating their rules and requirements to keep pace with the
technological and social changes. Further, many regulatory agencies do not have adequate
infrastructure and manpower to exercise superintendence and control of industrial safety
performance on a continuous basis. For example, number of safety inspectors, boiler
inspectors and environmental specialist are far less than that would e required to
4
undertake meaningful inspection visits to a large number of installations under their

jurisdiction. Further the back rod and training that many factory workers have, their visits
to factories are restricted to checking basic amenities like first aid facilities, guards for the
machines, personal protective equipment, potable water and canteen facilities etc. They
probably dont have right training and aptitude for identifying the many process hazards
which are not so obvious.
The regulatory requirements are just very minimum requirements to obtain license and
operate an installation, the petroleum operations which is hazardous industry. Lot of self
regulatory initiatives by the management is required to maintain a high level of safety. So
the best framework of HSE management is to comply with the regulatory requirements and
have highly efficient self regulatory system in house.
REGULATORY REGIEME:
To control or reduce industrial hazards, a number of regulations have been framed by

various statutory/regulatory authorities in the country to safeguard the interest of workers,
public and environment. Sustainable development and environmental safeguards are
important societal issues. These regulations specify minimum mandatory requirements to
be compiled by the industry. The industry should take these regulations in the right spirit
and be fully committed in their compliance. These regulations should not be considered
contrary to the interest of business and hindrance to its development.
REGULATORY/ STATUTORY AGENCIES:
Following is the list of various regulatory/statutory agencies having jurisdiction over the
different industries.
Central Pollution Control Board ( CPCB) under the Ministry of

Environment and Forest
Respective State Pollution Control Board under the Ministry of
Environment and Forest of The State
Chief Controller of Factories Of The Respective State (CIF) Under The
Ministry Of Labor
5
Chief Controller Of Explosives (CCE) , Ministry of Heavy Industry, Dept of

Explosives
Director General of Civil Aviation ( DGCA) under The Ministry of Civil
Aviation, National Air Port Authority Of India
Tariff Advisory Committee (TAC) Under the Association of Indian
Companies
Bhaba Atomic Energy Commission (BARC) Under Ministry of Atomic
Energy
Director General Mines Safety (DGMS) under the Ministry of Mines
Regional Transport Authority (RTA) under the Ministry of Surface
Transport
Director General Of Dock Safety (DGDS) under The Ministry of Shipping
International Maritime Organization (IMO) under United Nations
Oil industry safety directorate (OISD) under the ministry of petroleum and
natural gas
VARIOUS REGULATIONS/ REQUIREMENTS:
The different agencies of listed above framed various regulations under their purview.
Needless to say that over the years, these agencies have played a significant role in
promoting industrial safety and environmental protection.
Important regulations are briefly discussed below.
PETROLEUM ACT , 1934
The statutory requirements of the petroleum are governed by petroleum Act, 1934 and
petroleum Rules. 1976 under the jurisdiction of chief controller of Explosives. These
rules deal with the safety guidelines/ regulations for import, transport, storage, refining
blending and testing of petroleum and its fractions/ hydrocarbons. Under the petroleum
Act, the petroleum products are classified into class A having flash point below 23
degree Celsius, Celsius and class-B with flash point between 23 to 65 degree Celsius
and class-C having flash point above 93 degrees Celsius are exempted petroleum and do
not fall under the purview of petroleum rules.
6
The petroleum rules, 1976 detail the procedures and safety norms to be observed for
approval of containers, import, delivery and dispatch, loading, transport, storage,
refining and blending of petroleum and requirement for storage , refining and blending
of petroleum and requirement for storage and safety distances, testing and
maintenance of pipelines, electrical apparatus and degree of safety and license/ approval
procedures, under these rules, license is required for.
Import, storage and refueling

Transport by ships/vessels in bulk
Decanting from tank trucks in unlicensed premises
Transport by pipelines
Refining and blending
Fabrication of tank trucks
Manufacture of safety fittings
Construction of tanks
Design of containers
THE INDIAN EXPLOSIVES ACT, 1884
The compressed or liquefied gas filled in containers under pressure are notified by the
Government of India as explosives and brought under the purview of explosive act.,
1884 in 1938. The chief controller of Explosives administration used for various
purposes like mines/ rock blasting, crackers etc.
THE STATIC AND MOBILE PRESSURE VESSELES, SMPV (UNFIRED)

RULES, 1981
These rules stipulate various safety guidelines for the storage and transport of
compreesed and liquefied gases filled in pressure vessels (exceeding 1000 litres capacity)
at a pressure exceeding 1.5 kg/cm2 15 degrees celcius. Under these rules the storage
and transport vessel should be designed for the specific gas, maximum operating
temperature and working pressure, proper material of construction, capacity shape,
sizes etc. according to IS 2825 or any other approved code. The chief controller of
explosives should approve its design/drawings. The vessel should be fabricated by an
7
approved fabricator and installed as per the safety distances stipulated in the rules. the
rules call for periodic re-examination/testing of the pressure vessel and its fittings.
THE GAS CYLINDER RULES, 1981
The provisions of these rules pertain to the filling. Storage, handling and transportation
of gas cylinders exceeding pressure of 1.5kg/cm2 at 15 degrees Celsius or 2.5 kg/cm2 at
50 degree Celsius. The rules regulate the manufacture of cylinders, valves and
regulators, marking, stamping and color coding of cylinders, import of gas cylinders,
testing of cylinders and the procedures for appointing competent person authorized to
undertake the testing and inspection of gas cylinders.
THE FACTORIES ACT, 1948
The provisions of this act contained in different chapters on health, safety and welfare
are administered by the chief inspector of the factories in the respective state.
Each state has its own factories rules. The act was revised in 1987 to include hazardous
chemical factories and some other amendments brought in the factories rules of many
sates in 1995
The factories act make the occupier of a factory fully responsible for providing and
maintaining the plant and the systems of work that are safe and without any risks to
the health and safety of the workers and general public.
General responsibilities of occupier are listed below.
Declaring safety policy of the organization
Providing the material safety data sheet (MSDS) of each hazardous chemicals
Every factory should have a well written on-site emergency plan, clearly defining
the role of different persons in case of an emergency. The plan should be
rehearsed every year and updated from time to time.
Disclosures of information to workers, public and authorities. This should

include declaration of dangers/ health hazards and measures to overcome such
hazards.
8
A safety committee having equal representation of workers and management

should be in place. The meeting of this committee should be held at least every
quarter.
To maintain the limits of exposure of chemicals and toxic substances below the
limit prescribed under the rules.
Medical checkup of the workers once before the employment and once every six
months for health status in case of specific health hazards.
Setting up of medical/ occupational health center suitably equipped with

equipment and qualified medical personnel
Inspection, testing, examination and certification of equipment and vessels etc.

by competent persons approved by CIF.
Permit to work system should be in place with approved safety and rescue
equipment. All work associated with entry or work in confined spaces, working at
heights, hot works, cutting and welding excavation and other dangerous work
should have predetermined safe work procedure and should be undertaken under
a written work permit signed by a qualified supervisor.
Provide adequate fire protection system as per rules.
An emergency communication system alarm siren etc. should be in place and

everybody should know what to do in case of an alarm.
Safety manual containing the different safety procedures applicable to the

installation should be available to the workers.
Providing PPE to workers depending on the nature of hazard involved.
Display necessary precautionary notices and instructions at prominent places to

educate and warn the workers and visitors against the hazard involved.
Appointing a qualified safety officer in the premises as per rules.
9
Providing welfare amenities like drinking water facilities, washing facilities,

mess room, toilets etc.
Sending any accidental report and notice of any poisoning or occupational

diseases.
ENVIRONMENTAL LEGISLATION:
Sustainable development and environmental legislation are important issues for the
development of the society.
Keeping this in view, government of India enacted the various environmental

legislations related to industrial projects activities. These include:
The water (Prevention and Control of Pollution) Act, 1974
The water (Prevention and Control of Pollution) Cess Act, 1977
The air (Prevention and Control of Pollution) Act, 1981
The Environment ( protection) Act, 1986
The Environment (protection) Rules , 1986
Manufacture, storage, and import of hazardous chemicals Rules, 1989
Hazardous waste management ( management and handling) rules, 1989
Environmental clearance of project notification,1994

Chemical accidents (emergency planning, preparedness and response)
rules, 1996
Biomedical waste (management and handling) rules, 1998
The public liability insurance act, 1991 and the public liability insurance
rules, 1991
THE INDIAN BOILERS ACT, 1923
10
The current government and the state government independently, except Jammu and
Kashmir where this act does not apply, frame the act.
Each state has its own boilers regulations.
It is an obligatory for an owner to get his boiler registered under this act. Chief
inspector of steam boilers in the state is the registering authority.
The act stipulates requirement for safety of steam boilers and steam pipes.
For the purpose of the act, a boiler means any closed vessel exceeding 22.75 liters in
capacity which is used exclusively for generating steam under pressure and include any
mounting or other fittings attached to such vessel which is wholly or partially under
pressure when steam is shut off.
A steam pipe under the act means any pipe through which a steam passes from a boiler
to a prime mover or other user if the pressure at which steam passes through such pipe
exceeds 3.5 kg/cm2 above atmosphere or such pipes exceeds 254 mm in diameter
These regulations cover the design, construction and workmanship of boilers and
connected mountings, fittings and pippings.
The regulations specify the stages and procedures for inspection of new boilers and
inspection frequency of boilers in operation.
The regulations also lay down procedure for testing and qualifying welders who are to
work on boilers.
A registered boiler is permitted for use for a maximum period of one year.
A working certificate showing validity period, maximum allowable pressure etc. is

issued after every annul inspection by the boiler inspector.
The boiler owner is required to display the certificate so the boiler attendants and other
employees associated with boiler operation and maintenance get familiar with the
certificate.
As per the act the owner should provide a qualified person to take charge of boiler.
11
A second class boiler attendant can take charge of a single boiler or battery of three
boilers, the total heating surface of which does not exceeded 150 sq. meters.
A first class boiler attendant can take charge of a battery of boilers, the total surface
area of which does not exceed 700 square meters.
A proficiency engineer should be appointed for boilers larger than the above sizes.
The following acts/ omissions are treated as cognizable offence under the act.
If it is not registered or not having the valid certificate

Operating the boiler at pressure higher than that allowed in the certificate
Absence of duly qualified boiler attendant
Carrying out structural alteration, addition or renewal in or to a boiler
without prior sanction of chief inspector
Failure to report any accident to boiler or steam pipe to inspector within 24 hrs.
Tampering with safety valves.
Allowing a person to get inside the boiler without affecting disconnection
Fraudulent engraving of registry on a boiler.
THE INDIAN ELECTRICITY ACT, 1910
In exercise of the powers conferred by section 37 of the Indian electricity act, 1910, the
central electricity board formulated the Indian electricity rules(I.E. rules) in 1937
followed by amendments in 1956.
The objective of the I.E rules is to regulate the generation, transmission, distribution
and use of electricity in a safe manner.
The provisions of these rules are enforced in each state by the chief electrical inspector
of the state.
It is mandatory that all the electrical installations should confirm to requirements of

the Indian electricity rules.
The I.E rules do not stipulate specific requirements of electrical equipments and lines
and due to this, the interpretation of the rules by the electrical inspectors vary from
12
state to state. Also, the I.E rules do not cover the special requirement for electrical
equipment in hazardous locations encountered in petroleum installations.
THE OIL MINES REGULATIONS, 1984
These regulations were framed under sections 57 read with sections 59 of the mines act,
1952 and enforced in the 1984 in the oil industry. Consequently all the oil and gas
exploration , drilling production and transport facilities including general safety and
health education governed by these regulations under the competent authority of the
director general of mines and safety(DGMS).
Although the basic safety requirements are stipulated in oil mines regulations, 1984,
the specific requirements for certain systems like work permit, fire fighting facilities are
not covered.
THE INDIAN AIRCRAFT RULES, 1937
In exercise of the powers conferred by the sections 5,7, and 8 and 9A of the Indian air
craft act, the aircraft rules were framed in 1937, which were amended several times the
latest edition was updated in 1985.
An installation, which is in the proximity of the Aerodromes, is covered under the

purview of this rule.
The relevance rules in the case of statuary clearance of the design of tall structure and
buildings are framed under provision 9A of the said act.
It is mandatory that clearance be obtained from the national air port authority of India,
under the ministry of civil aviation, while planning to any tall structure or building.
Air warning as stipulated in the rules to be complied with owners of such buildings.
The owner has to forward the layout drawings showing the elevation details,
dimensions and other details of the structures/ buildings in the prescribed format and
submit to the nearest aerodrome officer.
Only after receipt of the approval, the construction can be taken up.
13
INTERNATIONAL MARITIME ORGANISATION (IMO-1986)
It was originally known as IMCO, Inter- Governmental Maritime Consultive

Organization established in 1948 as a specialized agency of United Nations,
which was later changed to IMO primarily works for development of maritime
regulations and standards for the promotion for maritime safety and prevention of
pollution from ships,
these regulations and standards were adopted in diplomatic conferences and published
by IMO.
Some important milestones achieved are.
Convention on the safety of life at sea in 1974(SOLAS74)
International convention for prevention of pollution from ships in 1973/8(MARPOL

73/78)
Convention on standards of training, certification and watch keeping for sea farers,
1978 ( STCW 78)
These conventions framed an important vehicle for the development and international
spread of knowledge, recommendations and codes of practice and protocols regarding
maritime safety throughout the world.
A wide range of topics covering all maritime activities for handling different types of
dangerous goods are dealt in the publications from these conventions and seminars.
However adoption and implementation of these regulations are not uniform in all parts
of the world.
DOCK WORKERS (SAFETY, HEALTH AND WELFARE) ACT, 1986
The dock workers (safety, health and welfare) regulations were framed in 1990 under the
above mentioned act. factory inspectorate does not have jurisdiction on the ports and
docks.. Director general of dock safety enforces safety requirement at ports/ docks where
crude and petroleum products moving through ships and barges are handled.
MOTOR VEHICLES ACT, 1988
14
the transportation of hazardous products by road is governed by central motor vehicles act,
1988, salient features of the rules include:
Educational qualifications of the drivers of the goods carriages carrying dangerous or

hazardous goods. Every drivers of such vehicles must have passed mandatory three days
training course from a recognized school in addition to having his heavy vehicle driving
license.
Every vehicle carrying hazardous goods must display mark of the class label appropriate to
the type of dangerous goods. The vehicle should be marked emergency information panel at
three places on the vehicle. His panel contains products technical name. UN identification
number, HAZCHEM code. Emergency phone number etc.
The vehicle must have TERM card transport emergency card available in the drivers cabin.
Every vehicle carrying hazardous goods must be equipped with the prescribed safety
equipment for the preventing fire, explosion or escape of hazardous goods. The vehicle
should be fitted with a spark a spark arrester and a tech graph ( an instrument to record
the lapse of running of the vehicle, time, speed maintained, acceleration/ declaration etc.)
Responsibilities of consignee, transporter and driver
OIL INDUSTRY SAFETY DIRECTORATE:
Oil industry safety directorate, OISD is an advisory body under the ministry of petroleum
and natural gas. Set up in the 1986 after Bhopal disaster, the directorate advises the oil
and gas industry in India on all matters of health, safety and environment. All public sector
(PSU) oil companies are members of OISD. Private oil companies can also become members
in case they desire. Unlike other regulatory agencies, OISD helps the member oil and gas
companies to enhance the level of safety through self regulation. OISD has published a
number of standard/ recommendations practice in sitting of petroleum operation,
philosophies, inspection, maintenance, fire protection etc. it is obligatory for the member
companies to use these standard and recommended practices for new installations and
installation in operations. Many other statuary agencies like CCE and other CITE OISD
standards/recommended practices in their procedure and requirements.
15
OISD has also published guidelines for internal and external safety audits. Based on these
guidelines, formal safety audits of oil/gas installations of various PSUs under Ministry of P
& NG are conducted periodically by an external team under the leadership of OISD.
Petroleum organizations can use these guidelines for their own internal audits. OISD has
also made a model disaster management plan that can be used by an installation as
guidelines for developing its own disaster/ emergency management plan.
TARRIF ADVISORY COMITEE:
Tariff advisory committee, TAC, is an advisory body formed to regulate rates, terms and
conditions of business of general insurance companies in India. TAC approves and monitors
various fire fighting facilities and electrical installations in the industry. Fire fighting
manual first brought out in 1903 by Calcutta fire association was revised, updated and
issued by TAC in 1982 in two parts- Part I and part II. These manuals lay down guidelines
for design and operation of private fire fighting facilities to be maintained by the industry.
These guidelines have been used extensively in petroleum installations. Based on the
degree of compliance to the recommendations of these manuals. TAC makes periodical
inspections of those installations where rebates have been given.
PERMISSIONS AND APPROVALS FOR NEW PROJECTS:
Before setting up any oil or gas installations, the following statuary approvals/permission
have to be taken by the organization. Some of these approvals/ permission are also
applicable for undertaking a major expansions or revamp of existing installations.
UNDER FACTORIES ACT-FROM CIF
Permission to construct, extend or take into use any building as a factory.
Approval of site and building plans
Approval of site (only for hazardous process units) by state site approval committee
Certificate of stability of factory building
Application for registration and notice of occupation
Application for license / renewals of license of a factory.
16
UNDER ENVIRONMENT PROTECTION ACT- FROM MOEF AND STATE PCBS
Notification of site in respect of hazardous chemicals
Environmental impact assessment
Environmental clearance from ministry of environment and forests
NOC from state pollution control board
Consent for discharge of trade effluents
Consent for operations of plants ( in air pollution control areas)
Authorization for handling hazardous waste in quantity exceeding regulatory values.
UNDER EXPLOSIVES AND PETROLEUM ACTS- FROM CCE
License for manufacture, possession, use, sale, transport and importation of explosives
License to import/store petroleum
License to carry petroleum by land license for filling and possession of gas cylinders with
compressed gases
License for transporting cylinders filled with compressed gas
OTHER APPROVALS/PERMISSIONS/CLEARANCES
Beside the above, permissions, approvals/clearances consent from other agencies listed
below have to be taken
Certificate of authorization for use of boilers from the states chief electoral inspector
Public liability insurance by owners handling hazardous substances
Authorization from BARC (under the ministry of atomic energy) for use of equipment/
instruments using radiation sources.
REGULATORY COMPLIANCE:
17
No doubt, as various regulations discussed above go in a long way to increase the industrial
safety standards, which is very important for hazardous industry like petroleum
operations. But the regulations will be useful and bring results only when they are
implemented in the right spirit. It is the responsibility of the owner/ occupier of an
installation and their authorized officials to ensure that the requirements of various
regulations are fully complied with. Besides taking the necessary approvals, permission,
consents and clearances from the concerned authorities and maintaining the conditions
specified therein, it is also required by some of these agencies to send them regular reports
of compliance.
In the recent past, the law has put lot of accountability and liability on the part of senior
management of an organization in the compliance of various regulations, and closure of
installations. The owner/occupier and other officials may even be put behind the bars in
serious violations. Even the public awareness about the safety hazards and environmental
pollution from industrial activities has increased significantly over time. It is very easy
these days for any person to file a PIL (public interest litigation) suing an organization for
violation of any regulatory requirement. The affected organization may get involved in
lengthy litigation casting lot of money harassment and loss of image and reputation. The
management of every installation therefore should ensure that the required regulations are
fully complied with.
LIMITATIONS OF REGULATORY AGENCIES:
Needless to say that over the years the regulatory agencies have played a significant
contribution in the promotion of industrial safety in the various industry in India. With
due respects to their role, it may be worthwhile to look into some of the inherent limitations
of these agencies, and this is the most important reasons why organizations should have
voluntary own self discipline and regulation to have a high level of safety standard. Some
limitations are:
MINIMUM REQUIREMENTS:
18
Most of the regulatory agencies lay down rules/regulations which are the minimum basic
requirements that are very important in the safe design and operations of industrial units.
They do not go into details of so many other requirements pertaining to safe management of
an installation. For example, sound and safe engineering practices are equally important
but are not addressed in these requirements.
CHANGE IS SLOW:
Technological developments and social awareness bring in new problems and challenges to
the industry. Adequate protection of society against new technological hazards would
depend upon the speed with which these regulatory agencies can identify the new problems
and change the rules. Since the provisions of these agencies cover a wide spectrum of
industry and any amendments has to go through a lengthy legislative procedure, the
statuary and law enforcing agencies are generally slow in updating their rules and
requirements to keep pace with technological and social changes. Some of the requirements
set forth in the regulations long ago may not be relevant in the present context. For
example, Factory Act, since its inception in 1948, underwent amendments only in
1954,1976 and 1987. Environment protection act came into being only in 1986. the Indian
electricity rules and Indian Boiler Regulations have not seen any revision for more than 15
years.
INADEQUATE INFRASTRUCTURE:
Many regulatory agencies do not have and adequate facilities and manpower to monitor
and control the safety performance of the industry on a continuous basis. For example, the
number of boiler inspectors in most states is far less than required to undertake and
meaningful inspection visits to a large number of industrial units under their jurisdiction.
Further, with the background and training that many factory inspectors have, their visits
to factories are restricted to checking the basic amenities like first aid boxes, machine
guards, personnel protective equipment, drinking water and canteen facilities, etc.
They probably do not have right training and background for identifying many serious
process hazards, which may not be obvious. It is only after Bhopal disaster that some
19
improvements with respect to quantity and quality of inspectors in these agencies have
taken place.
NOMINAL PENALITY FOR VIOLATIONS:
Some regulatory agencies provide for penalty to the industry for violating the rules and
compensation to the workers in case of injuries and fatalities. Though in the recent past
there have been some changes in the amount of these penalties and compensations, still
these are nominal in most cases, with the result that there is a little pressure on the
industry compelling them to spend more money in making an installation inherently
making an installation inherently safer and non-polluting. It appears, under the present
situation that the companies would prefer to violate some of the safety rules and pay the
penalty rather than implement these rules by additional investment. The logic may
however look very strange, but it is realty in some cases where the management is not fully
committed and lacks in self discipline to make the installation safe and non-polluting. In
contrast to this, very heavy penalties and sanctions are imposed for the violation of health,
safety and environment regulations in USA, Europe and Japan.
GENERAL AND SUBJECTIVE PROVISIONS:
Certain provisions of regulatory agencies are very general and subjective in nature. This
leads to ambiguities and confusions in their interpretations by users and the inspectors.
Besides it is observed that a large number of cross references to a particular provision of
the regulation are mentioned.
Permit to Work System
Introduction
As said earlier, most of the industrial operations are hazardous in nature which can lead to
serious accidents or mishaps if proper precautions are not taken. Many a times serious
accidents have occurred because proper precautions were not taken in preparing and
handing over equipment for repair, inspection or modification. For example, a leaking
pipeline was not completely isolated and made hydrocarbon free. An explosion took place
when a welder tried to weld it. An electrician was working on electrical switchgear without
removing its fuses on the supply line. He got electrocuted when someone by mistake
20
switched on the supply. There are numerous cases where people worked without proper
isolation of equipment, cutting off electrical supply, proper personnel protective equipment,
etc. Every petroleum installation must have an approved Permit to Work System in place.
The permit is an official record of safe working conditions agreed upon by the issuer and
acceptor of the permit for carrying out any maintenance, repair, inspection or modification
work.
TYPES OF PERMITS
Various permits applicable in a typical industry are listed below:
Cold Work Permit
Hot Work Permit
Confined Space Entry/Work Permit
Excavation Permit
Permit to Work on Electrical Equipment
Electrical Isolation/Restoration Permit
Permit for Closure of Roads
Permit for using a Radioactive Source
Permit for Working Over/Under Water
Vehicle/Crane Entry Permit
Permit for Photography
Permit for Isolation of Fire Water System
Mine/Rock Blasting Operations
Depending upon the nature of activities, some or all of the above permits may be applicable
to hazardous industry.
21
ELEMENTS OF A TYPICAL WORK PERMIT
Every installation should design work permit formats as per its requirement and nature of
activities. NSC give guidelines for designing work permit formats. Some important
elements a typical work permit are as below:
Type of permit
Date, time of issue and validity
Description of location where work is to be carried o
Brief description of the work
Detailed safety precautions to be taken
Name and signatures of person(s) issuing the permit
Name and signature of the person receiving t permit
Authorization by senior management person depending on seriousness of the hazard
Declaration of completion of job by the receiver with date and time.
PERMIT PROCEDURE
A work permit is generally issued by an operating supervisor called issue of the permit to
the maintenance supervisor a contractor, called the acceptor of the permit after ensuring all
the necessary precautions. The nature and location work to be done must be clearly
specified in the permit the issuer who should explain and show the same to the accepter
Wetting the area
Providing standby firefighting equipment
Providing standby rescue team
This is not an exhaustive list and some more precautions may be necessary to meet special
work requirements. Find out what are these before issuing a permit.
22
MANAGEMENT OF PLANT CHANGES
INTRODUCTION
Over the period of time a process industry may go for several changes/modifications to
increase capacity, reduce specific consumption of raw materials, chemicals catalysts;
increase energy efficiency; and bring in case of operation and flexibility or improve HSE
performance. Many serious accidents have occurred world over because changes were made
in plants, processes and/or management systems without proper scrutiny and review of any
unforeseen, effects. A classical example is the famous Flixborough accident in the ICI
petrochemical complex in England. It is Imperative that every installation must have in
place an approved written procedure for undertaking changes/modifications to avoid any
adverse safety repercussions. This procedure should take into account change, temporary or
permanent, that could affect integrity, reliability, quality, health and safety of personnel or
environment.
DEFINITION OF PLANT CHANGES
The following activities are considered as plant changes
Addition, deletion, alteration and relocation equipment, piping, instruments, material

construction, insulation, cathodic protection irrespective of its magnitude.
Any change to the supports to equipment, piping fittings or changes to the structure,
which could. Its load carrying capabilities including changes to platforms, ladders, etc.
ACCIDENT REPORTING AND INVESTIGATION
In spite of good systems in place and people taking, precautions while doing their
work, the possibility of, accident cannot be ruled out. It is necessary that each
organization should have a good accident reporting and investigating system in
place. Many people, at times, tend to look at accident investigation as an exercise to
collect some facts for the sole objective of putting blame or hanging someone for his
errors and omissions to set an example. For from this, accident investigation should be a
learning process to prevent accidents and for many other purposes.
23
The magnitude of accidents sometimes makes them appear to be beyond practical

s olution, but a s ys tematic investigation makes it possible to identify all the possible
circumstances and causes leading to the accident. Like peeling the onion, it enables
us to look at the underlying causes of an accident, which may not be so obvious. A
proper investigation helps to identify the root cause(s) of an accident enabling the
management to take appropriate corrective action. Some of the several objectives of
an accident investigation are listed below, the rationale of each being self-explanatory:
Define the root cause(s) of the accident to take appropriate corrective

measures
Define management errors
Satisfy company rules and identify violations of company; procedures
Satisfy insurance requirements
Prevent further accidents
Define operating errors
Satisfy regulatory requirements
Provide protection against litigation
Comply with workers' compensation rules
The extent of training depends on the target groups. The training received by the new
employees and contractors is called the initial training, which includes comprehensive
classroom and practical training in the various HS E procedures applicable in the
installation. Everybody working in a industry must receive at least a basic fire fighting
training before he is assigned any work. Those already working should also receive
periodic HSE refresher training to keep them updated with any changes or
developments. Third parties like truck drivers carrying products in /out of the installation
and various vendors should also be given minimum HSE training so that they understand the
basic safety rules to be followed in the installation. Similarly, visitors should be given a
safety brief before entry into the installation so that they don't do something
unknowingly that may put themselves or others into danger. Many good companies issue
24
entry passes/ID cards to those entering the premises only after they have received the
required HSE training.
METHODOLOGY
HSE training should be a mix of theoretical classroom lectures and practical training
in the use of various fire and safety equipment and appliances. Extensive use of audio-
visual aids is used for effective training. Care should be taken to select the right
language(s) to meet the requirement of multilingual workforce. Some companies have
produced video films, which are shown to the newcomers, especially contractors, third parties
and visitors to give them basic HSE training with minimum requirement of faculty.
Training through video films can also, to some extent, minimize the language problem.
To ensure that a candidate has understood the instructions, some validation is a must. This
can be an objective type of test at the end of the session. If a candidate has not performed
satisfactorily in the test, he should go through the session once again. Records of training
and validation should be maintained.
Thorough investigation of an accident is an essential step toward the prevention of

accidental losses of our precious resources including the people, property and environment. A
good and systematic investigation is therefore an important HSE management tool.
The first step is to have a proper accident reporting system. In this direction, every
petroleum installation should make a standard procedure for notification and reporting of
any accident to the concerned officials of the installation and outside agencies. This
procedure should list the contact telephone numbers of key people. In case of any accident,
the personnel on duty should inform the concerned people as per this procedure. These
numbers should be displayed at prominent locations in the installation.
Whenever an accident takes place howsoever small, it must be investigated. Depending upon
the nature of accident, an investigation team should be set up which should go into all
details-plant data, log sheets, strip charts, historian, interviews with personnel,
photographs, videos of effected area and equipment, etc. If required, external help of a
professional accident investigator can be taken. Effects and consequence models are available
which can be very helpful in the investigation of process type of accidents. The team
25
should make an honest report so that right decisions can be taken. Many a times
investigations done by internal teams are not very objective. They tend to blame only the
hardware and design of the facilities. They are not comfortable in bringing out the human
factors and fixing accountability. If we have to learn from an accident and take proper
corrective actions to avoid recurrence, the investigation report must be frank and unbiased.
There should be a system to follow up the investigation report. Management should

establish a system to determine
and document the response to each finding of the report to ensure agreed upon actions
are completed in a time frame. The lessons learnt from the accidents should be
disseminated to all the concerned personnel in the complex. In case of multi Unit
Company, the conclusions of the investigation report s hould g o to all the units
of the company. In some cases, the information could also be shared with the
industry.
CONTRACTORS' SAFETY
Employers who use contractors to perform work in and around installations that
involve highly hazardous processes and chemicals have to establish a screening
process so that they hire and use only contractors who accomplish the desired job
tasks without compromising the safety and health of any employee at the installation.
For contractors whose safety performance on the job is not known to the hiring
employer, the employer must obtain necessary references and information on the
safety record of the contractors. In addition, the employer must ensure that the
contractor has the required job skills, knowledge and certifications (for pressure
vessels, welding, etc.). Proper safety training to contract employees should be imparted.
Maintaining a site injury and illness log for contractors is another method employers
must use to track and maintain current knowledge of activities involving contract
employees working on or adjacent to processes covered by PSM. Injury and illness logs of
both the employer's employees and contract employees allow the employer to have full
knowledge of process injury and illness experience. This log contains information
useful to those auditing process safety management compliance and those
involved in incident investigation.
26
Contract employees must perform their work safely. Considering that contractors
often perform very specialized and potentially hazardous tasks, such as confined space
entry activities, and non-routine repair activities, their work must be controlled and
properly supervised by the employer's supervisors in addition to contractor's own
supervisors.
MECHANICAL INTEGRITY OF EQUIPMENT
Every industry must review its maintenance programmes and schedules to see if there are
areas where "breakdown" maintenance is used rather than the more preferable ongoing
mechanical integrity programme. Equipment used to process, store or handle highly
hazardous chemicals has to be designed, constructed, installed, and maintained to
minimize the risk of releases of such chemicals. This requires that a mechanical
integrity programme be in place to ensure the continued integrity of the plant.
Elements of a mechanical integrity programme include identifying and categorizing

equipment and instrumentation; inspections and tests and their frequency; maintenance
procedures; training of maintenance personnel; criteria for acceptable test results;
documentation of test and inspection results; documentation of manufacturers'
recommendations for maintenance, inspection and spare parts.
PRE-STARTUP SAFETY REVIEW
Safety of a new installation is of special significance. Before starting up a new

installation after completing construction requires a comprehensive programme of pre-
startup audits/ reviews. For new processes/facilities, the employer will find a PHA helpful in
improving the design and construction of the process from safety, quality and reliability
point of view. The safe operation of the new process is enhanced by making use of the PHA
recommendations before final installation is completed. P&IDS _should be completed, the
operating and safety procedures put in place and the operating staff trained to run the
installation before startup. The completed plant and facilities are thoroughly checked by a
team(s) of plant personnel against P&IDs and specifications to ensure that the construction
has been done according to these approved drawings and specifications. The initial startup
27
procedures and normal operating procedures must be fully evaluated as part of pre-startup
review to ensure a safe transfer into the normal operating mode.
28
UNIT-II
TYPES AND SEVERITY OF ACCIDENTS
WHAT IS AN ACCIDENT?
An unplanned and unwelcomed event which interrupts normal activity
Accidents on chemical plants may hazard the process. The personnel or both research on
accidents is relevant, there fore, both to accidents which result in property damage
and those which cause personal injury.
Accident research as a discipline tends to concern itself primarily with those accidents
in which people arc involved. It is primarily concerned, therefore, with injury to personnel.
But it does involve the study of the total accident situation. Often it is a matter of chance
whether this situation hazards the process or the peop1e. Clearly accident research is
closely related to work in other fields such as human factors and, in particular, human
error.
Accounts of accident research include Occupational Accident Research (Kjcllcn, 1984),

Information Processing and Human-Machine Interaction Rasmussen, 1986),
Individual Behavior in the Control of Danger (A.R. Hale and Glendon, 1987) and
Hunan Error (Reason, 1990). Classic papers in the field are given with commentary
in the collection Accident Research, Methods and Approaches (Haddon, Suchman and
Klcin, 1964).
Much work on the subject is concerned with areas which are not of prime interest here,
such as accidents to children, accidents in the home and traffic accidents.
In addition to work on personal accidents, it is convenient to deal here briefly with some
principal research programmes oil, and test sites for, major hazards.
GENERAL CONSIDERATIONS
The development of accident research has shown that here are a number of serious pitfalls
in the investigation of accidents. There is a tendency for a particular to be studied as a
29
possible cause of accidents and there is frequently a bias in favor of this feature.
Often no information is given on any work with a control group.
This situation was contrasted with that in medical work in a classic paper by Gordon
(1949), who suggested that tile approach taken in epidemiology is applicable to
accident research. The epidemiology model, which is described below, has been
widely used in work on accidents.
DEFINITION OF ACCIDENTS
The question of what actually constitutes an accident is, worth at least brief consideration.
It has been considered by Suchnian (1961), who distinguishes three defining;
characteristics:
1. Degree of expectedness,
2. Degree of avoid ability and
3. Degree of intention.
An event is more likely to be classed as in accident if it is unexpected,
unavoidable and unintended.
Other secondary characteristics are
1. Degree of warning,
2. Duration of Occurrence,
3. Degree of negligence and
4. Degree of misjudgment.
Classification of an event as an accident is more probable if it gives little warning
and happens quickly and if there is a large element of negligence and
misjudgment.
It is suggested, however, by Suchman that as knowledge increases an event is more

likely to be described in knits of its causal factors and less likely to be classed as an
accident
30
ACCIDENT:
An undesired event that results in harm to people, property, the environment, or

corporate reputation.
INCIDENT:
An undesired event that, under slightly different circumstances, could have resulted in
harm to people, property, the environment or corporate reputation.
NEAR MISS:
An unsafe act or condition which could have led to an undesired event.
HAZARD:
A condition or practice that has the potential for resulting in accidental loss; in other words,
anything which has the potential to harm people, the environment or property.
LOSS:
Avoidable waste of any resource

Unintended harm or damage that results from sub-standard acts, practices and/or
substandard conditions;
Includes injuries, illnesses, property damage, performance interruption, quality
degradation, environmental damage, loss of reputation and profit reduction.
RISK:
Product of probability or chance of loss and consequence or severity.
Risk Evaluation:
Assessment of:
The potential severity of loss (consequences of a loss);
31
Frequency that a loss occurs (based on historical, statistical data)

Frequency of exposure to hazard(s);
CLASSIFICATION OF ACCIDENTS
Much work on accidents is concerned with accident statistics. These statistics are
base on ail accident classification of some kind. Accident classifications are
therefore quite important. Unless a classification contains a particular category
which is of interest is no means of retrieving information on it.
There are a number of standard accident classifications; these include the

classification used by the HSE in its annual Health and Safety Statistics, published in
the employment gazette used in the International Labour office. Relevant Standards are
the American National Standard Institute (ANSI)
Three basic types of accidents
1. MINOR ACCIDENTS:
Such as paper cuts to fingers or dropping a box of materials
2. MINOR ACCIDENTS:
More serious accidents that cause injury or damage to equipment or property such as a
forklift dropping a load or someone falling off a ladder
3. ACCIDENTS THAT OCCUR OVER AN EXTENDED TIME FRAME:
Such as hearing loss or an illness resulting from exposure to chemicals
Accidents have two things in common
They all have outcomes from the accident
They all have contributory factors that cause the accident
OUTCOMES OF ACCIDENTS
a. Negative aspects
Death & injury
32
Disease
Damage to equipment & property
Litigation costs
Lost productivity
b. Positive aspects
Accident investigation
Change to safety programs
Causes of Accidents
Accidents are caused mainly by:-
* Human error - 88%
* Mechanical failures - 10%
* Other factors - 02%
Majority of the accidents are caused by:
a) The things that people do or fail to do i.e. their acts or omissions.
b) Unsafe working conditions.
- Accidents involving electricity are very serious.
- About 1 in 30 of all electrical accidents are fatal
-Compared with about 1 in 600 of other types of accidents.
In the manufacturing industry, the major causes of accidents resulting in personal injury
can be grouped as follows:
1. Handling goods and materials - 27 %
2. Machinery - 17 %
3. Persons falling from a height - 15 %
4. Persons stepping on or striking
33
against objects -10 %
5. Falling objects -08 %
6. Transport -08 %
7. Hand tools -08 %
8. Miscellaneous - 07 %
OTHER CONTRIBUTING FACTORS
1. Environmental
Noise
Vapors, fumes, dust
Light
Heat
Critters
2. Design
Workplace layout
Design of tools & equipment
3. Systems & procedures
Lack of systems & procedures
Inappropriate systems & procedures
4. Human behavior
Common to all accidents
Not limited to the person involved in the accident
ACCIDENT INVESTIGATIONS
The primary function is to determine causes of accidents & to prevent its recurrence.
Therefore, it is necessary to examine the background of an accident more carefully in order
to determine why unsafe conditions were created or unsafe acts performed.
The factors emerged during such an examination may include:-
* Proper selection of workers:
34
Educational / technical knowledge,

Medical fitness history in relation to the proposed employment,
Practical ability / experience.
* Training:
To ensure
Adequate knowledge of hazards,

Safe working techniques & documentation systems.
Supervision: to ensure that there is adequate supervision by properly trained & qualified
persons.
o Correct and safe working practices are observed.

o Systems of work to ensure safe working :
o Permit to work systems.
o Safe working practices.
o Measures necessary to control hazards.
If any of these factors are missing from the background then an accident is inevitable.
THE AIM OF THE INVESTIGATION
Absolve individuals or management

Satisfy insurance requirements
Defend a position for legal argument
Or, to assign blame
The key result should be to prevent a recurrence of the same accident
The main aim of accident research is to understand accidents so that they can be
prevented. The attempt to understand an accident is often is equated with a search for
its cause.
The concept of the cause of an accident, however, has become somewhat discredited. In
accident investigation an administrative requirement to report a single cause
usually does not do justice to the complexity of the situation. In accident research
there has been much criticism of work which isolates and overemphasizes a
particular factor.
35
It is more acceptable, therefore, to regard an accident as arising from a particular

combination of factors rather hit from a single cause. there is thus a tendency to
consider relationships between variables rather than causes.
WHO SHOULD INVESTIGATE?
Dependent on severity of the accident
INVESTIGATION TEAM
Individuals involved
Supervisor
Safety supervisor
Upper management
Outside consultants
INVESTIGATION STRATEGY
Gather information & establish facts

Isolate essential contributory factors
Determine corrective actions
Implement corrective actions
Fact gathering
Be impartial & objective
Compile procedures & rules for the area
Gather maintenance records on equipment involved
Isolate accident scene
Photos & diagrams
Do not discard or destroy anything
Fact gathering (continued)
Time is of the essence
Obtain information
Injured
Witnesses
Supervisors
36
Other personnel
Interviews (separately)
What were you doing?

How do you think the accident occurred?
How were you trained for the job?
What is the safety procedure for this job?
Obtain facts not opinions
Make it clear the object of the investigation is to avoid recurrence, not
to apportion blame
Evaluates all factors concerned
Isolate essential contributory factors
Isolates the key factor(s) by asking the following question....
Would the accident have happened if this particular factor was not present?
Determine corrective actions
INVESTIGATION TEAM
Interprets & draws conclusion

Distinction between intermediate & underlying causes
Interprets & draws conclusion
Distinction between intermediate & underlying causes
Recommendations based on key contributory factors and underlying causes
Recommendations based on key contributory factors and underlying causes
Recommendation(s) must be communicated clearly
Strict time table established
Follow up conducted
BENEFITS OF ACCIDENT INVESTIGATION
Preventing recurrence
Identifying out-molded procedures
Improvements to work environment
Increased productivity
37
Improvement of operational & safety procedures

Raises safety awareness level
When an organization reacts swiftly and positively to accidents and injuries, its actions
reaffirm its commitment to the safety and well-being of its employees
COST OF ACCIDENTS
The cost of accidents remains unacceptably high both in human and in financial terms.
Time lost by absenteeism from work due to injury &

Sickness is more than strikes or other industrial disputes.
The cost of an accident can be measured in both financial & human terms. An accident,
which is apparently minor, can have a major impact on both the company & the victim,
when all related factors are considered.
A) HUMAN ASPECTS COSTS TO THE VICTIM INCLUDE :-

* Mental strain.
* Suffering.
* Loss of earnings.
* Extra expenditure.
* Possibility of a continuing disability.
* Incapacity for some kinds of work.
* Loss of leisure activities.
* Effect on family, friends and colleagues.
FINANCIAL ASPECTS COSTS TO THE COMPANY INCLUDE :-
* Loss of skilled and experienced workers.
* Loss of production.
* Loss of profit from injured workers.
38
* Expense of re-training injured worker or a replacement.
* Time lost by the effect on other workers.
* Increased insurance premiums.
COSTS TO THE NATION INCLUDE:
* The burden on welfare benefits and other social services provided by government.
* The expense / burden on medical or health services and facilities.
REASONS OF ACCIDENTS
There are many reasons of accidents. Some of the common reasons are:-
* Lack of knowledge.
* Careless attitudes.
* Horseplay.
* Working without authority.
* Lack of ability.
* Poor tools and equipment.
* Taking short cuts.
Any and all of these reasons have been the cause of many serious accidents.
Analysis of the accident will often reveal that one or more of these factors were present in
an accident.
RESPONSIBILITY OF MANAGEMENT
Therefore, the management of a company has a responsibility both moral and legal to
ensure:
1. A safe place to work. This will include safe means of access and egress during
normal daily work routine as well as in emergencies.
39
2. Safe plant and equipment including the maintenance of it.

3. Safe systems of work, including safe working practices and work permits for
hazardous jobs.
4. A safe working environment and adequate arrangements for employee welfare. This
responsibility encompasses many factors including lighting, heating, ventilation,
fume and dust extraction, housekeeping, seating, drinking water, sanitary facilities
etc.
5. Safe methods for storing, handling and transportation of goods and substances.
6. Provision of such information, instruction, training and supervision as necessary to
ensure efficient and safe working, compliance with statutory legislation and
company rules.
7. Consultation with employees, or their representatives, with a view to making and
maintaining adequate and effective arrangements for health, safety and welfare.
8. A written statement with respect to the health, safety and welfare of the employees
is produced, published and revised as often as necessay. Such a statement should be
brought to the notice of the employees, kept up to date and monitored for its
effectiveness. It should contain details of the procedures which will put the policy
into effect and define individual responsibilities for safety.
40
UNIT-III
SAFETY POLICY, ORGANIZATION, MONITORING AND REPORTING
INTRODUCTION:
The scope and limitations of various regulations on health, safety and environment have
been discussed in the previous unit. As said already, regulations alone are not enough to
maintain a very high level of safety in petroleum and allied industries, which have many
inherent hazards. In order to prevent major accidents and mishaps and to win confidence of
general public, management leadership and commitment is very essential. Even for
implementing and compliance of regulatory measures, a committed leadership is necessary.
This can be achieved by establishing an effective and efficient Health, Safety and
Environment (HSE) Management System. This unit covers the planning, organizing,
implementing and controlling functions and outlines the policy, systems and procedures of
an effective HSE management in a typical petroleum installation.
HSE MANAGEMENT PROFILE
There are certain characteristics of an integrated HSE management system that should be
in place to ensure that the system functions most efficiently and effectively. These
characteristics are sufficiently generic to apply to any type of installation. Not all
characteristics or features may be needed in every installation; however, these have
particular value as a profile of the principal requirements of an effective HSE management
system that can be adopted to suit the particular needs of the installation. Some important
features of an effective and efficient HSE management system are discussed below.
HSE POLICY
Every organization must have a written policy on health, safety and environment signed by
the Head of the organization with date. The copies of this policy should be displayed at
prominent places in the organization so that everybody is familiar with its
contents/intentions. Some organizations ensure that every employee receives a copy of its
HSE policy. HSE policy spells out the values, beliefs and commitment of the organization
towards health, safety of its employees, community and at the macro level of the nation.
41
HSE policy of a large company is given below as a typical example, which can be suitably
modified to meet specific requirements.
Health and safety of personnel and protection of environment overrides all production
targets in our organization
Production and HSE are complementary to each other
Safety and environment protection is everybody's business in the organization
All statutory requirements must be complied with at all times
All personnel must use approved safe working procedures without making any risky
short cuts
All personnel-own or contractors-must be given relevant training before assigning

them work
All plants, facilities and work procedures/ systems must be audited periodically by in-
house teams as well as external agencies
Plant and ambient environment as well as various effluents must be monitored

continuously to maintain a clean and safe environment in and around the plants
A very high standard of housekeeping must be maintained at all places of work-plants,

offices and facilities
Every employee must be subjected to a pre-employment, periodic and any specific medical
check-up for early identification and treatment of any occupational health hazard
All employees must keep abreast with the latest codes, standards and practices on health,
safety and environment
All accidents, however small, must be investigated and followed up. The lessons learnt
from these accidents should be disseminated to all levels of workforce.
No modifications in plant, facilities or procedures will be done without proper scrutiny

and approval by an authorized person(s)
42
No contractor will be engaged without ascertaining his safety performance/record
Non-compliance of this policy will attract severe disciplinary action
HSE ORGANIZATION
In order for the HSE management of an organization to be efficient and effective, it is

important that the Chief of HSE should report to the Head of the organization. HSE should
be an advisory function reporting to the top management and the various line managers
should be directly responsible for Health, Safety and Environment activities pertaining to
their respective departments. If HSE Chief occupies a junior position in the organizational
hierarchy, he cannot work without fear or clash of interest with other functional managers.
He should have authority and important say in the decision making process. Even some
regulatory agencies also recommend HSE Chief reporting directly to the Head of the
organization. HSE Chief should be a qualified engineer with long experience in various
functions. He should have a team of qualified professionals to advise on safety, occupational
health, fire protection and environment. The number of professionals in HSE will depend
on the size and diversity of the organization, but it is recommended to have a leaner set-up.
HSE organization should be fully integrated with various safety and health committees.
CUSTODIANSHIP/OWNERSHIP
Health, Safety and Environmental management are teamwork. Every member of the team
contributes in maintaining a high level of safety in his area of work. In order to manage
HSE effectively in a petroleum installation or complex which is usually a large entity it is
important and desirable to demarcate each area of the installation/complex and assign the
ownership/custodianship to a senior member of the concerned area. These areas are
commonly called safety districts. A big industrial complex may have 10-15 safety districts.
These districts should be shown on the layout drawing of the complex with all the
boundaries clearly identified and marked. The objective of safety districts is to decentralize
the HSE responsibility to the functional owner/ custodian of the area who is fully
responsible and accountable for all management functions in his district with specific
reference to control/management of health, safety and environment. HSE department acts
as a catalyst.
43
PLANS AND PROCEDURES
Plans and procedures is the heart of a good HSE management system. They are the basis of
setting up an effective and efficient management system. A large number of industrial
accidents and mishaps have occurred all over the world due to human errors and the main
cause of these errors has been the lack of written procedures and/or non-compliance of the
same. In some cases, courts have penalized the organizations because victims of the
accident did not have written procedures to be followed by them.
It is essential that well-written and approved operating and safety procedures of all
important activities/functions performed in any industrial installation are in place and the
same are strictly followed. No short cuts to these procedures should be allowed. The various
HSE related procedures should be developed broadly based on Process Safety Management
System, PSM, which is a well-known framework of HSE management all over the world. All
these procedures should be compiled in the form of an HSE manual-many times called the
HSE bible. The various procedures documented should address the following main elements
of PSM:
Process Technology Information
Process Hazard Analysis
Operating Procedures
Work Permit System
Management of Change
Training and Validation
Contractor Safety
Incident Investigation and Communication
Safety and Environment Auditing
Quality Assurance
Mechanical Integrity
44
Pre Start-up Safety Reviews
Emergency Planning and Response
Following is a broad list of typical procedures on health, safety, and fire protection and
environment functions applicable for most industrial operations. The procedures relevant to
a particular installation should be identified and documented clearly in simple language so
that everybody working in the installation understands these. These procedures should also
be accessible to all concerned. The procedures should be revised and updated periodically to
reflect changes that might have taken place over time.
Safety Related Procedures
Basic safety rules for employees, contractors and visitors

Safe work permit system
Mechanical isolation
Pre-start up safety review
Entering and working in confined spaces
Working at height
Safe scaffolding and ladders
Safe evacuation
Safe handling of hazardous substances
Safe handling of hydrogen sulfide, chlorine, ammonia etc.
Safe uses of hoses
Contactor safety
Ionization radiation safety
Traffic safety inside and outside the installation
Safe use of cranes, hoists and other mechanical devices
Safety in manual handling of material
Accident/ incident reporting and investigation
Selection and safe use of personnel protective equipment
Safe transportation of hazardous materials by road, water and rail
Management of plant changes and procedures
Safety audits
45
Personnel movement and transportation by road, cranes, basket, boats and

helicopters
Grinding, welding and cutting
Safety signages labeling and posters
Onsite emergency and disaster management.
ENVIRONMENT RELATED PROCEDURES
Air Pollution Control and Monitoring
Effluent Monitoring
Industrial Wastes Management
Biodegradable and Office Wastes Management
Fugitive Emission Monitoring
Ground Water Monitoring
Environment Inspection and Audit
OCCUPATIONAL HEALTH RELATED PROCEDURES
Health Care System
Medical Management of Obnoxious Substances
Hygiene and Sanitation
First-aid
Health Risk Assessment
Pre-employment and Regular Medical Checks
Wellness and Fitness Programme for Employees and Families
Emergency Medical Care
Basic Safety Rules for Employees, Contractors and Visitors
46
Safe Work Permit System
Mechanical Isolation
Pre Start-up Safety Review
Entering and Working in Confined Spaces
Working at Height
Safe Scaffolding and Ladders
Safe Excavation
Safe Handling of Hazardous Substances
Safe Handling of Hydrogen Sulfide, Chlorine, Ammonia, etc.
Safe Use of Hoses
Contractor Safety
Ionization Radiation Safety
Traffic Safety Inside and Outside the Installation
Safe Use of Cranes, Hoists and other Mechanical Devices
Safety in Manual Handling of Material
Accident /Incident Reporting and Investigation
Selection and Safe Use of Personal Protective Equipment, PPE
Health, Safety and Environmental (HSE) Challenges
FIRE PROTECTION RELATED PROCEDURES
Fire Services Organization and Job Specifications
Fire and Emergency Turnouts
Rescue Operations
47
Mutual Aid Scheme
Inspection and Maintenance of Fire Protection Systems
Emergency Drills and Fire Training
Safe Use of Self Contained Breathing Apparatus and 'c
Other Life Saving Devices
BASIC SAFETY RULES
Because of inherent hazards in a industrial installation, it is absolutely necessary that all

employees, contractors, visitors, vendors and other third parties must be fully aware of
some basic safety requirements to be followed inside the 'A installation. Management
should document these basic rules/., requirements and anybody entering the premises must
be made familiar with the same. This document should address following items related to
the health, safety and environment aspects of the installation:
Access/entry to the premises
Restriction on naked lights, sparks, use of cameras and mobile phones
Prohibition of smoking, alcohol and drugs

Traffic control
Use of Personnel Protective Equipment, PPE
Safe Work Permit System
Accident/Incident reporting
Maintaining good house keeping standard
Basic color codes of piping/equipment, etc.
Safety signage's
Electrical safety
Access/Entry to the premises
48
Prohibition of smoking, alcohol and drugs
Hazards of flammable products and chemicals
Emergency alarms and communication and what to do in such situations
Some general dos and don'ts
Other specific rules
BASIC RULES FOR VISITORS
As a bare minimum requirement, every visitor to the premises must be given a safety
briefing before giving him an entry pass. As an illustration, a safety briefing developed by
petroleum refinery is given below. Every installation should make a similar briefing
relevant to its operations and local conditions.
ACCESS /ENTRY TO THE PREMISES
Visitors should report to security gate for entry pass
Every person must. display a valid identification badge issued by the security
Visitor should visit the designated area only for which he has obtained the
entry pass
He should be accompanied by a company employee
It is forbidden to take children inside the premises
TOBACCO /ALCOHOL RESTRICTIONS
The entire.-refinery is a tobacco free zone
Tobacco in any form-cigarettes, biddies, gutka, etc. , is prohibited
Use of alcohol and drugs is prohibited
REGULATIONS ON NAKED LIGHTS AND SPARKS
Matchboxes, lighters, flashlights and cameras are not allowed inside the premises
49
Only intrinsically safe mobile phones are allow inside
No shoes with nails in the soles to be worn inside premises
Use of 100% nylon or synthetic clothes inside t1 premises is prohibited
TRAFFIC RULES
Vehicles should have valid access pass to enter the premises
All vehicles entering hazardous areas should have spark arrestor and a unit entry
permit
Maximum speed limit inside the premises is 30 km/hr
Park the vehicle at designated places
Overtaking is prohibited
In case of an emergency alarm, stop the vehicle and take to the side of the road and
wait for clearance.
GENERAL
Visitor shall be responsible for his own safety
Photography inside is prohibited
Never go to the site in case of any fire or other emergency
Visitor is not allowed to touch any equipment interfere with the plant activities
All persons must wear safety helmets and safe shoes in process areas. Requirement of
any other personal protective equipment will be advised by plant personnel
Use following telephone nos. in case required: Fire l00 Security 101, Medical 102
50
UNIT-IV
PROCESS SAFETY MANAGEMENT
INTRODUCTION
Process Safety Management is a regulation, promulgated by the U.S. OSHA,

intended to prevent a disaster like the 1984 Bhopal Disaster. "Unexpected releases of toxic,
reactive, or flammable liquids and gases in processes involving highly hazardous chemicals
have been reported for many years. Incidents continue to occur in various industries that
use highly hazardous chemicals which may be toxic, reactive, flammable, or explosive, or
may exhibit a combination of these properties. Regardless of the industry that uses these
highly hazardous chemicals, there is a potential for an accidental release any time they are
not properly controlled. This, in turn, creates the possibility of disaster. To help assure safe
and healthful workplaces, OSHA has issued the Process Safety Management of Highly
Hazardous Chemicals regulations.
Just as Process safety is a line management, responsibility, the same can be

said of risk management. To be able to manage this risk a coordinated program needs to be
established that will assists the line manager in his duties. This program, process safety
management, includes the following:
Process documentation
Operating Procedure
Training
Incidents Investigation
Hazard Identification
Risk Assessment
Preventive Maintenance
Management of Change
Safety Reviews
The first thing the manager must do is establish an organization to coordinate the
activities of the program. This organization must prepare standards defining the local
program. The content, as determined by the organization, must be based on the special
51
characteristics of the process including complexity, batch or continuous, and process

condition.
PROCESS DOCUMENTATION
Requirements to consider for the process documentation section include:
Process Transmittal
Engineering Calculation
Flow Sheets
P and IDs
HAZOPS
ORRs
Reaction grids
Usually these items are generated at some point during the evolution of a process
but often are not stored in an organized way so that when they are needed they are not
available.
The process transmittal is the information generated in the research and process
development. The chemistry, side reaction, corrosion testing, process development, and
reaction kinetics all are part of a process transmittal.
Engineering calculation includes reactor sizing, agitation requirements, line sizing,

heat transfer area, and other design criteria.
Flow sheets and P& IDs are the engineering diagrams generated by the design
engineers. Part of the program must be to keep these drawing up-to-date.
HAZOPs are the hazard identification reviews made during the design phase and
subsequently on approximately three year intervals.
The updating of the drawing is important to conducting a comprehensive HAZOP.
An ORR is an operational readiness Reviews which is the last look at a process

before start-up. ORR type reviews should also be done at regular intervals during the life of
the process this again assures that the process is being run correctly.
52
Reaction grids are a matrix of all the chemicals used in the process and their
interaction. They are developed as part of the HAZOP to answer the question of changing
errors.
These items, along with data generated from other parts of the program, make up
the process documentation file that must be maintained to assure a safe chemical process.
OPERATING PROCEDURES
Comprehensive written procedures serve as the basis for effective training and as a
resource for the operator. They must be kept current or their usefulness is diminished.
Procedures should be written for any job, routine or infrequent, which requires specific
skills or knowledge, which, if not followed, could result in an hazard. Procedures should be
explicit and continuous- that is, the operator response should be specified for each perceived
condition or combination of conditions.
Specifically, the following steps should be covered:
Safety and health consideration

Start up
Normal operations
Normal shutdown
Abnormal operations
Emergency shutdown
And should include :
Simplified process flow sheets

Process description defining the operation and indicating flows, temperature,
and pressure
Description of abnormal or emergency condition including operator responses
and recovery steps
Pre start-up activities including checklist to assure readiness
Start up sequences
Shutdown procedures, both normal and emergency
53
Post shutdown activities including storage of materials in equipment and

clean-out methods
description of critical equipment such as pressure relief devices, interlocks,
and alarms, with the activation level of each
Sampling procedures including sampling methodology, analytical procedures,
and sampling schedules
Maintenance preparation and inspection activities including relevant
checklists to assure completeness
MSDS sheets for all raw materials, finished products, and isolated
intermediates
Personal protective equipment requirements
Symptoms of and first aid treatment for chemical exposures
Utility failure procedures
A method for upgrading operating procedures should be developed as part of the
management of change. Otherwise they should be reviewed at least every two years
to assure that current practices are reflected.
TRAINING PROGRAMME
A formal training program must be developed to assure safe operation. All

personal involved, including management and engineers should participate in the training
program.
Included in the program are the following:
A written job description which details the duties, responsibilities, education,

experience, and qualifications of each position.
Methods to determine whether an operator has developed the ability to
perform the duties of the job.
A schedule for completing each segment of the program.
Documentation of the training.
Qualification and validation of instructors.
The training should contain, as a minimum, the following elements.
54
Site orientation including rules, practices, and safety and emergency

procedures.
Classroom training which includes unit specific safety procedures, operating
procedure, MSDSs, safe material handling practices, unit hazards, and
emergency procedures relating to process fires, explosions, or leaks.
On the job training including equipment familiarization; data collection and
recording; and process start-up, operation, control, and shutdown.
Annual refresher training that includes review of MSDSs, incidents,
procedural and equipment changes, and safety procedures.
INCIDENT INVESTIGATION
All incidents which resulted in or could have resulted in a release of toxic or

flammable materials should be investigated by a trained investigation team as soon as
possible after the incident. Additionally, all relief device release should be investigated.
The incident should be investigated timely to reduce the possibility that information
or evidence will be destroyed, altered, or forgotten during clean-up or mitigation efforts.
The incident report must be prepared for each incident and shall include;
Location
Date and time
Investigation team member
Equipment involved
Quantity of chemicals released
Employees involved
Comprehensive description of the incident
Consequences of the release
Incident facts
Cause of the incident, basic and contributory, direct or indirect
Corrective actions to prevent recurrence
Implementation schedule for corrective actions including those responsible for
completion
55
Follow up should be done systematically to assure that all recommendations are

addressed. Distribution of the report should include all other plants that have similar
operations and should be reviewed with all personal involved both operation and
maintenance.
Incident investigations should become part of the process documentation file.
HAZARD IDENTIFICATION
Identification, evaluation and control of hazards in processes are essential to loss

prevention and require a comprehensive knowledge of the chemical and physical aspects of
the unit being studied. Unrecognized hazards have been created in existing process by
changes in process conditions, operating practices, or equipment; inadequate knowledge of
reactions; or behavior of materials of construction.
An accurate assessment of the potential of each identified hazard will assure that
releases of hazardous materials and the resulting injuries and property loss will be
minimized. Sound engineering knowledge must be applied to formulate corrective
measures.
These hazard identification activities can be accomplished by trained plant personal

working with outside specialists where required. It is their responsibility to study the
P&IDs or the production unit thoroughly, identifying all the potential hazards, and
recommending changes or reviews to eliminate or control the identified hazards.
An organized approach is essential to effective and efficient process hazard reviews.

The HAZOP, qualitative fault tree, event tree, or failure modes and effects methodology all
meet this systematic requirement.
A written report of the hazard identification should be issued. Included should be:
Participants
Methodology
List of documents such as P&ID numbers and issue
Summary of the findings
Recommendations for further study
56
Follow up should be done until all items of concern are addressed through periodic
starts reports.
All hazard identification reports, status reports, and documentation should become
part of the process documentation file.
All process should be re-reviewed every two to four years based on the hazards of the
process.
RISK ASSESMENT
A risk assessment should be conducted whenever a potential release can result in a

toxic or flammable release that can affect the neighbors.
A risk assessment consists of:
An estimate of the potential release quantity

A quantitative evaluation of the frequency of the event
A dispersion model of the release
Consequence analysis of the effects of the toxic or flammable release both on and
off site
The consequences should be evaluated based on the frequency to determine if the
risk is acceptable. If is not acceptable, then recommendation must be made to
decrease the frequency or the consequences. The consequences may be lowered
by reducing the amount released, the resulting dispersion, or by mitigation
methods. The frequency can be affected by redundant equipment or by increasing
reliability.
Risk assessment should be performed by trained, experienced personal.
Again, a follow-up system to report the status of recommendations is needed.
The risk assessment, recommendation, and status reports shall be part of the
process documentation.
57
PRENTIVE MAINTENANCE
A comprehensive preemptive maintenance program is a necessary part of a total

process safety management system. The program should include;
Identification of all equipment requiring preventive maintenance.

Schedules for the inspections of vessels. These schedules should be based on
corrosion rates calculated from inspection history.
Proof-testing of critical equipment such as pressure relief devices, interlocks, fire
pumps, emergency generators, and alarms. Test methods, completion checklists,
and inspection intervals are required for this program.
Quality control procedures to ensure that fasteners, valves, and replacement
parts meet quality specification.
Any documentation of the PM program shall be part of the process documentation file.
MANAGEMENT OF CHANGE
A procedure for handling changes of process or equipment should be developed.

Included in the procedure should be:
An adequate review by all concerned personnel

Documentation of the technical basis for the change
Authorization by appropriate management
Communication of the changes and training personal in the details and
consequences of the change.
Updating of drawings and operating procedures
For temporary changes a system should be developed to track these changes and, to
then, revert to the original condition. If made permanent, the management of change
should be used.
All changes should become part of the process documentation file.
SAFETY REVIWES
Two types of reviews should be part of a Process safety Management Program. The
first is the operational readiness review (ORR) which is conducted on all new processes.
58
Recommendations resulting from the ORR must be addressed by plant management before
the introduction of chemicals.
The second type, operating plant survey (OPS) is conducted on existing processes.
The OPS includes:
Comparisons of the process documentation file to verify that plant practices

match the information.
A review of current operations versus company, regulatory, or accepted industry
practices.
All reviews also become part of the documentation file.
These are the nine elements of a comprehensive Process safety Management

Program that will provide a system to ensure an operation that will be safe and efficient.
HEALTH, SAFETY & ENVIRONMENTAL AUDIT
Statistics show that the root cause of many major accidents and mishaps all over the
world is human error. And the main cause of human errors has been the lack of
written procedures and/or non-compliance of the same. New plant facilities get
normalized over a period after meeting the initial challenges of commissioning
and stabilization. Thereafter people tend to start relaxing and the systems)
procedures/facilities are not followed as in the earlier times. Many a times
systems/procedures are not followed and hardware is not maintained, inspected
and tested as intended. Sometimes they are bypassed because of negligence,
over-confidence and complacency. Various health, safety and environment
programmes including their management systems require thorough auditing to
exercise proper control and ensure that the systems are working effectively. Such
audits are conducted periodically on the systems, procedures and operational
aspects to ensure that a desired level of health, safety and environmental
standards are maintained as per the requirements of company policy and
statutory requirements. A brief discussion on the objectives, methodology and
procedures of conducting such audits is given below as guidelines based on which each
organisation should develop its own audit programme.
59
OBJECTIVES OF AUDITS
Major objectives of audits are:
Ensure that all statutory requirements are met fully.
Ensure that set procedures are complete, up to date and compliant with
applicable standards, codes, company policies, good engineering and process
safety practices.
Ensure that the management systems in place are effective.
procedures can be strengthened.
Identif y opportunities w here the s ys tems and
Ensure that set procedures are complete, up to date and compliant with
applicable standards, codes, company policies, good engineering and process
safety practices.
Ensure that the management systems in place are effective.
Identify opportunities where the systems and procedure can be strengthened
TYPES OF AUDITS
HSE audits are broadly categorized as internal audits or external audits.
INTERNAL AUDITS
Internal audits can be periodic detailed audits of one or more plants/facilities of an

installation conducted by a multi-disciplinary team drawn from various departments of
the installation. In a company having more than one site, inter-site audits by combined
teams drawn from various sites can also be a good method of conducting internal audits.
An internal audit may take 3-4 days by a team of 4-5 professionals from different
disciplines. The audit team reviews the systems, procedures and facilities for complete
and updated documentation and their compliance. Each plant/facility of an installation
should be audited every two to three years.
60
Besides detail or comprehensive internal audits, there are mini audits. A mini safety
audit is of short duration (typically 2-3 hours) conducted by a two-men team using
checklists to ensure the compliance of a particular procedure at a time. Such audits are
done more frequently to cover various procedures relevant to the installation. This is a
very useful and quick method of finding the weaknesses/ deficiencies in the system. _
Another type of internal audits is called BSC audits. These are self-audits based on
British Safety Council's standard checklists. Each plant/department maintains these
checklists for various systems pertaining to its activities.
EXTERNAL AUDITS
The external audits are done by outside or third parties approved by statutory
authorities to meet the requirements under various statuary rules and regulations.
In leading companies, external audits are done not only to meet statutory
requirements but also to bring in a fresh approach and additional objectivity
through a third eye. It must be understood that external audits are supplementary
to the internal audits. External audits are generally mot global covering the entire
premises/installation. Some typical external audit agencies approved by various
statutory, authorities include
OISD
British Safety Council (5-star audit)
National Environmental Engineering Research' Institute, NEERI
Central Labor Research Institute, CLRI
Loss Prevention Association, LPA
National Safety Council, NSC
Engineers India Limited, EIL
Lloyds Register of Shipping
Det Norske Veritas
61
Comet Consultancy Services
Netal Chromatographs
SGS India Limited
Others as approved from case to case.
METHODOLOGY OF AUDITS
Though each external audit agency might have its o wn methodology and approach
to conduct an audit, a common methodology for conducting internal audits is given
below:
COMPOSITION/SELECTION OF AUDIT TEAM
The team for a comprehensive internal audit comprise member each from operation,
engineering/maintenance technical services/technology, HSE and any other specific
discipline if required. The chief of the installation through an office order nominates the
team.
The Chief of HSE nominates the team for a mini audit in consultation with
individual departments. The team comprises of two members-one from the
area/department to be audited and the other from HSE. The programme of such
audits is published by HSE through procedures audit schedule published by him every
month.
CONDUCTING THE AUDIT
To start with, the team gets organized and holds a kick-off meeting to discuss the
plan of action. They try to collect all relevant data of the area/plant/department they
are going to audit. The team visits the area and talks to various personnel there to
get feedback about their plant/area. The team checks the various systems/procedures
and records. The safety aspects of the plant are checked using checklists. These
checklists could be standard lists made as part of a written audit procedure and
supplemented by specific checklists made for special systems/equipment by each team
before starting the audit. Checklists are very useful as they save a lot of time and also
62
to ensure that all aspects or sub-systems have been looked into and not missed
inadvertently.
In case of mini audits, the two-man team goes to the area where audit is to be done.
The team ensures the compliance of the procedure under audit by using a standard
checklist made for the particular procedure (see some sample checklists in
Appendix-2). They check the level of compliance to each checklist item by talking to the
plant personnel and seeing the situation in the field and rate the item on a 1-5 scale
(1 is least compliant, 5 full compliance). The overall compliance level is indicated in
percentage.
AUDIT REPORT
After completing an audit, the team prepares a draft report which is presented to the
custodian/ manager of the area and his team. After discussion, the final report with action
plan for implementing the agreed recommendations is issued by the leader of the audit
team to the concerned action parties with copies to top management team.
In case of mini audits, the audited checklist is itself the report. This is issued to the
concerned custodian/manager of the area immediately on the same day after the
audit is done.
FOLLOW-UP
The effectiveness of the audit lies in the degree o implementation of the agreed
recommendation. Therefore it is essential to monitor the implementation programme
HSE plays a pivotal role in monitoring the recommendation; of various audits and
presenting the implementation statutory to the top management. Record of an
audit report is maintained with the custodian and HSE till all the
recommendations agreed to be implemented are liquidated
63
UNIT-V
EMERGENCY/DISASTER MANAGEMENT PLAN
INTRODUCTION
Disasters are major accidents which cause wide spread disruption of human and
commercial activities. Normally, common accidents are absorbed by the community, but
disasters are major accidents and community cannot absorb them with their own
resources. Most of the disasters, natural or technological (man made) have sudden
onset and give very short notice or not item to prevent the occurrence. Disasters
may cause loss of human life, injuries and long term disablement of people working in
the organization and local community around the industrial area. Normally, loss of
lives, total or partial disability have more impact on the community than damage to the
properties. Damage to the property has a long term social impact like loss of revenue,
employment and rebuilding cost and lead to sever economic constraints.
The likelihood of disaster need be foreseen, as the past experiences indicate.

Therefore, if disasters are foreseeable, the mitigating efforts can be planned in
advance. Paramount in importance should be given to protect human life and
environment, in such planning.
In spite of hazardous industries are following sound design, engineering and management
practices, the possibility of a major accident or disaster cannot be ruled out. The threat
of a major fire, explosion, toxic release or natural disasters involving employees,
property, public and environment is always there. When an emergency situation
like this develops, it is necessary that a concise and well-written emergency plan
should be in place in every installation which can be put into action without loss of any
time. Most of the emergency situations can be controlled by careful evaluation of the
anticipated possible events and evolving a plan to meet such situations and organize
suitable drills or rehearsals for effective implementation at the time of emergency.
64
DEFNITION OF EMERGENCY:
The type of emergency primarily considered here is the major emergency which may
be defined one which has the potential to cause serious danger to persons and /or damage to
property and which tends to cause disruption inside and /or outside the site and may require
the use of outside resources.
Emergency is a general term implying hazardous situation both inside and outside the
factory premises. Thus the emergencies termed "on-site" when it confines itself within the
factory even though it may require external help and "off-site" when emergency extends
beyond its premises. It is to be understood here, that if an emergency occurs inside the
plant and could not be controlled, it may lead to an off - site emergency.
EMERGENCY PLANNING:
A major emergency in a works is one which has the potential to cause serious
injury or loss of life.
May cause serious disruptions both inside or outside the works

A major emergency can develop due to failure of operating and containment systems or
due to natural disasters like cyclones, earthquakes, floods, lightning, etc. In case of
natural disasters, not much can be done to avoid their occurrences, but a good
disaster/emergency plan can minimize the casualties and damages by well
conceived evacuation, rehabilitation and clean-up programmes.
ACTIVITIES THAT CAN REDUCE THE RISK OF ACCIDENTS:
Good Design
Good Operation
Good Maintenance
Good Inspection
BASIC OF MAJOR EMERGENCY MANAGEMENT PLAN
A major emergency plan also called On-site Emergency Plan or a Disaster Management
Plan is a master plan containing the emergency response, responsibilities of key
members, communication means and response strategies to control a range of major
65
incidents. The word "disaster" refers to those emergency situations where the number
of casualties is very large like in natural calamities. However, the term is used quite
broadly for any major emergency. This plan is drafted after a careful analysis and
assessment of various risks associated with the installations. The plan should also
follow the provisions of Section 41-B of the Factories Act, 1948 and the guidelines from the
Chief Inspector of Factories of the state. OISD also gives guidelines for developing an
emergency plan.
The civic authorities of the area usually prepare disaster plans for emergency situations
outside the premises. The management of the installation should give full cooperation to
the civic authorities in preparing what is called as Off-site Emergency Plan. This is
of importance especially in case of emergencies arising during transportation of
petroleum and other hazardous products from/to an installation.
OBJECTIVES OF EMERGENCY PLAN
The overall objectives of a major emergency management plan are summarized as below:
To localize the emergency and if possible eliminate it or to minimize the effect of accident
on people and property.
To contain and control emergency incidents.
To prevent loss of life and minimize the risk of bodily injuries to employees and
neighboring population.
To minimize damage to company installation and public property.
To minimize impact on environment.
To provide maximum possible safety to the emergency response personnel.
To inform employees, public, and authorities about the risks assessed, safeguards
provided and role of the organization.
To dovetail properly with the off-site plan of the local authorities.
To seek help from the company's corporate office, sister companies and outside agencies.
66
EMERGENCY/DISASTER SCENARIOS
Every petroleum installation should identify the possible major emergency situations
for which a disaster plan has to be made. A list of probable emergency scenarios applicable
to petroleum installations is given below:
Fire
Explosion
Toxic Release
Blow-out
Drowning
Oil spill on water
Oil spill on land
Cyclone/Storm
Earthquake
Flood
Air raid
Product/Transport emergency
CATEGORIZATION OF EMERGENCIES
As a general practice, emergency situations are categorized into three levels depending
upon their magnitude and consequences. These levels are:
LEVEL-1
The emergency situation arising in any section of one particular plant/area which is
minor in nature and can be controlled within the affected section itself with the help of
in-house shift staff. Such an emergency does not have the potential to cause serious
67
injuries or damage to property, environment and the domino effect to other sections of
the installation.
LEVEL-2
The emergency situation arising in one or more plants/areas which has the potential to
cause serious injuries, property loss and/or environmental damage in the installation. Such
an emergency situation always warrants to mobilize all the resources available in-house
and /or outside to mitigate the emergency. The impact of this level of emergency is however,
within the installation.
LEVEL-3
If level-2 emergency by virtue of its consequences can spread and affect the nearby
community outside the premises, it is termed as level-3 emergency.
ON-SITE EMERGENCY PLANNING
a. FORMULATION OF PLAN AND EMERGENCY SERVICES:
They are site specific. They should include the following elements.
Assessment of nature of extends of hazard or accidents.
Formulation of plan and lioson with outside authorities.
Procedures
Raising the alarm

Communication both within and outside works
Appointment of key personnel
Works incidents controller

Works main controller
EMERGENCY CONTROL ROOM
Action on-site
Action off-site
68
ELEMENTS OF A MAJOR EMERGENCY MANAGEMENT PLAN
A good and effective emergency or disaster plan should have the following elements:
Emergency Organisation with responsibilities of key members
Key Members and their contact numbers
Emergency Control centre
A brief explanation of these elements is given below which can be helpful in preparing
disaster plan of any installation.
b. ALARM AND COMMUNICATION MECHANISM:
Communication is a crucial factor any employee should be able to raise the

emergency alarms so that action can be taken immediately.
C. APPOINTMENT OF PERSONNEL
The site or works incident controller responsibilities include.
To assess the situation

To invite emergency procedure
To divert rescue and firefighting control fire brigade activities.
To search for casualties to arrange evacuation of non -essential
persons
To set up communication with emergency control centre
To ensure the responsibilities of site main controller until he arrives,
the site main controller often chosen from senior management has
the responsibility of diverting from emergency control centre. After
retiring the incident controller for overall control.
Emergency Organization and Responsibilities of Key Members
Management of a major emergency in an installation requires a well-coordinated

team with a senior member of the installation acting as head of the emergency team.
He is called the Chief Emergency Commander. An organogram of the emergency
management team showing the reporting of various key members should be made.
69
The responsibilities of each key member should be clearly written and made
known to the member. The members should be made familiar with their roles by
regular drills/rehearsals as explained later on.
KEY MEMBERS AND THEIR CONTACT NUMBERS
A key member for coordinating each of the following functions of an emergency

should be identified:
i. Operations
ii. Security
iii. Medical
iv. Rescue/Evacuation
v. Human Resources
vi. Emergency Maintenance and Repairs
vii. Emergency Materials
viii. Technical and Engineering Services
ix. Transportation
x. Public Relations
A list showing the contact telephone numbers of all the key members should be made
which should be regularly updated to incorporate any changes. This list should be
available to each member to be kept handy in his wallet.
EMERGENCY CONTROL CENTRE
An emergency control centre in a safe place in the installation should be

identified. This centre should be equipped with necessary communication
equipment-telephones, walkie-talkies, VHF radio sets, mobile phones, etc. and
essential documents of the installation. The chief emergency commander and most
of the emergency team members will operate from this centre.
70
EMERGENCY COMMUNICATION
A reliable system of informing the various people in the installation should be in

place. This can be a siren or an alarm system, which is audible in the whole
installation. VHF radio can be used to communicate the emergency situation to
civic authorities and other outside agencies, which need to be informed of the
emergency who have already become the victims of the emergency. Alternate
locations for housing the evacuees should be identified. A safe assembly point should
be identified for each plant/area in the installation where people not required during
the emergency will assemble from where they can be easily taken out to alternate
locations. This aspect of the emergency plan is very critical during natural disasters
when a large-scale evacuation/rescue is called for.
END OF EMERGENCY
The plan should identify the arrangements for declaring the end of emergency. There
should be a proper siren/ alarm to be given under the direction of the Chief
E m e r g e n c y C om m an d e r t o d e c l ar e t h e e n d of emergency.
EMERGENCY RESOURCES
The plan should include lists of important consultants/ agencies from whom additional
help could be obtained in case required during emergency situations. Lists of important
suppliers and vendors of medicines, safety equipment, fire fighting equipment and
materials, pollution control equipment and consumables, etc. should also be
included. All the information on emergency resources should be nicely compiled in
the annexure to the emergency plan.
MOCK DRILLS.
The emergency plan should be rehearsed regularly by conducting mock drills

to keep the emergency team members refreshed with their roles during an
emergency. Based on the weaknesses or shortcomings observed during the
mock drills, the emergency plan should be updated. As required by the statutory
authorities, mock drill of a major on-site emergency plan should be conducted at least
once every year. Organization may opt for more frequent drills.
71
MUTUAL AID
Some times the internal resources of an organization may not be adequate to handle a
major emergency situation. In such situations, external help can be sought from
the neighboring units and government agencies. A written agreement s hould
be made w ith the neighboring organizations in the area to help each other with
additional resources in case of any emergency situation arising in their installations.
The contact numbers for all these organizations should be available with each
organization. Regular mock drills should be conducted to check the response of
the mutual-aid members. Tariff advisory committee (TAC) allows certain rebates in
the insurance premiums to those organizations which are members of the local
Mutual aid schemes.
Some industrial areas like Vadodra; Mumbai, Ankleshwar etc. have very effective
mutual aid schemes. Member industries in each of these areas have pooled their
resources to set up a round the clock emergency/disaster management control room in
the area, which coordinates the mutual aid efforts of various agencies involved.
Besides rendering mutual aid to each other in case of on-site emergencies, these
control rooms have also helped in many off site emergencies like road accidents
involving vehicles carrying hazardous goods, gas leaks, etc.
EMERGENCY INVENTORIES
It is necessary for every installation to maintain a minimum inventory of various

emergency consumables and equipment for fire fighting, medical, pollution control and
safety. A list of these inventories should be a part of the emergency plan. Regular
physical check of stock levels of these inventories should be done against this list
and immediate action should be taken to replenish them if required.
In spite of all the precautions and safe procedures followed, the chance of an
emergency arising in a industrial operation cannot be ruled out. Therefore a good
written emergency/disaster management plan should be in place. This unit
discussed important guidelines for making emergency plan specific to your
installation. The importance of rehearsing this plan periodically was also discussed.
72
UNIT-VI
FIRST AID:
First aid may be defined as skilled assistance to the victim in case of accidents or sudden
illness. The person who renders skilled assistance is called the First Aider.
First aid is primarily a temporary measure to arrest the worsening of victims condition till
arrival of a doctor. This first aid is no substitute for treatment by a qualified doctor, which
must be sought at once.
it is very important that one should get immediate treatment for every injury, regardless
how small you think it is.
Many cases has been reported where a small unimportant injury, splinter wound or
puncture wound, quickly led to infection, threatening the health and limb of the employee.
Even the smallest scratch is large enough for the dangerous germs to enter, and in large
bruises or deep cuts , germs comes in by the millions. Immediate examination and
treatment is necessary for every injury.
The health and safety (First Aid) Regulations 1981 require from the owner of the plant to
provide adequate and appropriate equipment, facilities and personnel to enable first aid to
be given to the employees. If they are injured or become ill at work.
What is adequate and appropriate will depend on the circumstances in the workplace and
in general first aid needs are:
The minimum first aid provisions on any work site are:
A suitably stocked first aid box
An appointed person to take charge of first aid arrangements
It is important to remember that accidents can happen at any time . First aid provision
needs to be available at all times people are at work,
73
Many small firms will need to make the minimum first-aid provision. However, there are
factors which might take greater provision necessary. The following checklist covers the
point you should consider.
GENERAL CONTENTS OF FIRST AID BOX:
There is no standard list of items to put in a first aid box. It depends on what you assess the
needs are. However, as a guide, and where there is no special risk in the workplace , a
minimum stock of first aid box should contain:
1. A leaflet giving general guidance on first-aid e.g. HSE leaflet basic advice on first-
aid at work.
2. 20 individually wrapped sterile adhesive dressings
3. Two sterile eye pads
4. Four individually wrapped triangular bandages.
INSTRUCTIONS TO FIRST AIDER:
1. Gather information as to how the accidents or illness came about.

2. Look for signs such as swelling, bleeding and immobility etc.
3. Looks out whether victims feels nausea, cold, pain etc.
4. Pay special attention to severe bleeding , failure of breathing and shock.
5. Arrange for speedy removal of victim to proper medical care.
DOS & DONT OF FIRST AID:
Do the first thing first quickly, quietly and calmly

Stop severe bleeding if any
Administer artificial respirators if required and continue it till doctor arrives.
Treat for shock
Boost up the morals of victims
Avoid crowding around victims
Unless required dont remove clothes
Dont try to achieve too much
Dont soak victim to wake him up.
Unless victim complains of cold , dont rap with blanket or coat.

74
REPORT ALL INJURIES TO YOUR SUPERVISOR:
As with getting medical attention for all injuries, it is equally important that you report
all injuries to your supervisor. It is critical that the employer check into the causes of
every job-related injury, regardless how minor, how it happened. There may unsafe
procedures or unsafe equipment that should be corrected.
FIRST AID FOR SPECIFIC ACCIDENT OR ILLNESS:
TREATMENT FOR SHOCK:
1. Keep patient warm

2. Keep head lower than feet
3. Cover with blankets or coat
4. Give hot coffee or hot tea
TREATMENT FOR SUNSTROKE:
Measure temperature with a clinical thermometer
If the temperature is high put the naked victim into a tub of cold water or gave full bath
or apply wet sponge over his body
If there is a rise in temperature apply ice bag or clothes wing in cold water.
TREATMENT FOR ORDINARY WOUNDS:
1. Prevent touching of wound

2. Dont apply ordinary water since it may contain infectious germs
3. don;t use strong antiseptics like dichloride or mercury on carbolic acid
4. Cover the wound with several layers of sterile gauze and bondage firmly but not
tightly
5. Call the doctor as early as possible.
TREATMENT FOR ACID AND ALKALI BURNS:
1. Wash off which copious amount of clean water

2. Place several layers of clean water over burn. Saturate with 5% tannic acid if
available and apply bandages
75
3. For serious burns on body remove all clothing carefully and treat it.
4. If there are signs of collapse keep the victim warm and give sips of warm offer or
warm tea , if not unconscious.
TREATMENT FOR GAS POISIONING:
1. In all cases of gas poisoning, call the doctor at once.

2. Remove victim to fresh air if possible
3. Put the victim on a bed in a comfortable position that he is quite & conscious.
4. In case of unconscious victim is having difficulty in breathing, administer artificial
respiration at once.
FIRST AID FOR POISONS:
These are few instructions in case of poisoning.
Administer 4 or more glasses of an emetic ( salt & Luke warm water or soapy warm
water)
NOTE: do not induce vomiting if poison is corrosive
FIRST AID FOR POISONS:
1. Induce the vomiting by putting the finger down the victims throat.
2. Administer the antidote if you know the exact cause.
3. After emptying the stomach and cleaning it give a soothing drink such as milk or
water.
4. In case the patient is weak and faints he should lie down without pillow and should
drink coffee or tea. He may use smelling salt
5. Induce the vomiting by putting the finger down the victims throat.
6. Administer the antidote if you know the exact cause.
7. After emptying the stomach and cleaning it give a soothing drink such as milk or
water.
8. In case the patient is weak and faints he should lie down without pillow and should
drink coffee or tea. He may use smelling salt
FOLLOW THESE INSTRUCTIONS FOR UNCONSCIOUSNESS PATIENTS:
Dont feed anything into the mouth
76
Dont cause vomiting

Keep patients in lying position on left side and keep head low
Remove chewing gum, tobacco or other foreign objects from mouth
If patients is not breathing, place in prone position and apply artificial respiration
Keep patients warm
If breathing is shallow or skin, lips Cass finger, nail beds are blue give oxygen with
CO2 or commercial oxygen.
If poison is unknown give the universal antidote but only after the patients regains
consciousness.
ARTIFICIAL BREATHING:
If breathing is stopped artificial respiration should be applied immediately to restore

the normal breathing and prevent death- by means of artificial respirator, breathing is
re-established.
First of all clear the passage by pinching for a movement and clearing it by
handkerchief. Remove foreign object if any .
MOUTH TO MOUTH METHOD:
The patient is laid on his back with his head is slightly sloping down, a pillow or rolled
coat placed under his shoulders. The head is tilted so that the lower jaw is higher than
the upper jaw. The patients mouth is opened after a deep breath; the helper places his
mouth over the victims mouth making air tight contact. Patients nose is pinched and
patients mouth is blown till his chest rises. The helpers mouth is removed for the
victims to exhale. The first 8-10 breaths are as rapid and thereafter rate is slowed down
to 12-15 times a minute.
ARTIFICIAL RESPIRATOR:
Artificial respirator consists of a rubber balloon, a special valve and mouth piece tubing.
The mouth piece is cupped on the patients mouth for the artificial respiration. During
inhaling balloon is defatted into patients mouth, upon release, the balloon gets inflated
from atmospheric air entering via the valve. The process is continued till the normal
breathing is restored.
77
EXTERNAL CARDIAC MASSAGE:
If the patients pulse is not felt, heart beat has stopped; in such a case external cardiac
massage is applied.
The injured person is laid on his back on a firm surface and knelled at his side.
The heel of one hand is placed on the lower half of the persons sternum.
Other hand is placed on the top of the first hand and downward pressure is exerted
till the bones dip by 1.5 inches.
Then the pressure is released. This cycle is repeated 60 times.
UNIVERSAL ANTIDOTE:
Universal antidote is a glass of water a heaping teaspoon full of two parts of activated
charcoal, one part of magnesium oxide, one part of fullers earth and one part of tonic
acid, if any body is not able to is not able to prepare an antidote, give an emetic of
induce vomiting.
To prevent collapse or shock keep the victim warm , quite and lying position with head
low. If there is consciousness give strong tea, or coffee. Give smelling salts or aromatic
sprits of ammonia may be inhaled.
TREATMENT FOR SPECIFIC POISONS:
ALKOLLOID POISONS:
Observe general instructions for poisons, use universal antidote.
CARBON-DISULPHIDE:
Give a mixture of 93% O2 and 7% CO2 or oxygen. In case of breathing, failure use
artificial respiration.
BENZENE:
If swallowed, follow general instructions for poisoning, if inhale administered oxygen.
78
METHYL CHLORIDE:
Administer O2, use artificial respirants . For skin contact use cold water. Dont use
distilled grease.
SULPHUR-DIOXIDE:
Administer oxygen. In case of breathing failure use artificial respiration.
WHEN TO CALL FIRST AIDER
Any life threatening or injury situation

If you are light headed and think you may lose consciousness
Alone in the facility and seriously injured
When someone is injured seriously
Any time there is an injury or when someone may need First Aid or CPR
Any time someone is feeling ill or needs to use the First Aid room
If you notice any type of irregular behavior in your coworker
If any non Trane employee changes behavior dramatically
GET HELP AS QUICKLY AS POSSIBLE BE AWARE OF YOUR OWN
CONDITION
1. Are you dizzy ?

2. Light headed?
3. Chilled and sweating?
4. Shortness of breath ?
5. Pain in center of chest spreading to neck, shoulder or arms?
6. Something gets caught in your throat
7. Sudden weakness/numbness of the face
8. Loss of speech / trouble talking or understanding speech
9. Sudden severe headache
10. Are you diabetic? eating or checking you blood sugar?
11. Are you allergic to certain things / been stung by a bee before?
79
Unit-VII
SAFETY OFFICER ROLE & RESPONSIBILITY
SPECIFIC HEALTH AND SAFETY ROLES:
(a) HR Health and Safety Advisory Services , Staff of HR Health and Safety Advisory
Services develop policy, advise managers, health and safety committees, staff and labour on
workplace health and safety matters, audit health and safety performance, provide training
courses and coordinate health and safety programs for installation as a whole.
(b) Workplace Health and Safety Officers (WHSO's) and Workplace Health and Safety
Representatives (WHSR's)
It is recommended that managers nominate at least one Workplace Health and Safety
Officer (WHSO) and encourage the election of at least one Workplace Health and Safety
Representative (WHSR) in their area of authority.
Workplace Health and Safety Officers (WHSOs) are nominated by management to advise
managers and anyone who supervises others on aspects of the Workplace Health and Safety
Act (coupled with local knowledge) on a day-to-day basis. These persons are not health and
safety specialists and the role is generally secondary to their usual job.
The statutory function of a WHSO is to
describe the overall state of health and safety for a section

conduct regular inspections of the work area
report hazards or unsafe practices
establish educational programs
investigate or assist with investigation of accidents, illnesses and injuries
report such events to HR Health and Safety Advisory Services
assist with the annual review/audit of health and safety management
Help an inspector in the course of their work.
Workplace Health and Safety Representatives (WHSRs) are elected by co-workers to act as
their representative in health and safety matters. WHSRs are entitled to
inspect their work area weekly or as negotiated with the employer
80
be advised of work caused injuries, illnesses or dangerous events

be present at worker interviews if asked by a worker
review circumstances of injuries, illnesses and events and make recommendations
be consulted on changes proposed to workplace, plant or substances that may affect
health and safety
help in health and safety issue resolution
be advised when an inspector is at the workplace (WHSR area)
report health and safety issues to WHSO or employer
seek co-operation in remedying the issue or report to an inspector
report previous issues/hazards unsatisfactorily completed.
WORKPLACE HEALTH AND SAFETY COMMITTEES:
Workplace health and safety committees are identified by the Workplace Health and Safety
Act as the preferred mechanism for facilitating consultation between management and staff
with the aim of preventing injuries and illnesses. Workplace health and safety committees
should seek to
encourage and maintain at the workplace an active interest in health and safety
consider measures for training and educating persons at the workplace about health
and safety issues including documented local safety inductions
tell workers about the formulation, review and distribution (in appropriate
languages) of standards, rules and procedures about health and safety
review circumstances surrounding work injuries, work caused illnesses and
dangerous events referred to the committee for review having regard to the legal
definitions of those terms (see Workplace Health and Safety Act 1995 - Schedule
Three Dictionary)
tell the employer of the review results and make recommendations arising out of the
review help in the resolution of issues about workplace health and safety.
SAFETY OFFICER RESPONSIBILITIES
COMMON RESPONSIBILITIES
The following responsibilities
Provides guidance on industrial safety compliance and technical subjects
81
Coordinates or provides training on occupational health and safety requirements

Requests information and clarification on regulatory requirements from EH&S
Assists EH&S in evaluating program effectiveness
Assists in responding to any regulatory actions or investigations
Communicates department manager/chair and MSO on Industrial safety and
injury/illness prevention efforts and activities
Participates in the development of the Department Emergency Operations Plan
(DEOP)
Provide equipment, materials and protective devices, and shall maintain them in good
condition .
Ensure the measures and procedures prescribed are carried out in the workplace.
Provide information, instruction, and supervision to employees to protect their health
or their safety.
Ensure that when appointing supervisors, they are competent with respect to their
responsibilities.
Afford assistance and co-operation to the Occupational Health and Safety Committee
or any of its members in discharging their responsibilities .
Provide the Occupational Health and Safety Committee with the results of reports
prepared respecting occupational health and safety.
Advise workers of the results of occupational health and safety reports.
Safeguard workers from undue exposure to biological, chemical or physical agents as
prescribed .
Provide workers with written instructions as to the measures and procedures to be
taken for the protection of employees.
Carry out training programs for employees, supervisors and committee members as
may be prescribed .
Beside this the other responsibilities are
Receive assignment, notification, reporting location, reporting time, and travel
instructions from your home agency.
Upon arrival at the incident, check in at designated check-in locations. Check-in
locations may be found at: Incident Command Post, Base or Camps, Staging Areas,
Division Supervisors (for direct line assignments).
82
Agency representatives from assisting or cooperating agencies report to .

All radio communications to Incident Communications Center will be addressed:
"(Incident Name) Communications".
Use clear text and in all radio transmissions.
Receive briefing from immediate supervisor.
Acquire work materials.
Organize, assign, and brief subordinates.
Ensure continuity using in/out briefings
Respond to demobilization orders
SPECIFIC RESPONSIBILITIES
The Safety Officer is responsible for monitoring and assessing hazardous and unsafe
situations and developing measures to assure personnel safety.
The Safety Officer will correct unsafe acts or conditions through the regular line of
authority, although the Safety Officer may exercise emergency authority to prevent
or stop unsafe acts when immediate action is required.
The Safety Officer maintains awareness of active and developing situations.
The Safety Officer ensures the Site Safety and Health Plan is prepared and
implemented.
The Safety Officer ensures there are safety messages in each Incident Action Plan.
Only one Safety Officer will be assigned for each incident, including incidents
operating under Unified Command and multi-jurisdiction incidents. The Safety
Officer may have assistants, as necessary, and the assistants may also represent
assisting agencies or jurisdictions.
During initial response, document the hazard analysis process, hazard
identification, exposure assessment and controls.
Participate in planning meetings to identify any health and safety concerns inherent
in the operations daily work plan.
Review the Incident Action Plan for safety implications.
Exercise emergency authority to prevent or stop unsafe acts.
Investigate accidents that have occurred within incident areas.
Ensure preparation and implementation of Site Safety and Health Plan (SSHP)
83
Assign assistants and manage the incident safety organization.

Review and approve the Medical Plan
Maintain Unit/Activity Log.
FUNCTIONS OF THE SAFETY STAFF
Site Safety Officer Assistant:
Provide assistance to the Safety Officer. Ensure all Safety functions continue when
the Safety Officer is attending meetings.
Site Safety Plan
Draft initial emergency response site safety plan. Ensure copies get distributed as
soon as possible to staging areas and field personnel.
Receive reports from Site Safety Enforcement Assistant and incorporate changes
into the site safety plan.
Ensure site safety plan is completed in time to be incorporated into Incident Action
Plan.
Review Medical Plan and forward to the Safety Officer for signature.
Review Incident Action Plan. Ensure plan provisions are in compliance with 29 CFR
1910.120. Review HAZWOPER (Hazardous Waste Operations and Emergency
Response Standard) Compliance Checklist to ensure requirements met.
Site Safety Enforcement:
Enforce site safety plan on scene.
Use site safety enforcement log and ensure completion in time for updating new site
safety plan for next operational period.
Terminate all imminently dangerous operations immediately. For other non-time
critical safety hazards contact the Safety Officer for termination guidance.
Attend morning field safety briefings at Staging Areas and assembly points to ensure
site safety plan was covered.
RESPONSIBILITIES OF TOP MANAGEMENT
Keep informed of the health and safety needs of employees under their authority;
Initiate necessary preventive measures to control health and safety hazards associated
with activities under their authority;
84
Incorporate preventive measures in all functions and activities in which there may be
some incident or accident with health-related consequences;
Ensure that their supervisory personnel are aware of their health and safety
responsibilities and that they provide proper information and instructions to individuals
under their supervision;
Provide safety training opportunities for all their personnel;
RESPONSIBILITIES OF SUPERVISORS AND PRINCIPAL INVESTIGATORS
Supervisors and principal investigators or anyone who has charge of a workplace or
authority over other employees must show due diligence in the application of health and
safety measures in general; in particular they must also:
Keep informed of the health and safety regulations applicable to the employees
under their authority;
Initiate necessary preventive measures to control health and safety hazards
associated with activities under their authority;
Incorporate preventive measures in all functions and activities in which there may
be some incident or accident with health-related consequences;
Ensure that employees under their authority work in the manner and with the
protective devices, measures and procedures .
Ensure that employees under their authority use or wear the equipment, protective
devices or clothing required,
RESPONSIBILITIES OF EMPLOYEES
The responsibility for health and safety lies with all University personnel in the
performance of their duties. In addition, the following particular requirements must be
adhered to by all Industry employees:
Work in compliance with the provisions of the OH&S Act and all health and safety
procedures and instructions;
Use or wear the equipment, protective devices or clothing that the industry requires
to be used or worn and report to their supervisors the absence of or defect in any
equipment or protective device of which they are aware and which may endanger
themselves or other employees;
Report to the appropriate supervisory staff all known health and safety hazards or
any violation of the OH&S Act or its regulations;
85
Not use or operate any equipment, machine, device or thing or work in a manner
that endangers themselves or other employees and not remove or make ineffective
any protective device required by the regulation or by the industry, without
providing an adequate temporary protective device; when the need for removing the
protective device has ceased, the original protective device shall be reinstalled
immediately;
Not engage in any prank, contest, feat of strength, unnecessary running or rough
and boisterous conduct or otherwise endanger their co-workers or themselves;
TRAINING
The Industry must ensure that workplace-specific and mandatory training is
provided to employees to conduct their activities safely.
Employees are required to attend mandatory training sessions related to their work
environment.
Units where health-and-safety-related training has been provided will maintain up-
to-date data bases regarding the training provided (centrally or locally).

WORKPLACE HAZARDOUS MATERIALS INFORMATION SYSTEM (WHMIS)
o All employees exposed to or likely to be exposed to, a hazardous material or to
a hazardous physical agent must receive and participate in instruction and
training regarding the use, storage, handling and disposal of these materials.
o Top management is responsible for ensuring that all legally required systems
and procedures are in place with respect to WHMIS. In particular, they must
ensure that material safety data sheets are available and up-to-date, for
consultation by all employees exposed to or likely to be exposed to hazardous
materials or who must handle such materials that all hazardous materials in
the workplace are identified in the prescribed manner.
o If material safety data sheets are accessible on a computer terminal at a
workplace, top management and principal investigators shall take all
reasonable steps necessary to keep the terminal in working order give a
worker a copy of the material safety data sheet upon request; and teach
committee members and employees who work with or close to hazardous
86
materials how to retrieve the material safety data sheet on the computer
terminal.
o Employees who are exposed to or likely to be exposed to, a hazardous
material or agent have the responsibility of consulting material safety data
sheets for these materials.
REPORTING AND INVESTIGATION OF INCIDENTS AND ACCIDENTS
The supervisor must advise Protection Services immediately after a serious or
critical injury or fatality, or after accidents and incidents involving chemicals,
biological or radioactive substances and physical agents, including accidental spills
and emissions both inside and outside the workplace. The Occupational Health and
Safety Officer must notify the Ministry of Labor immediately after a critical injury
or a fatality and must send a written report to the Ministry of Labor within 48 hours
or its occurrence.
All accidents, fires, and other potentially serious incidents (e.g. spills, emissions)
must be entered on an Accident, Incident or Occupational Disease Report, and the
supervisor must submit the report to the Occupational Health, Disability and Leave
Sector within 24 hours of the occurrence.
Responsibility for investigating and for taking appropriate actions against
recurrences lies primarily with the dean or director concerned. The Occupational
Health and Safety Committee may assist when necessary and will make appropriate
recommendations for corrective actions to the dean or director involved. In cases of
critical injury or death, the Occupational Health and Safety Committee may
investigate and inspect the workplace where the accident occurred. This must be
done according to the industry Investigation Guidelines Following a Work-related
Accident or Incident.
87
UNIT-VIII
Major Disaster
PIPER ALPHA
Introduction:
The Piper Alpha Oil Platform was owned by a consortium consisting of Occidental
Petroleum (Caledonia) ltd, Texaco Britain ltd, International Thomson plc and Texaco
Petroleum Ltd and was operated by occidental.
The Piper Alpha Platform was located in the piper field some 110 miles north-east of
Aberdeen. The piper platform separated the fluid produced by the wells into oil, gas and
condensate .the oil was pumped by the pipeline to the Flotta oil terminal in the Orkneys
,the condensate being injected back into the oil for transport to shore .The gas was
transmitted by pipeline to the manifold compression platform MCP-01 (manifold
compression platform),where it joined the major gas pipeline from the Frigg field to St
Fergus.
There were two other platforms connected to Piper Alpha. Oil from the Claymore Platform,
also operated by the Occidental was piped to join the Piper oil line at the Claymore.
Claymore was short of gas and was therefore connected to Piper Alpha by a gas pipeline so
that it could import Piper gas. Oil from Tartan was piped to Claymore and then to Flottta
and gas from Tartan was piped to Piper and then to MCP-01.
The production deck level consisted of four modules A-D.A module was wellhead, B
module the oil separation module, C module the gas compression module and D Module
the power generation and utilities module.
There were fire walls between A and B Modules, between B and C modules, and
between C and D modules (the A/B,B/C, and C/D firewalls respectively); these firewalls
were not designed to resist blast.
At 10 pm on 6 July 1988 an explosion occurred in the gas compression module of the Piper
Alpha oil production platform in the North Sea. A large pool fire took hold in the adjacent
oil separation module, and a massive plume of black smoke enveloped the platform at and
88
above the production deck, including the accommodation. The pool fire extended to the deck
below, where after 20 min it burned through a gas riser from the pipeline connection
between the Piper and Tartan platforms .The gas from the riser burned as a huge jet flame
.Most of those on board were trapped in the accommodation .The lifeboats were inaccessible
due to the smoke .Some 62 men escaped, mainly by climbing down knotted ropes or by
jumping from a height, but 167 died, the majority in the quarters. The Piper Alpha
explosion and fire was the worst accident which has occurred on an offshore platform.
Following the disaster a public inquiry was set up under the public inquiries
regulations 1974 presided over by Lord Cullen to establish the circumstances of the disaster
and its cause and to make recommendations to avoid similar accidents in the future.
The inquirys the public inquiry into the piper alpha disaster (the Piper
Alpha Report or Cullen Report) (Cullen 1990) is the most comprehensive inquiry conducted
in the UK into an offshore platform disaster, onshore or offshore.
The Piper Alpha inquiry has been of crucial importance in the development of
the offshore safety regime in the UK sector of the north sea. The Piper Alpha inquiry not
only discharged the function of an inquiry into the specific disaster but made
recommendations for changes to the offshore safety regime which were accepted by the
government.
Platform systems included the electrical supply system, the fire and gas detection system,
the fire water deluge system, the emergency shut down system, the communications system
and the evacuation and escape system.
Electrical power was supplied by two main generators which normally ran off the
gas supply but could be fired by diesel-fired emergency generator and also a drilling
generator and an emergency drilling generator. In addition, there were uninterrupted
power supplies for emergency services. The main production areas were equipped with a
fire and gas detection system.
89
PROCESS
The fluid from the wellhead, containing oil, gas, condensate and water passed through the
wellhead Christmas tree to the two separators where the gas was separated from the oil
and water. The oil was then pumped into the mail oil line .The gas was then compressed in
the three centrifugal compressors to 675 psi, with some gas being taken off at this point as
fuel for the mail generators, and then boosted in the first stage of two reciprocating
compressors to 1465 psi .Condensate was removed and the gas was further compressed in
the second stage of the reciprocating compressor to 1735 psi. The gas then went three ways:
90
1. To serve as lift gas at the wells.

2. To MCP-01 as export gas.
3. To flare.
The condensate was removed in 2 ways:
1. In the first method (phase 2) gas passed from reciprocating compressor to gas
conversion module (GCM) where it was dried.
2. In the second method (phase 1) the gas was passed through a flash drum so that
condensate was knocked off by Joule-Thomson effect. This was done before GCM
came into use.
The condensate injection pump was used to inject condensate into the main oil line.
There was normally one condensate injection pump line operating and one on
standby. Each condensate injection pump was protected from overpressure on the
delivery side by a single pressure safety valve (PSV).the PSV was on a separate
relief line rather than on the delivery line itself.
In accordance with the standard practices Methanol was injected into the process at
various points to prevent formation of hydrates which would tend to cause blockage
EVENTS PRIOR TO EXPLOSION
On 6th July there was a major work programme on the Platform. The extra accommodation
for the workforce was provided on the THAROS, a large floating fire fighting vessel
anchored near the platform.
The GCM was out of service on that day, so the plant operation
had reverted to phase 1 mode so the gas was relatively wet. The resulting increased
potential for the hydrate formation was recognized by the management onshore,. The
increased methanol injection rates were calculated and communicated to the platform
together with suggestions for configuration of methanol pumps. The methanol injection rate
was some 12 time greater than the phase 2 operation.
However there was an interruption of the methanol supply to the most critical point
between 4:00 and 8:00 pm that evening.
91
There were 2 condensate injection pump A and pump B. The operating condensate injection
pump was B pump. The A pump was down for maintenance. There were three maintenance
jobs to be done on this pump.
1. A full 24 month preventive maintenance (PM).

2. Repair of the pump coupling.
3. Recertification of the pressure safety valve, PSV.
In order to carry out the 24 month PM ,the pump had been isolated by closing the gas
operated valves (GOVs) on the suction and the delivery lines but slip plates had not
been inserted.
Work on the coupling, which was suffering from a vibration problem, would not involve
breaking into the pump. With the pump in this state, with the GOVs closed but without
slip plate isolation, access was given to remove PSV for testing. It was taken off in the
morning of July 6 by a two man team from the specialist contractor SCORE UK LTD.
They were unable to resolve the PSV that evening. The supervisor in this team came
back to the control room some time before 6:00pm to suspend Permit to Work (PTW)
and the team then went off duty intending to put the PSV back the next day.
At about 4.50 pm on that day, just at shift change over, the maintenance status of the
pump underwent a change .The maintenance Superintendent decided that the 24 month
PM would not be carried out and that work on the pump should be restricted to the
repair of the pump coupling.
About 9:50 pm on that evening B pump tripped out. The Lead Production Operator and
phase 1 Operator tried to restart it but without success. the loss of this pump meant
that with A pump also down condensate would be back in the flash drum and within
some 30 min would force a shut down of the gas plant. There was a possibility that if the
gas supply to the main generator was lost and if the changeover to the alternate diesel
failed, the wells would also have to be shut down. It would then be necessary to
undertake a black start.
The Lead Operator in consultation with lead maintenance

hand decided to start pump A. the lead operator signed the Permit for A pump so that it
92
could be electrically de-isolated and restated there was no doubt that the lead operator
wanted to start the pump A.
About 9:55 pm the signals for the tripping of 2 compressors came up. Then the third
compressor tripped. Before the control room could take any action three low gas alarms
and a high gas alarm went up. The operators had his hand out to control the alarm
when he was blown across the room by explosion.
EXPLOSION , ESCALATION AND RESCUE.
The initial explosion occurred at 10:00 pm .it destroyed most of the firewalls and blew
across the rooms. The explosion was followed almost immediately by a large fireball and
also large oil pool fire. The large oil pool fire gave rise to massive smoke plume which
enveloped the platform. Majority of the personnel on the platform were in the
accommodation. The escape routes from the module to the lifeboats were impassable
.The fire water drench system did not operate. There was only a trickle of water from
the sprinkler heads.
The explosion disabled the mail communications system which was centered on piper.
The emergency procedure was for personnel to report to their lifeboat, but in practice
most evacuations would be by helicopter and personnel would be directed from the
lifeboat to the dining area on the upper deck and then to the helideck. Personnel found
the escape route to the lifeboat blocked and waited in the dining area. The
OIM(Offshore Installations Manager) told them that a Mayday (an international radio
signal by ship /plane which are in danger) signal had been sent to effect the evacuation
.In fact the helideck was inaccessible to helicopters.
By 12:15 am on 7th July the north end of the platform had disappeared/by
morning only A module, the wellhead, remained standing.
93
MAJOR DISATER:
B. THE BHOPAL PLANT
The Bhopal pesticide plant where took place this fatal accident was built in 1970's and was
owned and operated by Union Carbide India Limited (UCIL), an Indian company in
which Union Carbide Corporation of US held just over half of the stock. Indian financial
institutions and thousands of private investors in India held the rest of the stock. Union
Carbide India Limited (UCIL) was established in 1934, when Union Carbide Corporation
(UCC) became one of the first U.S. companies to invest in India
Between 1977 and 1984, UCIL, located within a crowded working class neighborhood in
Bhopal, under license from the Madhya Pradesh Government produced pesticides for use
in India to help the countrys agricultural sector increase its productivity and contribute
more significantly to meeting the food needs of one of the world's most heavily populated
regions. Methyl isocyanate (MIC) was produced at the Bhopal plant by reacting
monomethylamine and phosgene in the plant's MIC production unit. The refined MIC was
then transferred to a separate MIC storage area where it was stored in two horizontal,
mounded, 15,000-gallon, and stainless-steel tanks. A third storage tank was kept empty for
emergencies and for off-specification material waiting reprocessing. The MIC was used to
make SEVIN carbaryl and several other carbamate pesticides. The MIC was processed into
SEVIN carbaryl pesticide in the SEVIN unit. The MIC was transferred in one-ton batches
to a charge pot in the SEVIN unit using nitrogen pressure. A nitrogen pressure of at least
14 psig in the MIC storage tank was necessary to move the material from the storage area
to the SEVIN unit charge pot at a reasonable rate. From there, each batch would be reacted
with alpha-naphthol to make SEVIN carbaryl.below is presented the reaction producing
carbaryl.
94
THE DISASTER
On the early morning of the 3rd December 1984, water inadvertently entered the MIC
storage tank, where over 40 metric tons of MIC was being stored. The addition of water to
the tank caused a runaway chemical reaction, resulting in a rapid rise in pressure and
temperature. The heat generated by the reaction, the presence of higher than normal
concentrations of chloroform, and the presence of an iron catalyst , produced by the
corrosion of the stainless steel tank wall, resulted in a reaction of such momentum, that
gases formed could not be contained by safety systems. As a result, MIC and other reaction
products, in liquid and vapor form, escaped from the plant into the surrounding areas.
AFTER EFFECTS
LIFE AND PROPERTY
The heavier-than-air MIC gas mixture when released into the air rolled along the ground
through the surrounding streets and spread around. The transportation system in the city
collapsed and many people were trampled trying to escape. There was no warning for
people surrounding the plant as the emergency sirens had been switched off. The effect on
the people living in the shanty settlements just over the fence was immediate and
devastating. Many died in their beds, others staggered from their homes, blinded and
choking, to die in the street. Many more died later after reaching hospitals and emergency
aid centers.
The majority of deaths and serious injuries were related to pulmonary edema, but the gas
caused a wide variety of other ailments. Signs and symptoms of methyl isocyanate exposure
normally include cough, dyspnea, chest pain, lacrimation, eyelid edema, and
unconsciousness. These effects might progress over the next 24 to 72 hours to include acute
lung injury, cardiac arrest, and death.
Information on the exact chemical mixture was never provided by the company, but blood
and viscera of some victims showed cherry-red color characteristic in acute cyanide
poisoning. A series of studies made five years later showed that many of the survivors still
suffered from one or several of the following ailments: partial or complete blindness,
95
persistent respiratory problems, gastrointestinal disorders, impaired immune systems, post

traumatic stress disorders, and menstrual problems in women. A rise in spontaneous
abortions, stillbirths, and offspring with genetic
defects was also noted.
According to the state government of Madhya Pradesh, approximately 3,800 people died
initially and several thousand other individuals experienced permanent or partial
disabilities.
Greenpeace cites 20,000 total deaths as its conservative estimate till date from the harmful
effects.
According to the Bhopal Medical Appeal, around 500,000 people were exposed to the
leaking chemicals. Approximately 20,000, to this date, are believed to have died as a result;
on average, roughly one person dies every day from the effects. Over 120,000 continue to
suffer from the effects of the disaster, such as breathing difficulties, cancer, serious birth-
defects, blindness, gynecological complications and other related problems. It is believed
that 50,000 people are unable to work because of their debilitating ailments.
Union Carbide, on their Bhopal Information Center website, maintain that approximately
3,800 died, while 40 people have permanent disabilities and 2,800 have partial
disabilities.
The International Campaign for Justice in Bhopal, however, claim that these figures are
derived from an affidavit submitted to the Indian Supreme Court on 12th July 1990. This
affidavit was apparently based on only roughly 15% of medical evaluations; the Indian
Supreme Court would hear, in 1991, that 495,000 people had been classified as injured
(22,000 permanently disabled, 3,000 seriously, and another 8,500 temporarily disabled).
Even today, according to the campaign, evaluation continues: 15,000 death claims and more
than 560,000 injury claims have so far been granted. The campaign also suggest that
official figures only tell part of the story, as many injury and death claims have been
96
denied arbitrarily. It is also difficult to demarcate which deaths can be attributed to the
incident directly.
The Indian Council for Medical Research reported that, in 1988 alone, approximately 2,500
extra deaths had occurred in places affected by the disaster
The factory was closed down after the accident.
ENVIRONMENTAL CONTAMINATION
Besides the huge loss of human life and property, a BBC investigation conducted in
November 2004 confirmed that contamination is present in drinking water, as well as in
the abandoned chemical factory site and the former chemical dumping grounds of the
factory thus creating environmental pollution also.
Lack of political willpower has led to a stalemate on the issue of cleaning up the plant and
its environs of hundreds of tonnes of toxic waste, which has been left untouched.
Environmentalists have warned that the waste is a potential minefield in the heart of the
city, and the resulting contamination may lead to decades of slow poisoning, and diseases
affecting the nervous system, liver and kidneys in humans. Studies have shown that the
rates of cancer and other ailments have already moved higher in the region since the event.
In 2002, an inquiry found a number of toxins, including mercury, lead, 1,3,5
trichlorobenzene, dichloromethane and chloroform, in nursing womens breast milk. Well
water and groundwater tests conducted in the surrounding areas in 1999 showed mercury
levels to be at 20,000 and 6 million times higher than expected levels; heavy metals and
organochlorines were present in the soil. Chemicals that have been linked to various forms
of cancer were also discovered, as well as trichloroethene, known to impair fetal
development, at 50 times above safety limits specified by the US Environmental
Protection Agency (EPA).
Some areas are reportedly so polluted that anyone entering the area for more than ten
minutes is likely to lose consciousness. Rainfall causes run-off, polluting local wells and
boreholes, and the results of tests undertaken on behalf of the BBC by accredited water
analysis laboratories in the United Kingdom reveal pollution levels in borehole water 500
times the legal maximum in that country. Statistical surveys of local residents, with a
control population in a similarly poor area away from the plant, are reported to reveal
higher levels of various diseases around the plant. Carbide states that after the incident,
UCIL began clean-up work at the site under the direction of Indian central and state
97
government authorities, which was continued after 1994 by the successor to UCIL,
Eveready Industries, until 1998, when it was placed under the authority of the Madhya
Pradesh Government. Critics of the clean-up undertaken by Carbide, such as the
International Campaign for Justice in Bhopal, claim that several internal studies by the
corporation, which evidenced severe contamination, were not made public; the Indian
authorities were also refused access. The successor, Eveready Industries, abruptly
relinquished the site lease to one department of the State Government while being
supervised by another department on an extensive clean up programme. Environmental
problems resulting from lack of a proper clean-up persist today also. The Madhya Pradesh
authorities have announced that they will pursue both Dow and Eveready to conduct the
clean-up as joint efforts.
Infact the International Campaign view Carbides sale of UCIL in 1994 as a strategy to
escape the Indian courts, who threatened Carbides assets due to their non-appearance in
the criminal case. The successor, Eveready Industries India, Limited (EIIL), ended its 99
year lease in 1998 and turned over control of the site to the state government of the
Madhya Pradesh. Currently, the Madhya Pradesh Government is trying to legally force
Dow and EIIL to finance clean-up operations.
INVESTIGATION
Shortly after the gas release, Union Carbide launched an intensive effort to identify the
cause.
An initial investigation by Union Carbide experts showed that a large volume of water had
apparently been introduced into the MIC tank and caused a chemical reaction that forced
the chemical release valve to open and allowed the gas to leak. A committee of experts,
working on behalf of the Indian government, conducted its own investigation and reached
the same conclusion.
An independent investigation by the engineering consulting firm Arthur D. Little

determined that the water could only have been deliberately introduced into the tank, since
safety systems were in place and operational that would have prevented water from
entering the tank by accident.
98
ARGUMENTS AGAINST UNION CARBIDE
COST-CUTTING MEASURES
In the early 1980s, the demand for pesticides had fallen: the factory was making a loss and
overproducing MIC that was not being sold, leading to a series of cost-cutting measures
from around 1982 onwards.
As a long-term cause of the catastrophe, authorities had tried and failed to persuade
Carbide to build the plant away from densely populated areas. Carbide explained their
refusal on the expense such a move would incur.
Union Carbide previously produced their pesticide, Sevin (the commercial name of
Carbaryl), without MIC but, after 1979, began using MIC because it was cheaper. Other
manufacturers, such as Bayer, made Sevin without MIC, although this caused greater
expenses. The recent discovery of documents, obtained through discovery in the course of a
lawsuit against Union Carbide, for environmental contamination before a New York
Federal District Court, revealed that Carbide had exported "untested, unproven technology"
to the Indian plant.
WORK CONDITIONS
Attempts to reduce expenses affected the factorys employees and their conditions:
Kurzman argues that cuts meant less stringent quality control and thus looser
safety rules. A pipe leaked? Dont replace it, employees said they were told MIC
workers needed more training? They could do with less. Promotions were halted,
seriously affecting employee morale and driving some of the most skilled
elsewhere.
Workers were forced to use English manuals, despite the fact that only a few had a
grasp of the language.
By 1984, only six of the original twelve operators were still working with MIC and
the number of supervisory personnel was also cut in half.
No maintenance supervisor was placed on the night shift and instrument readings
were taken every two hours, rather than the previous and required one-hour
readings.
99
Workers made complaints about the cuts through their union but were ignored. One
employee was sacked after going on a 15-day hunger strike. 70% of the plants
employees were fined before the disaster for refusing to deviate from the proper
safety regulations under pressure from management.
In the words of the International Campaign for Justice in Bhopal, poorly trained
personnel, rapid turnover, leaking valves, shoddy gauges and inadequate water
spray protection were all identified as representing a higher potential for a serious
incident or more serious consequences if an incident should occur.
EQUIPMENT AND SAFETY REGULATIONS
Cost-cutting initiatives affected the quality of equipment and the effectiveness of safety
regulations:
It emerged in 1999, during civil action suits in India, that, unlike Union Carbide
plants in the USA, its Indian subsidiary plants were not prepared for problems. No
action plans had been established to cope with incidents of this magnitude. This
included not informing local authorities of the quantities or dangers of chemicals
used and manufactured at Bhopal.
The MIC tanks alarms had not worked for 4 years.
The flare tower and the vent gas scrubber had been out of service for 5 months
before the disaster. The gas scrubber therefore did not attempt to clean escaping
gases with sodium hydroxide (caustic soda), which may have brought the
concentration down to a safe level. Even if the scrubber had been working, according
to Weir, investigations in the aftermath of the disaster discovered that the
maximum pressure it could handle was only one-quarter of that which was present
in the accident. Furthermore, the flare tower itself was improperly designed and
could only hold one-quarter of the volume of gas that was leaked in 1984.
To reduce energy costs, the refrigeration system, designed to inhibit the
volatilization of MIC, had been left idle the MIC was kept at 20 degrees Celsius,
not the 4.5 degrees advised by the manual, and some of the coolant was being used
elsewhere.
Slip-blind plates that would have prevented water from pipes being cleaned from
leaking into the MIC tanks via faulty valves were not installed. Their installation
had been omitted from the cleaning checklist.
100
Water sprays designed to knock down gas leaks was poorly designed set to 13
metres and below, they could not spray high enough to reduce the concentration of
escaping gas.
The MIC tank had been malfunctioning for roughly a week. Other tanks had been
used for that week, rather than repairing the broken one, which was left to stew.
The build-up in temperature and pressure is believed to have affected the explosion
and its intensity.
According to Lepowski, virtually every relevant safety instrument was either in
short supply, malfunctioning or designed improperly, and internal documents
show that the company knew this prior to the disaster, but did nothing about it.
AFTERMATH OF THE EXPLOSION
In the immediate aftermath of the explosion:
Though the audible external alarm was activated to warn the residents of Bhopal, it
was quickly silenced to avoid causing panic among the residents. Thus, many
continued to sleep, unaware of the unfolding drama, and those that had woken
assumed any problem had been sorted out.
Doctors and hospitals were not informed of proper treatment methods for MIC gas
inhalation. They were told to simply give cough medicine and eye-drops to their
patients.
PREVIOUS WARNINGS AND ACCIDENTS
A series of prior warnings and MIC-related accidents had been ignored:

Reports issued months before the incident by scientists within the Union Carbide
corporation warned of the possibility of an accident almost identical to that which
occurred in Bhopal. The reports were ignored and never made it to senior staff.
Union Carbide was warned by American experts who visited the plant after 1981 of
the potential of a runaway reaction in the MIC storage tank; local Indian
authorities warned the company of problems on several occasions from 1979
onwards. Again, these warnings were not heeded.
11 of the 30 major hazards documented in a 1982 review occurred in the MIC and
phosgene units.
101
From 1981, inhalation accidents were reported at the factory. Five workers were
hospitalised in 1982 after a leak of MIC.
A previous leak of MIC had affected local communities outside the plant[10].
The International Campaign for Justice in Bhopal suggests that leaks were so
frequent that the safety siren was turned off.
UNION CARBIDES DEFENSE
These claims given by the International Campaign for Justice in Bhopal and others are
countered by Union Carbide. It denies allegations against it on its website dedicated to the
tragedy. The corporation believe that the accident was the result of sabotage, claiming that
safety systems were in place and operative. It also stresses that it did all it could to
alleviate humanitarian suffering following the disaster.
The corporation denies the claim that the valves on the tank were malfunctioning, claiming
that documented evidence gathered after the incident showed that the valve close to the
plant's water-washing operation was closed and leak-tight. Furthermore, process safety
systems in place and operational would have prevented water from entering the tank by
accident.
Carbide states that the safety concerns identified in 1982 were all allayed before 1984 and
none of them had anything to do with the incident.
The company admits that the safety systems in place could not have prevented a chemical
reaction of this magnitude from causing a leak.
According to Carbide, in designing the plant's safety systems, a chemical reaction of this
magnitude was not factored in because the tank's gas storage system was designed to
automatically prevent such a large amount of water from being inadvertently introduced
into the system and process safety systems in place and operational would have
prevented water from entering the tank by accident. Instead, they believe that employee
sabotage not faulty design or operation was the cause of the tragedy.
INVESTIGATION OUTCOME
THE WATER WASH THEORY
According to this story, an MIC operator was told to wash a section of a sub header of the
relief valve vent header ("RVVH") in the MIC manufacturing unit. Because he failed to
102
insert a slip-blind, as called for by plant standard operating procedures, the water
supposedly backed up into the header and eventually found its way into the process vent
header ("PVH") through a tubing connection near the tanks. It then was supposed to have
flowed into the MIC storage tank, located more than 400 feet by pipeline from the initial
point of entry.
This to a layman, appeared an apparently plausible, easily understood explanation of the

water source, which did not require any detailed knowledge of the plant process or layout.
It also was a theory that had popular appeal because it focused on a simple, minor human
inadvertence which caused a great tragedy -- a "for-want-of-a-horseshoe-nail-the-kingdom-
was-lost" explanation. It was readily accepted by those eager to believe the incident had
been caused by improper operating practices at a purportedly shoddy chemical plant in a
Third World country. The water washing theory was also publicly embraced by the Indian
Government.
THE DIRECT-ENTRY AND SABOTAGE THEORY
Another investigation shows, with virtual certainty that the Bhopal incident was
Caused by the entry of water to the tank through a hose that had been connected directly to
the tank. The following sequence of events occurred. At 10:20 p.m. on the night of the
incident, the pressure in Tank 610 was at 2 psig. This is significant because no water could
have entered prior to that point; otherwise a reaction would have begun, and the resulting
pressure rise would have been noticed. At 10:45 p.m., the shift change occurred. During this
period, on a cold winter night, the MIC storage area would be completely deserted. It is
believed that it was at this point -- during the shift change -- that a disgruntled operator
entered the storage area and hooked up one of the readily available rubber water hoses to
Tank 610, with the intention of contaminating and spoiling the tank's contents. It was well
known among the plant's operators that water and MIC should not be mixed. He unscrewed
the local pressure indicator, which can be easily accomplished by hand, and connected the
hose to the tank. The water and MIC reaction initiated the formation of carbon dioxide
which, together with MIC vapors, was carried through the header system and out of the
stack of the vent gas scrubber by about 11:30 to 11:45 p.m. It was these vapors that were
sensed by workers in the area downwind as the earlier minor MIC leaks.
103
Investigations suggest that only an employee with the appropriate skills and knowledge of
the site could have tampered with the tank. An independent investigation by the
engineering consulting firm Arthur D. Little determined that the water could only have
been introduced into the tank deliberately as in designing the plant's safety systems, a
chemical reaction of this magnitude was not factored in for two reasons:
1. The tanks gas storage system was designed to automatically prevent such a large
amount of water from being inadvertently introduced into the system; and
2. Process safety systems -- in place and operational -- would have prevented water from
entering the tank by accident. The system design did not, however, account for the
deliberate introduction of a large volume of water by an employee.
RESPONSE
In the wake of the release, Union Carbide Corporation provided immediate and
continuing aid to the victims and set up a process to resolve their claims.
In the days, months and years following the disaster, Union Carbide took the following
actions to provide continuing aid:
Immediately provided approximately $2 million in aid to the Prime Ministers Relief

Fund
Immediately and continuously provided medical equipment and supplies Sent an
international team of medical experts to Bhopal to provide expertise and assistance;
Funded the attendance by Indian medical experts at special meetings on research
and treatment for victims;
Provided a $2.2 million grant to Arizona State University to establish a vocational-
technical center in Bhopal, which was constructed and opened, but was later closed
and leveled by the government
Offered an initial $10 million to build a hospital in Bhopal; the offer was declined;
Provided an additional $5 million to the Indian Red Cross;
Established an independent charitable trust for a Bhopal hospital and provided
initial funding of approximately $20 million. The hospital was begun in October
1995 and was opened in 2001. The hospital caters for the treatment of heart, lung
and eye problems.
104
The company stresses the immediate action taken after the disaster and their continued
commitment to helping the victims.
THE SETTLEMENT
During the 1980's, as Union Carbide continued to provide interim relief funds and work
with the Bhopal community on medical and economic aid, legal actions proceeded in both
the U.S. and India. The courts ultimately decided that the proper country for legal
proceedings was India and matters were consolidated there and proceeded before the
Supreme Court of India.
In May 1989, Union Carbide and Union Carbide India Limited (UCIL) entered into a $470
million legal settlement with the Government of India, which represented all claimants in
the case. The settlement was affirmed by the Supreme Court of India, which described it as
just, equitable and reasonable, and settled all claims arising out of the incident. Ten days
after the decision, Union Carbide and UCIL made full payment of the $470 million to the
Indian government.
In its opinion, the Court said that compensation levels under the settlement were far
greater than would normally be payable under Indian law. Pursuant to the settlement, the
Government of India assumed responsibility for disbursing funds from the settlement and
providing medical coverage to citizens of Bhopal in the event of future illnesses.
In July 2004, fifteen years after reaching settlement, the Supreme Court of India ordered
the Government of India to release all additional settlement funds to the victims. News
reports indicate that there was approximately $327 million in the fund as a result of earned
interest from money remaining after all claims had been paid. In April 2005, the Supreme
Court of India granted a request from the Welfare Commission for Bhopal Gas Victims and
extended to April 30, 2006, the distribution of the rest of the settlement funds by the
Welfare Commission. News reports now indicate that approximately $390 million remains
in the settlement fund as a result of earned interest.
In September 2006, Indian media reported the registrar in the office of Welfare Commission
said that all cases of initial compensation claims by victims of the 1984 Bhopal gas
tragedyand revision petitions had been cleared; no case was pending. If the media
report was accurate, this could mean that all the settlement money has finally been
distributed.
105
UNIT-IX
PERSONNEL RISK IN INDUSTRIAL OPERATIONS
MINERAL EXPLORATION
Mining is the act of extracting ores, coal etc from the earth. Mining on an industrial scale
can causes environmental damages, resulting from exploration, and even after mines are
closed.
Mining operation are carried out two methods:
Open Cast Mining: minerals are excavated on the open ground.

Under Ground Mining: Tunnels and access shafts are excavated underground to dig
the minerals.
THE INDIAN MINERAL SECTOR:
INTRODUCTION:
India produces as many as 84 minerals comprising 4 fuels, 11 metallic, 49 non metallic

industrial and 20 minor minerals. Their aggregates production in 1999 2000 was about 55
million tones, contributed by over 3,100 mines producing coal, lignite, lime stone, iron ore,
bauxite, copper, lead, zinc etc. More than 80% of the mineral production comes from open
cast mines.
History of Indias Mineral Sector:
Large scale production of various minerals was created in the public sector.
106
CURRENT STATUS OF MINING INDUSTRY IN INDIA:
The recoverable reserves status of some important minerals are given below
Table: Recoverable reserves of mineral / ore in India (1970 and 1995).
Table: Mineral reserves in India.
107
Table: Production of some selected minerals in India (by mineral groups)
108
INTRODUCTION TO SAFETY IN MINERAL EXPLORATION:
The most accidents occur during traveling, manual handling or drilling, and frequently are
caused by slipping and falling.
Fatal accidents in Australia have involved fixed wing air craft and helicopter crashes, head
stroke, vehicles overtaking, and people being caught by rotating rods on drilling rigs.
Another facility involved a hydrofluoric acid spill.
WAYS TO REDUCE ACCIDENTS:
By ensuring that all employees are competently trained to do their work.

Identifying hazards in the job.
Assessing the risks from the hazards.
Managing the risk.
POLICY AND COMMITMENT TO SAFETY AND HEALTH:
A SAFETY AND HEALTH POLICY SHOULD:
Be in written and be signed and dated by the chief executive.

Clearly state the organizations safety and health objective.
Declare managements commitment and determination to achieve those objectives.
Be clearly understandable.
Be available to all employees.
Be implemented at all levels.
Be reviewed periodically.
MANAGEMENT CAN SHOW ITS COMMITMENT TO SAFETY AND HEALTH BY:
Providing adequate financial and human resources to cover safety and health needs.
Providing adequate training to carry out work safely.
Developing and adopting safety management systems.
Involving all employees in safety issues relevant to their work.
Introducing safety committees and tool box meetings.
Empowering employees to take the necessary action to improve safety.
Providing feedback to safety requests.
109
Reviewing policies and procedures as required.

Employees will be committed to a safety and health ethos only if they believe, and are
shown, that the company itself is committed. They must be able to see that improvements
in safety are being made and that policies are implemented in the field.
CONTROL AND MANAGEMENT OF RISK:
Risk is effectively managed when all persons individually and as part of the work group
and organization take action to keep the risk to an acceptable level. In Particular, this
means following risk management procedures and practices that are appropriate for the
work being carried out.
RISK MANAGEMENT IS THE SYSTEMATIC APPLICATION OF POLICIES,

PROCEDURES AND PRACTICES TO:
Identify, analyze and assess risk.

Avoid or remove unacceptable risk.
Monitor levels of risk and the adverse consequences of retained residual risk.
Investigate and analyze causes of accidents and high potential incidents to prevent
their recurrence.
Review effectiveness of risk control measures.
Take appropriate corrective and preventive action.
If there is an unacceptable level of risk to persons, they must be evacuated to a safe location
and action must be taken to reduce the risk to an acceptable level.
WHEN HAZARDS ARE IDENTIFIED AND RISKS ANALYZED, THE STANDARD

HIERARCHY OF HAZARD CONTROLS SHOULD BE ADOPTED, AS FOLLOWS:
Elimination of the hazard.

Substitution with a lesser hazard.
Separation of persons from the hazard.
Engineering controls.
Administrative controls.
Use of personal protective equipment (PPE).
110
ENVIRONMENTAL IMPACTS OF MINING:
The exploratory phase generally causes the least impact, but during drilling holes to
determine the existence of deposits involve transporting heavy equipments and building
roads, such activities can disturb the local habitat and increase access to remote areas of
forest.
The operational phases have the following list of adverse impacts of mining on forest and
environment.
Open pit mining, generates enormous quantities of waste, compared to any other
methods.
The water interacts with the wastes to generate contaminated fluids that can pollute
solids, rivers and ground water.
o The fluids can be highly acidic and metal laden or highly alkaline and they
contain various forms of cyanide, depending on the waste source.
o Acid mine drainage can occur when water and air come into contact with
geologic materials containing iron sulphide, as in abundance waste piles.
o Erosion and sedimentation is another environmental issue for mine sites. In
the mining process, large quantities of sediments are transported by water
erosion, and eventually settle at down stream.
Dust generated from mining activity can cause air pollution.
o In human being it causes respiratory trouble.
o In plants and trees it causes asphyxia.
o Gasses and toxic vapors are released; sulphur dioxide is responsible for acid
rain.
o Carbon dioxide and methane are two of the main green house gases causes
climate change, this are released due to burning of fossil fuels.
o The dust also contains toxic heavy metals such as arsenic, lead and other.
o The dust can deposit in surface water causing sedimentation and turbidity
problem.
Noise is another major problem from mining operations.
o The sounds of the machinery used in mining and the blasting create condition
that may become unbearable for the local population and the forest wildlife.
111
The large disturbance caused by mining disrupts environments.

o Aquatic habitats (i.e. lakes, ponds, streams, rivers).
o Terrestrial habitats (i.e. deserts, grasslands, forests).
o Wetlands.
Effects hydrology by large consumption or release of water.
Effects topography.
Release of particulates and chemicals can all have indirect impacts on various
habitats.
Table: Mineral production, waste generation and land affected in 1999 2000.
SOCIAL DAMAGES OF MINING:
Agricultural land is destroyed turning farmers to laborers in mines, which become

unemployed after the mine is exhausted.
Appropriation of the land belonging to the local communities.
Impacts on health.
Alteration of social relationships.
Social disintegration.
Radical and abrupt changes in regional cultures.
Displacement of other present and / or further local economic activities.
REMEDY MEASURE TO PROTECT ENVIRONMENT:
Illegal mining should be stopped.
112
Environmental Impact Assessment should be made as per standards and political or

corrupt decisions should be curbed.
Waste land management should be carried out by using the land by construction of
buildings, rods, rails etc, other than agricultural activities.
113
PERSONNEL RISK IN: MATERIAL HANDLING PROCESS:
INTRODUCTION:
Manual materials handling (MMH) is a component of many jobs and activities

undertaken in life. Typically it involves lifting, lowering, pushing, pulling, and carrying
objects by hand.
Manual materials handling permeates all aspects of life on and off the job.
The one thing all these tasks have in common is the potential to result in some adverse
health effect, from simple cuts, bruises, and sore muscles to more serious conditions
related to low back pain (LBP).
HAZARDS:
The hazards associated with improper material handling are associated with:
Struck by a load
Losing control of a load,
Physically overexerting oneself,
Exceeding equipments capacity.
Such accidents can lead to:
Small Injuries (e.g., abrasions-Scraping of skin, Cut of skin, etc.)

Major Injuries (e.g., Fall of object on Head, Press of Hand/Leg under Heavy Wt. and
broken bones)
musculoskeletal disorders, chronic low back
Loss of life
CONTROLS MEASURES FOR PROTECTION AGAINST INJURY:
1. WORK PLANNING:
The injuries significantly increase when:
Lifting or moving of bulky, heavy objects that cannot be held close to the body.
Repetitive lifts of lighter objects over long periods of time.
Task without required assistance or because of inadequate worker training, poor
judgment, poor selection, improper use or maintenance of equipment.
114
Therefore, supervisors and workers should perform an appropriate analysis to determine

the proper technique or lifting device required for all material-handling activities. As part
of the analysis, consider whether a worker is able to carry out the materials-handling task
in question, even with assistance. In addition, consider the following other factors:
CONTAINER CHARACTERISTICS:
Weight, length, width, height, and depth.
Center of gravity (i.e., weight distribution within container).
Handles, texture, and grasp point.
Stability (particularly in the case of liquids and bulky items).
WORKPLACE CONFIGURATION:
Height of lifts.
Carrying distance and direction changes.
Obstacles (e.g., stairs and slopes).
Traction on working surfaces (i.e., observe whether surfaces are slippery, smooth, or
rough).
TASK CHARACTERISTICS:
Forward reach.
Duration, frequency, and pace.
Temperature, lighting, and humidity.
Work organization (e.g., teamwork, time pressure, and the availability of help).
MECHANICAL LIFTING DEVICES:
Weight demand and equipment limitations (i.e., load limit).

Accessibility requirements.
Worker experience.
Maintenance status.
2. WORKERS TRAINING AND QUALIFICATION:
Workers should be properly trained and physically capable for any work assignment that
involves the lifting of heavy objects or the repetitive lifting of lighter objects over long
periods.
TRAINING:
115
Workers shall be properly trained in correct lifting techniques and in the use of powered
and mechanical material-handling equipment, such as lifts, hoists, powered industrial
trucks and cranes.
PHYSICAL QUALIFICATION:
Workers need to be physically qualified to perform tasks requiring lifting of heavy objects,
repetitive lifting of modest-weight objects, or lifting of lighter objects outside of a normal
work routine, (e.g., moving office supplies and furniture).
3. PERSONAL PROTECTIVE EQUIPMENTS:
A work supervisor shall evaluate job assignments to determine the need for safety-toed
shoes, gloves, and other types of personal protective equipment (PPE).
Back belts may help reduce the risk of injury when properly used in combination with a
back care training program, ongoing evaluations of lifting and material-handling
techniques, and continuous supervision.
4. PRECAUTIONS FOR SAFELY LIFTING AND HANDLING MATERIALS:
Never attempt to lift objects that are too heavy or bulky to handle safely.
Never overestimate your ability to perform a task.
Whenever possible, push rather than pull loads:
Pushing uses the strong leg muscles, whereas pulling uses the easily strained back
muscles.
When occasional lifts of compact loads [<70 kg (154 lb)] are required, observe the following
precautions:
Loads should be handled no more than 18 cm (7 in.) in front of the body as measured
from the ankles. The heavier a load, the more closely to the body the load should be
held.
Very low lifts [25 cm (10 in.) or less from the floor] are not desirable because of the
difficulty of maintaining balance when squatting to lift.
Medium lifts [75-135 cm (30-54 in.) from the floor] are more desirable because more
strength is available in the lower part of this height range.
116
High lifts [135-188 cm (54-75 in.) from the floor] are not recommended, except when
the item to lift weighs less than 5 kg (11 lb).
Muscle fatigue can potentially occur where lifting is required more than once every 2-5 min.
Therefore, the weight for repetitive lifts should be less than that for occasional lifts. If the
lifting rate exceeds six lifts per minute, lifting should be limited to 20 min or less to allow
for muscle recovery. Moving objects by sliding, rather than lifting, is recommended for
repetitive handling tasks.
5. SAFE LIFTING PRACTICES:
The following are recommended safe practices for lifting and moving heavy objects:
Provide good handholds on an object to be carried.

Firmly grip an object to be carried.
Use carts and handling aids to support an object's weight.
Try to minimize the distance that an object is moved.
Carry a load close to your body and at a proper height from the floor. When
standing,
Avoid lifting an item to a height greater than 50 cm (20 in.) or lowering an item to a
height less than 20 cm (8 in.).
Push or pull objects whenever possible, rather than lifting or lowering objects.
Position storage materials on racks or shelves in ways that make handling easier
(e.g.,
Place the heaviest objects at elbow height).
Keep your torso in a neutral, upright position whenever possible when lifting a
heavy
Load. The neutral position is 0-15. An angle greater than 15 is considered high
risk.
Do not twist or bend while lifting or handling a heavy load.

Do not using jerking motions to move a load.
Provide elbow support for long reaches.
Warm up before starting a strenuous task after a less-strenuous task (e.g., changing
117
From sitting to performing a rapid, dynamic task).
Avoid lowering materials that need to be later lifted.

Plan movements of material in direct paths (i.e., do not zigzag or backtrack).
Avoid using stairs when handling heavy objects. As a general rule, if the use of stairs
is unavoidable, keep one hand free to grasp the rail quickly to prevent falling.
Use an adjustable/tilt able table or a reach extender to reduce forward bending or
Extended reaches.
Use a step stool or low platform to reduce back hyperextension.

Use roller bearings or roller conveyors to reduce twisting.
6. PRE-LIFT INSPECTIONS AND CONSIDERATIONS:
Contact your area ES&H Team industrial safety engineer or the Health Services
Department representative for assistance with, or information on, the following:
Material-handling task hazard analyses.

Lifting techniques.
Mechanical aids.
Methods for determining general weight-limit guidelines.
A worker's ability to perform a task.
BEFORE LIFTING A HEAVY OBJECT:
Inspect the load for sharp edges, slivers, and wet or greasy spots.
Wear gloves (and, if necessary, a long-sleeved shirt) when lifting or handling objects
with sharp or splintered edges. To ensure a good grip on the object, make sure the gloves
are free of oil, grease, or other slippery materials.
Inspect the route over which the load is to be carried. The route should be free of
obstruction or spills that could cause tripping or slipping.
Consider the distance over which the load is to be carried. Gripping power may
weaken over long distances.
Size up the load, and make a preliminary lift to be sure the load is within your
capacity. If the load is beyond your capability, get help or use a mechanical lifting device.
118
7. TECHNIQUES FOR MOVING AND LIFTING MATERIAL:
In addition to following the precautions, use the techniques given below when moving or
lifting heavy materials.
Two-Hand Squat Lift

Assisted One-Hand Lift
Team Lifts
8. PACKING AND CRATING:
Personnel in the Shipping Department typically pack and crate materials for offsite
shipment. The Shipping Department shall be consulted for guidance regarding material-
handling and transportation safety requirements.
9. MECHANICAL LIFTING DEVICES:
Mechanical lifting devices (rather than manual effort) should be used to lift and move
objects whenever practical. Workers are always encouraged to use mechanical equipment to
lift heavy or bulky objects. Various types of mechanical lifting devices are described below.
Hand Trucks
Dollies
Wheelbarrows
Pallet Jacks
Crowbars
10. POWERED LIFTING DEVICES:
Powered mechanical devices shall be used for lifting and moving objects that are too heavy
or bulky for safe manual handling. However, only workers who are properly trained and
qualified are permitted to operate such equipment. Heavy objects that require special
handling or rigging shall be moved only by qualified riggers or under the guidance of
workers specifically trained for such tasks. The Hazards Control Department conducts
training programs and licenses workers who demonstrate the ability to operate powered
industrial trucks (e.g., fork trucks), cranes, and hoists in a safe manner.
119
All materials that are loaded onto trucks for over-the-road use shall be firmly secured to the
truck using rope, nylon strap, chain, or other suitable equipment to prevent shifting during
transit.
MAINTENANCE:
All mechanical lifting and moving devices shall be inspected periodically and repaired as
necessary. Under no circumstances shall defective equipment be used. All lifting equipment
shall list its rated load capacity, which operators shall not exceed. As a safety precaution,
check for faulty or defective parts before lifting a load that is near the load capacity of the
equipment.
11. RESPONSIBILITIES:
"General Worker Responsibilities and Integrated Safety Management," in the ES&H

Manual. Specific responsibilities for work involving heavy lifting and powered industrial
trucks are listed under each title below.
11.1 ADMINISTRATIVE CONTROLS:
The purpose of administrative controls is to limit the duration of personal exposure to the
risk factors associated with MMH tasks. Administrative controls can take many forms,
among them are:
Job rotation (rotating the exposed population into less physically demanding jobs, or
jobs that do not tax the same muscle groups as the job of concern)
Job enlargement or enrichment (providing added task variety, adding less taxing
aspects to the job, and sharing tasks among several muscle groups)
Increasing the number of people performing the job (thereby spreading the exposure
to a wider population, but reducing individual exposure duration)
Training in safe handling techniques
Worker selection and placement
11.2 SUPERVISORS:
Evaluate job assignments, and consider ways to redesign tasks to reduce or

eliminate material-handling hazards.
120
Determine the proper technique or lifting device required and the necessary PPE for
material-handling activities.
Enforce the use of safe lifting techniques.
Ensure that:
Workers know how to manually move objects in a safe manner.
Workers who routinely lift heavy objects are evaluated by the Health Services
Department prior to initial work assignment.
Only trained and licensed personnel operate powered industrial trucks, cranes,
or hoists.
Ensure that large or heavy objects are moved mechanically and that material-
handling equipment is kept in good mechanical condition.
11.3 JOB DESIGN:
Jobs should be designed to avoid overtaxing the worker physiologically. Heavy work should
be alternated with light work. Wherever possible, work place should be governed by the
person performing the job, rather than by the supervisor, other employees, or equipment
demands. Self-pacing of a job is almost always preferable to having a work pace imposed on
the worker.
In physically demanding jobs, rest breaks become all the more important. Sometimes
short work periods with short rest periods result in better physiological recovery and lower
stress levels than long work periods with long rest periods. This is a good general principle
for scheduling work and rest to maximize recovery and minimize stress in jobs that require
physical stamina.
Job designers need to remember that male or female, young or old, fit or unfit will probably
perform the job at some point in time.
11.4 WORKERS:
Never lift or move objects that exceed your physical limitations.

Observe all established safety requirements, and exercise good judgment when
lifting or moving heavy objects.
Use appropriate mechanical devices when handling materials.
121
Obtain and maintain the required licenses to operate cranes, hoists, and powered
industrial trucks.
11.5 HAZARDS CONTROL DEPARTMENT:
Assist supervisors and workers with material-handling issues

Provide formal and informal training courses.
11.6 HEALTH SERVICES DEPARTMENT:
Evaluate a worker's physical ability to perform work that requires heavy or

repetitive lifting.
Issue work restrictions, as necessary.
Provide ergonomic assessments of complex work situations. Ergonomic assessment
includes assisting workers in returning to work after injury-related leave or restricted duty.
Conduct formal and informal training.
122
PERSONNEL RISK IN MANUFACTURING PLANT
INTRODUCTION:
Cement manufacturing process consists principally of grinding and blending in a

definite proportion, a material containing calcium oxide (such as limestone, chalk, marl)
with a siliceous material (such as clay, shale, sand) along with certain additives or
corrective materials (such as bauxite, laterite iron ore) and when burning the mixture at
high temperatures in a kiln. The resulting clinker is cooled and then ground with gypsum
& fly ash to produce the finished products.
A. MINING UNIT:
limestone is extracted through mining and then limestone is transported by
dumper's to stationary crushing plant. Limestone is crushed in a mobile
crusher and crushed limestone is transported to the plant.
B. CRUSHING UNIT:
Crushing is done by means of impact crushers. The purpose of crushing is to prepare

the material for grinding in raw mill
C. STACKER UNIT:
The crushed limestone is stacked in a multi layer fashion in two preblending stock piles of
35,000 MT capacity each. The quality of material is made uniform during reclaiming. The
reclaiming is done by a bridge type scraper reclaimer and the reclaimed limestone is
transported to the raw mill hopper by belt conveyors.
After testing the CaCO3 content in the raw material, the materials are divided in 3
grades namely-
1. High Grade
2. Normal Grade
3. Low Grade
123
D. RAW MILL UNIT:
The conveyor belt carrying from the raw material passes through a magnet to
remove any iron particles present in the raw material. The raw material feeding belt is
connected to the gravel gate of raw mill so that hot air used for drying the material should
not escape through the feed point. The material are ground in a raw mill having vertical
rollers.
E. PRE-CALCINATION UNIT:
The raw meal is extracted from the CB silo and fed to the top of the four stage pre-
heater with the help of an air lift pump. The feed rate is accurately controlled by the
'POLDOS' system. As raw meal flows downward from first stage to fourth stage it comes in
contact with rising and progressively hotter gases from kiln and the raw meal gets heated
from ambient temperature to about 860C by utilising the sensitive heat of kiln waste gases.
During the pre-calcination, limestone (CaCO3) gets converted to lime (CaO) as per
the following reaction.
CaCO3 + Heat = CaO + CO2
As this reaction is highly endothermic, the heat is supplied for supporting the
calcination reaction by firing controlled quantity of pulverised coal in pre-calciner.
F. KILN UNIT :
From the precalciner the precalcined raw meal enters the kiln. The kiln is rotary
type and has a capacity of 3000 MT/day. The kiln is fired with controlled quantity of finely
ground coal and maintained at a temperature of 1300 to 1400 0C at the firing end. Chemical
reactions take place and material melts to small pebbles (upto 25 mm) called clinker.
G. CLINKER-COOLER UNIT:
From the kiln the hot clinker flows to the reciprocating grate cooler, where it is
effectively cooled to about 80 0C by cross current contact with cooling air blown by ten
cooling air fans. Hot clinker falls on cooler plates and is transported from one plate to
another by the reciprocating movement of plates.. Beneath these plates the cooling air fans
124
are fixed to cool the clinker. The air which gets heated up during clinker cooling is put back
in the kiln and precalciner as secondary and tertiary air for coal combustion.
H. COAL HANDLING UNIT:
Coal received from collieries by trucks is unloaded in the coal yard for obtaining a
uniform quality of coal. It is transferred to the coal stockpiles where it is stacked and then
the coal is crushed in the coal crusher and transported to raw coal hopper having a capacity
of 300 MT in the coal mill plant by belt conveyors.
I. CEMENT MILL UNIT:
The clinker is extracted with the help of vibro-feeders installed below the clinker
stock-pile and transported to the cement mill hopper by belt conveyors. Gypsum and
Pozzolona are also stored in cement mill hoppers. These materials are taken from the
hopper in proportionate quantity with the help of weigh feeders and fed to the cement mills
by belt conveyors. Each cement mill is a double compartment, horizontal ball mill filled
with grinding media. The clinker which is ground with gypsum to a very fine powder to
yield a good quality of cement. Gypsum is added to the clinker while grinding to the extent
of 4 to 6% for dealing the commencement of the setting time. The fined ground cement from
ball mill is removed continuously by carrying air and separated in high efficiency ESP. The
cement collected in ESP is transported by air slide and air lift, pump and stored in four
cement silos .
J. PACKING UNIT:
The cement is taken from the cement silos and transported to the packing plant with
the help of air slides and bucket elevators. The cement is fed to the automatic rotary
packing machines through rotary screens. Each packing machines packs 50 kg of
cement in jute/HDPE bags. The filled bags are transported to trucks loading points
with the help of belt conveyors and loaded into the trucks with the help of shuttle and
lifting conveyors.
125
COMMON PERSONNEL RISK IN MANUFACTURING PLANT
Hazards in work place need to be eliminated, minimized or effectively controlled. Following

are some of the common methods of eliminating, minimizing, controlling hazards:
Interlocks and trips.

Guards,
Infra-red sensors with trip mechanism,
Two handed operation to prevent entry of hand in the hazard
zone, Use of handled tools like chisels etc.,
Use of PPE.
Following are some of the common hazards and means adopted for
controlling them:
MECHANICAL HAZARDS
I. Trips: Pipelines crossing passages are a trip hazard. Such trip hazards of low
lying ground level pipe crossings of small size piping nee d to be covered with a
ramp with zebra markings. Higher level and bigger size piping need to be provided with
step crossing.
II. HEAD BUMPERS: Any obstacle at the head height (less than 6 feet) in the passage,
stairway is a head bump hazard. Such head bump s need to be either removed or
prominent caution board with yellow background and black letters to be put up.
Further it is very useful to provide thick sponge padding on the head bump to
absorb any impact of a head bumping on the obstacle.
III. OBSTACLE ACROSS PASSAGES: THERE SHALL BE NO PROTRUDING

obstacles across any passage. All such protruding obstacles must be removed.
IV. TOE GUARDS AND FIRST ' RAILING FOR PLATFORMS AND STAIRS'
LANDINGS: All platforms and stairs' landings are required to have toe gua rds to
prevent the foot slipping out of the platform. All first railings of platforms must be
low enough to prevent leg slipping out of the platform.
126
V. MACHINE GUARDING: MACHINE GUARDS SHOULD BE SUCH THAT

EVEN a small finger should not be able to penetrate inside. All machine guards
to be fixed properly after maintenance.
VI. VERTICAL LADDERS: All vertical ladders to have cat-rings for protection.
VII. HAMMER AND CHISEL HAZARD: A frequent cause of workshop activity involves
hand and finger injuries due to use of chisel and hammer for cutting gaskets and
sheets. Use of chisel with handle eliminates this hazard.
VIII. IN-RUNNING NIPS CUTTER MOVEMENTS: These are the oldest of

hazards and still persisting, Nip guards are useful. There are advanced systems where
starting the machine requires both hand operation so that no hand enters the in-
running nip of moving cutter. There are also infra red sensor trips, that trip the
machine when a hand enters the hazard zone. All machine operations should be
free of in-running nip/cutter hazard.
CORROSION HAZARDS
(I) PREVENTING CORROSION OF STRUCTURES, LADDERS, RAILINGS ETC:

Use of GI structures and piping prevents corrosion without any painting. For other MS-
Structures use of effective sand blasting and 5-coats of Zinc primer has proved very
effective and is now used widely.
ELECTRICAL HAZARDS
(i) EFFECTIVE EARTHING: All electrical equipments to have earthing,
(ii) SEALING OF CABLE ENTRY POINTS: All cable entry points in flame proof
areas need to be sealed by electrical water proofing compound,
(iii USE ELECTRICAL DUTY TOOLS AND PPE: Only approved ISI marked
electrical duty tools and PPE to be used.
STATIC CHARGE HAZARD
Static charge is the most ubiquitous hazard in flameproof areas. Prevention of static charge
hazard in chemical industries is one of the most challenging tasks.
127
AIR EMISSIONS SOURCES
SOURCE EMISSION
Raw material crushing, grinding----PARTICULATES
Kiln operation and cooling-----------PARTICULATES, CO,SO2,NOx,HC
Product grinding and packaging----PARTICULATES
COMMON AIR POLLUTANTS AND THEIR EFFECTS:
1. SUSPENDED PARTICULATE MATTER:
Atmospheric particulate matter is defined to be any dispersed matter, solid or liquid

smaller than 500um. Under various conditions of their generation, they are also called by
other names such as dust, fume , smoke and mist. The common diseases caused by the
these particulates are : bronchitis, bronchopneumonia and asthma.
SULPHUR DIOXIDE:
Sulphur dioxide when released in the atmosphere can also convert to SO3, which leads to
production of sulphuric acid. When SO3 is inhaled it is likely to be absorbed in moist
passages of respiratory tract. When it is entrained in an aerosol, however it may reach to
deeper into lungs.
NITROGEN OXIDE
Almost all NOx emissions are in the form of NO, which has no, known adverse health
effects in the concentrations found in the atmosphere, which in turn may give rise to
secondary pollutants, which are injurious. NO2 may also lead to formation of HNO3, which
is washed out of the atmosphere as acid rain.
CARBON MONOXIDE:
Most of the CO emissions are from transportation sector. Peek concentrations occur at
street level in busy urban centers particularly when there is no atmospheric mixing as it
happens during winter season. Carbon monoxide interferes with bloods ability to carry
oxygen. It also causes headache and dizziness.
128
LEAD:
Lead released from motor vehicle exhaust may affect human populations by direct
inhalations , in which case people living nearest to highways are at greatest risk. Lead can
be ingested also after it is deposited on the foodstuffs. it may also cause behavioral changes,
learning disabilities and permanent brain damage.
129
PERSONNEL RISK IN CHEMICAL PLANT
INTRODUCTION
The chemical industry is intimately connected with all the basic needs of society such as
food, clothing, housing and health. Its development and performance depend on several
factors directly connected with demographic dynamics of the country and national
policies. For example, the adverse implications of monsoon failure on agricultural
production and, in turn, on the demand for fertilizers and pesticides; or the role of drugs
and pharmaceuticals in providing health care needs to a growing population. The
petrochemical sector which caters to clothing and polymeric consumer products depends
on regular and adequate feedstock availability which, in turn, is determined by the
hydrocarbon resources and government policies. Notwithstanding these factors, the
chemical industry is poised for an impressive growth, aided by a strong scientific and
industrial infrastructure, manpower resources and favorable government policies.
5. New industry initiatives encouraged by government policies and incentives are

generating a vast range of industrial development programmes. Balanced dispersal of
chemical industries is an important consideration not only for distributing the
opportunities but also to avoid overcrowding which would place unduly heavy strain on
social infrastructure and associated facilities.
Problems connected with environmental pollution call for care in the selection of
environmentally acceptable options for mass production of chemical products. Compared
to the situation during the initial phases of its development, the chemical industry is now
increasingly responsive to the hazards of pollution and is willing to bestow more care in
the selection of process technologies as well as plant sites. The infrastructure
corporations of various State Governments and Union Territories have also started
planning for functional industrial estates exclusively meant for highly polluting chemical
Industries. The concept of preliminary treatment at the individual unit level and a well-
conceived collection system followed by combined treatment and disposal of effluents is
gradually getting accepted in industrial area planning. However, keeping in view the
heterogeneous nature of chemical industry which consists of tiny, small, medium and
130
large scale sectors, there is need for developing appropriate strategies for treating
effluents and gaseous emissions so that damage to environment is minimal.
GOVERNMENT'S CONCERN FOR CHEMICAL PLANT SAFETY
Chemical and petrochemical manufacturing activities involving hazardous chemicals

have the potential to give rise to serious injury or damage beyond the vicinity of the
manufacturing area. Some indicative data on accidents and losses are shown in
Annexure I. Practical guidelines are needed for the protection of the health and safety of
plant personnel and population living outside the concerned manufacturing plant
boundary as well as the protection of the environment. The chemical and petrochemical
plants employing dangerous, explosive, flammable and toxic substances have therefore,
to convince the environmental protection agencies and the Government that major
accident hazards have been recognized and measures have been taken to prevent accidents
and to control and minimize the consequences of those that do occur. Recent chemical
disasters - particularly Seveso, Mexico and Bhopal - have increased public awareness of
potential hazards to the community. This has brought a greater urgency to undertake
scientific safety assessment of the existing chemical plant installations.
RISKS IN CHEMICAL PLANT
The types of risks in chemical and

petrochemical manufacture can be broadly classified as under:
o Runaway reactions, explosion, fire or such disaster in a plant handling or

producing dangerous, inflammable or toxic substances;
o Design faults leading to accidental mixing of chemicals and consequent
hazards;
o Storage of large quantities of dangerous substances vulnerable to
decomposition, explosion or toxic emissions caused by variations in
temperature, pressure or ingress of foreign substances;
o Contamination of products intended for human or animal consumption by toxic
products or substances in the same plant;
o Accidents during transportation;
131
o Improper waste disposal practices resulting in serious environmental

pollution.
o Accidents due to human failure;
9. The Department of Chemicals and Petrochemicals, Ministry of Industry,
Government of India, has been concerned about these risk aspects with particular
reference to industrial manufacture of chemicals, pesticides, drugs and petrochemicals.
The following points have been identified as crucial for the safety of these plants:
Hazard identification
Location of an installation in relation to its surroundings; subsequent
additions and expansions
Assessment of likely damage
For new chemical plants, safety will have to feature very prominently in process
technology selection and implementation. From purely technological consideration, safety
has clearly a higher priority than economics, but from techno-economic considerations,
safety and economics can be made compatible by adequate attention to design. By using
the concept of inherent or intrinsic safety, new plants can be so designed that they use
relatively safer raw materials and intermediates or use the hazardous chemicals at
milder operating conditions. Inherently safe design requires the approach of risk
assessment. This is an area wherein expertise available within the country is very
limited and there is urgent need to develop this capability.
To undertake the inspection and survey of the hazardous

chemicals, petrochemicals and drug units.
To make specific recommendations to control the hazards in

the plants and suggest measures required to improve the overall
safety.
To prepare a check list of items requiring periodical inspection

in such plants.
132
133

Elements of Safety Management

Caricato da

Informazioni sul documento

Descrizione originale:

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

Elements of Safety Management

Caricato da

Copyright:

Formati disponibili

Elements of Safety Management MEEG721

M.Tech in Health, Safety & Environment Engineering

Educational Qualification Improvement Programme

Indian School of Petroleum & Energy

University of Petroleum & Energy Studies

S.NO. CHAPTER NAME PAGE NO.

UNIT-I Introduction to SHE aspects 3

UNIT-III Safety Policy, Organization, Monitoring and 41

UNIT-IV Emergency/Disaster Plans 64

UNIT -V Process safety management 51

UNIT-VI First Aid 73

UNIT-VII Safety officer role & responsibility 80

UNIT-VIII Major disaster 88

Material Handling Processes

INTRODUCTION TO SHE ASPECTS

HSE MODEL AND ITS INTEGRATION WITH BUISNESS:

HSE is an integrated management comprising discipline of occupational, health and

Injury/ loss of life to self or co-workers

HSE MANAGEMENT FRAME WORK:

undertake meaningful inspection visits to a large number of installations under their

To control or reduce industrial hazards, a number of regulations have been framed by

REGULATORY/ STATUTORY AGENCIES:

Central Pollution Control Board ( CPCB) under the Ministry of

Chief Controller Of Explosives (CCE) , Ministry of Heavy Industry, Dept of

VARIOUS REGULATIONS/ REQUIREMENTS:

Important regulations are briefly discussed below.

PETROLEUM ACT , 1934

Import, storage and refueling

THE STATIC AND MOBILE PRESSURE VESSELES, SMPV (UNFIRED)

THE GAS CYLINDER RULES, 1981

THE FACTORIES ACT, 1948

General responsibilities of occupier are listed below.

Declaring safety policy of the organization

Disclosures of information to workers, public and authorities. This should

A safety committee having equal representation of workers and management

Setting up of medical/ occupational health center suitably equipped with

Inspection, testing, examination and certification of equipment and vessels etc.

Provide adequate fire protection system as per rules.

An emergency communication system alarm siren etc. should be in place and

Safety manual containing the different safety procedures applicable to the

Providing PPE to workers depending on the nature of hazard involved.

Display necessary precautionary notices and instructions at prominent places to

Appointing a qualified safety officer in the premises as per rules.

Providing welfare amenities like drinking water facilities, washing facilities,

Sending any accidental report and notice of any poisoning or occupational

Keeping this in view, government of India enacted the various environmental

The water (Prevention and Control of Pollution) Act, 1974

The water (Prevention and Control of Pollution) Cess Act, 1977

The air (Prevention and Control of Pollution) Act, 1981

The Environment ( protection) Act, 1986

The Environment (protection) Rules , 1986

Manufacture, storage, and import of hazardous chemicals Rules, 1989

Hazardous waste management ( management and handling) rules, 1989

Environmental clearance of project notification,1994

THE INDIAN BOILERS ACT, 1923

Each state has its own boilers regulations.

A working certificate showing validity period, maximum allowable pressure etc. is

If it is not registered or not having the valid certificate

It is mandatory that all the electrical installations should confirm to requirements of

THE OIL MINES REGULATIONS, 1984

THE INDIAN AIRCRAFT RULES, 1937

An installation, which is in the proximity of the Aerodromes, is covered under the

INTERNATIONAL MARITIME ORGANISATION (IMO-1986)