Lecture 2

Safety Practices in Chemical and

Nuclear Industries
Chemical Laboratory Safety
&
Personal Protective Equipments

Dr. Raghuram Chetty

Department of Chemical Engineering
Indian Institute of Technology Madras
Chennai- 600 036.
Planning for accidents

Murphy’s Law: “If there are two or more ways to do

something, and one of those ways can result in a
catastrophe, then someone will do it.”
Introduction

 Significant technological advances have been made in

chemical plant safety.
 Today, safety is equal in importance to production and has
developed in to a scientific discipline that includes many
highly technical and complex theories and practices.
 Recent advances emphasize the use of appropriate
technological tools to provide information for making
safety decisions with respect to plant design and
operation.
Introduction

 The word “safety” used to mean the older strategy of

accident prevention through the use of hard hats,
safety shoes, and a variety of rules and regulations.
The main emphasis was on worker safety.

 More recently “safety” has been replaced by loss

prevention. This term includes hazard identification,
technical evaluation, and the design of new
engineering features to prevent loss.
 Safety Programs

A successful safety program requires several elements:

 System
 Attitude
 Fundamental
 Experience
 Time
 You
Most effective means of implementing a safety program is to make
it everyone responsibility in a chemical plant.
We'll explore safety issues from lab safety to personal protective
equipment to chemical plants.
Safety

Image courtesy: Google Images

Risk and Hazard

 A hazard is any source of

potential damage, harm or
adverse health effects on
something or someone under
certain conditions at work.
Hazard can cause harm or
adverse effects (to individuals
as health effects or to
organizations as property or
Risk = Hazard x Exposure
equipment losses).

Image courtesy: Google Images

Risk and Hazard

 Risk is the chance or

probability that a person
will be harmed or
experience an adverse
health effect if exposed to
a hazard. It may also apply
to situations with property
or equipment loss.
Risk = Hazard x Exposure
 Danger & Accident

 Danger: Relative exposure to

hazard

 Accident: An undesirable or
unfortunate happening that
occurs unintentionally and
usually results in harm, injury,
damage, or loss, casualty,
mishap. Risk = Hazard x Exposure
 Hazard
Workplace hazards can come from a wide range of sources.
General examples include any substance, material, process,
practice, etc. that has the ability to cause harm or adverse
health effect to a person under certain conditions is given
below.
Examples of Hazards and Their Effects

Workplace Hazard Example of Hazard Example of Harm Caused

Thing Knife Cut
Substance Benzene Leukemia
Material Asbestos Mesothelioma
Source of Energy Electricity Shock, electrocution
Process Welding Metal fume fever
Hazard

Workplace hazards also include practices or conditions that

release uncontrolled energy like:
 an object that could fall from a height (potential or
gravitational energy)
 a run-away chemical reaction (chemical energy)
 the release of compressed gas or steam (pressure;
high temperature)
 entanglement of hair or clothing in rotating equipment
(kinetic energy)
 contact with electrodes of a battery or capacitor
(electrical energy).
Risk

 Risk is the chance or probability that a person will be

harmed or experience an adverse health effect if
exposed to a hazard. Factors that influence the degree
of risk include:
 how much a person is exposed to a hazardous thing
or condition,
 how the person is exposed (e.g., breathing in a
vapour, skin contact), and
 how severe are the effects under the conditions of
exposure.
Risk

 For example:
 The risk of developing cancer from smoking cigarettes
could be expressed as "cigarette smokers are 10 times
more likely to die of lung cancer than non-smokers or
‘X’ number of smokers are likely develop lung cancer.

 Whereas, hazard refers to lung cancer, heart disease,

etc. from cigarette smoking.
How do I know if it is hazardous?
 Many commonly used chemicals are hazardous
(potentially dangerous).

 Hazard information is usually provided on the label in

the form of a symbol, a letter or a standard wording.

 Hazards are related to the properties (or activity) of the

compound.

 Further information is found in the suppliers catalogue

(Risk/Safety factors), chemical safety indexes, MSDS.
Chemical Hazard Symbols

Oxidising Agent
Corrosive

Explosive
Harmful

Toxic
Dangerous for the
environment
Flammable

Radioactive
Biohazard
 Flammable

Examples of safe work

Hazard Class Class description Hazards practices

Flammable and Keep away from heat,

Combustible material sparks, and open flames.
Solids, liquids, and May readily burn or
gases capable explode if placed Post no smoking signs in
of catching fire or near heat, sparks, work or storage areas.
exploding in the or open flames.
presence of an ignition Keep the minimum quantity
source. in the work area.

Store away from oxidizers.

Examples:
white phosphorus, Label containers
acetone, propane FLAMMABLE.

Make sure fire

extinguishers are available
and working.
 Oxidising agent

Hazard Class Class Hazards Examples of safe work

description practices

Oxidizing May cause fire if in contact Use only the minimum

material with flammable and amount necessary.
Materials that combustible materials,
provide oxygen even without a source of Keep only the minimum
or similar ignition or oxygen. amounts needed in the
substance work area.
May increase the speed
and intensity of a fire. Keep the work area
clear of unneeded
May cause materials materials that could
normally considered non- react with the oxidizers.
Examples: combustible to burn
organic rapidly. Store away from
peroxides, flammable materials,
nitrates, May react with other organic materials, and
perchlorates chemicals to produce toxic reducing agents.
gases.
 Corrosive
Hazard Class Class Hazards Examples of safe work
description practices

Corrosive material Use corrosion-resistant

equipment and containers.
Caustic or acid Burns eyes and
materials that skin on contact. Always use eye protection
can destroy skin and gloves; use other
or eat through Burns tissues of personal protective
metals. respiratory equipment as appropriate.
system if vapours
are inhaled. Add acid slowly to water;
never add water to acid.
Store acids and bases
separately from each other.
Examples:
hydrochloric acid, In case of skin or eye contact
sodium hydroxide with corrosives, flush area
with cool water for 15
minutes, remove affected
clothing, and get medical
help.
Toxic
Hazard Class Class Hazards Examples of safe work
description practices

Poisonous materials Use appropriate control

causing immediate measures (e.g., fume
and serious toxic Materials that May cause hood, personal protective
effect. can cause the immediate and equipment).
death of a serious toxic
person exposed effects. Use engineering controls
to and personal protective
small amounts. May cause death equipment to eliminate or
or serious injury ifminimize exposure.
inhaled, swallowed,
or absorbed Establish wash-up and
through the skin. clean-up procedures to
prevent contamination.
Examples:
sodium cyanide, Ensure that workers
hydrogen sulfide understand the health
hazards and the primary
routes of exposure before
using chemicals.
Symbols in Chemicals Supply List

 Toxic (T)

 Very toxic (T+)

 Harmful (X)

 Irritant (Xi)

 Corrosive (C)
 Label Information

 A chemical hazard label is a

pictogram applied to containers of
dangerous chemical compounds to
indicate the specific risk, and thus
the required precautions. There
are several systems of labels.
 The US based National Fire
Protection Association use a
diamond with four colored sections
each with a number indicating
severity 0-4 (0 for no hazard, 4
indicates a severe hazard).
 Label Information

 The blue section denotes

health risks.
 Yellow represents reactivity
(tendency to explode).
 The red section denotes
flammability.
 The white section denotes
special hazard information.
 This label is used primarily in
the USA.
Image courtesy:
Google Images
 Incompatible chemicals
Chemical Incompatible with the following common chemicals

Acetone Concentrated nitric and sulfuric acid mixtures, and strong bases

Ammonia (anhydrous) Mercury, chlorine, calcium hypochlorite, iodine, bromine, HF

Carbon tetrachloride Diborane, fluorine, sodium

Dimethyl sulfoxide Perchloric acid, silver fluoride, potassium permanganate, acetylchloride,

benzene sulfonyl chloride

Hydrogen peroxide Copper, chromium, iron, most metals or their salts, alcohols, acetone,
organic materials, aniline, nitromethane, flammable liquids,
combustible materials

Nitric acid (concentrated) Acetic acid, aniline, chromic acid, hydrocyanic acid, hydrogen sulfide,
flammable liquids, flammable gases, copper, brass, any heavy metals

Oxalic acid Silver, mercury

Potassium permanganate Glycerol, ethylene glycol, benzaldehyde, sulfuric acid

Sodium Carbon tetrachloride, carbon dioxide, water

Sulfuric acid Potassium chlorate, potassium perchlorate, potassium permanganate

(and similar compounds of light metals such as sodium, lithium)
Incompatible chemicals

Image courtesy: Google Images

 Classes of Toxicity
All chemicals are toxic at sufficiently high concentrations.
Toxicologists determine safe levels. Toxic may be immediate or
may require an incubation time.
Poisons
 In our bodies, various organs (liver, kidney, digestive tract,
heart and so on) perform specific aspects of necessary
body function. These contains a variety of cells containing
proteins, enzymes.
 A foreign chemical may reach a concentration in the body at
which its presence begins to interfere with one or more of
these normal enzyme-catalyzed cell processes. The cell
then alters its functions, reduces its contribution to the
organism, or dies. E.g. cyanides, CCl4, Pb, Hg, Cd.
Classes of Toxicity
Mutagens
 A mutagen is a substance that cause damage to the
DNA. The most important mutagens are either specific
chemicals or radiation such as X-rays, radioactive
emissions, and ultraviolet light.
Carcinogens
 Carcinogens increase the likelihood of cancer
occurring. Most carcinogens are mutagens.
Teratogens
 Teratogens damage a fetus during development,
producing birth defects.
 Chemical Accident
 Depending upon the toxicity of the material involved, the
most common kinds of problems that might be caused due
to a chemical leak or accident might include:

 Irritation to eyes, throats, difficulty in breathing, etc.

 Pollution and/or poisoning of air, water-bodies etc.
 Impact on vegetation and animals (including species in
water-bodies)
 Fumes
 Fire and explosion
Fire Classification

Fires are identified according to one or more fire

classes for firefighting purpose.

Each class designates the fuel involved in the fire,

and the classifications allow selection of
extinguishing agents along lines of effectiveness at
putting the type of fire out, as well as avoiding
unwanted side-effects. For example, non-conductive
extinguishing agents are rated for electrical fires, so
to avoid electrocuting the firefighter
Fire Classification

American European Australian/Asian Fuel/Heat source

Ordinary
Class A Class A Class A
combustibles
Class B Class B Flammable liquids
Class B
Class C Class C Flammable gases
Electrical
Class C UNCLASSIFIED Class E
equipment
Class D Class D Class D Combustible metals

Class K Class F Class F Cooking oil or fat

Fire Classification in US
Class Source Examples

Ordinary
A Wood, paper, cloth
combustibles

B Liquid fuels Solvents, oil, gasoline

C Electrical Fuse boxes, motors

Combustible Sodium, potassium,

D
metals phosphorous

K Cooking Media Oils, fats

 Fire Classification in India

India - Classification of fires as per ISI 2190/1979

Class 'A' Fires

Fire involving combustible material such as wood,
paper, cloth, rubber, plastic requiring the heat
absorbing effects of water, water solutions.
Class 'B' Fires
This type of fire involves flammable or combustible
liquids greases, petroleum products and similar
materials for extinction, a blanketing effect is essential.
 Fire Classification in India

India - Classification of fires as per ISI 2190/1979

Class 'C' Fires
Which involves flammable gases, substance under
pressure including liquified gasses. Here it is
necessary to dilute the burning gasses at very fast rate
with an inert gas, Dry chemical powder or CO2 .
Class 'D' Fires
Fire involving combustible metals such as sodium,
magnesium, zinc, potassium. These burning metal
react with water and water containing agent. These
fire requires special media to extinguish such as
carbon dioxide or special dry chemical powder.
 Fire Extinguisher

Class of
Extinguisher characteristics
fire
Dissipates so quickly that hot fuel may
Carbon dioxide B, C
reignite. Ineffective on class A fires
A-B-C Most versatile, but leaves mildly
A, B, C
Dry chemical corrosive powder that must be cleaned
Dangerous if used in many laboratory
Water A situations, such as around equipment
or water-reactive chemicals
Class D
D Designed for metal fires only
Dry chemical
Reduces the fire’s temperature with
Class K extinguishing the flames by reacting
K
Wet Chemical with cooking oils. Designed for
commercial kitchens.
 Fire Extinguisher

Type A: Water
extinguisher
Type BC extinguishers:
Sodium or potassium
bicarbonate.
Type ABC extinguishers:
Ammonium phosphate
Type D: Metal/Sand
Extinguishers

Image courtesy: Google Images

 Fire Extinguisher

Image courtesy:
Google Images
 Fire Extinguisher

 Dry chemical extinguishers can be quite corrosive to

metals such as aluminum and are also potentially abrasive.
 ABC extinguishers are much more corrosive than BC
extinguishers because the ammonium phosphate agent
can undergo hydrolysis to form phosphoric acid and
because the molten agent flows into minute cracks
 For this reason, dry chemical ABC extinguishers are not
recommended for use on aircraft or electronics such as
computers and scientific instruments.
Fire Extinguisher

 CO2 (carbon dioxide) extinguishers are for class B and C

fires. They don't work very well on class A fires because
the material usually reignites. CO2 extinguishers have an
advantage over dry chemical in that they leave behind
no harmful residue. That makes carbon dioxide a good
choice for an electrical fire involving a computer or other
delicate instrument.
 CO2 is a bad choice for a flammable metal fires such as
Grignard reagents, alkyllithiums and sodium metal
because CO2 reacts with these materials. CO2
extinguishers are not approved for class D fire.
 Fire Extinguisher

 Metal/Sand Extinguishers are for flammable metals (class

D fires) and work by simply smothering the fire. The most
common extinguishing agent in this class are sodium
chloride, powder Cu metal, graphite powder.
Occupational Health and Safety Administration

 OSHA, created within the Department of Labor, U.S.

Govt. in 1970, to bring uniformity to health and safety
standards.

 The OSH Act intends to prevent injury or illness among

workers.
Occupational Health and Safety Administration
The power and responsibilities of OSHA include the
following:
 To establish safety and health standards.
 To conduct workplace inspections and issue citations
for health and safety violations.
 To require records of safety and health to be kept by
employers, and in conjunction with the Department of
Health, keep occupational health and safety statistics.
 To train employers, employees and personnel
employed to enforce the act.
 OSHA and the EPA share information.
International Labour Organization (ILO)

 International Labour Organization (since 1919) has

maintained and developed a system of international labour
standards aimed at promoting opportunities for women
and men to obtain decent and productive work, in
conditions of freedom, equity, security and dignity.
International Labour Organization (ILO)

 In today's globalized economy, international labour

standards are an essential component in the international
framework for ensuring that the growth of the global
economy provides benefits to all.

 The ILO Constitution sets forth the principle that workers

should be protected from sickness, disease and injury
arising from their employment.
 The Factories Act, 1948

In India the first Factories Act was basically designed to protect

children and to provide few measures for health and safety of
the workers.
“Factory” is defined in Section 2(m) of the Act. It means any
premises including the precincts thereof-
 Whereon ten or more workers are working, or were working
on any day of the preceding twelve months, and in any part
of which a manufacturing process is being carried on with
the aid of power, or is ordinarily so carried on; or
 But does not include a mine subject to the operation of the
Mines Act,1952 or a mobile unit belonging to the Armed
forces of the Union, a railway running shed or a hotel,
restaurant or eating place.
 The Factories Act, 1948

 The following have held to be a factory:

 Salt works
 A shed for ginning and pressing of cotton
 A Bidi making shed
 A Railway Workshop
 Composing work for Letter Press Printing
 Saw Mills
 Place for preparation of foodstuff and other eatables
 The Factories Act, 1948

The Factories Act, 1948 came into force on the 1st day of
April, 1949 and extends to the whole of India.
The Factories Act was amended in 1949, 1950, 1954, 1956,
1976 and 1989.
The Act has been enacted primarily with the object of
protecting workers employed in factories against
industrial and occupational hazards. For that purpose, it
seeks to impose upon the owner or the occupier certain
obligations to protect the workers and to secure for them
employment in conditions conducive to their health and
safety.
 The Factories Act, 1948

 Employer to ensure health of workers pertaining to

 Cleanliness, disposal of wastes and effluents - Sec 12

 Ventilation and temperature dust and fume - Sec 13
 Overcrowding artificial humidification Lighting – Sec. 14
 Drinking water spittoons - Sec. 18
 The Factories Act, 1948
Safety Measures
 Fencing of machinery – Sec. 21
 Work on near machinery in motion – Sec 22
 Employment prohibition of young persons on dangerous
machines – Sec 23
 Striking gear and devices for cutting off power – Sec 2
 Self-acting machines - Sec 25
 Casing of new machinery- Sec 26
 Prohibition of employment of women and children near
cotton-openers - Sec 27
 Hoists and lifts - Sec 28.
 The Factories Act, 1948
OFFENCE
 For contravention of the Provisions
of the Act or Rules
 On contravention of Chapter IV
pertaining to safety or dangerous
operations.
 Obstructing Inspectors
 Wrongful disclosing result pertaining
to results of analysis.
 For contravention of the provisions
of Sec.41B, 41C and 41H pertaining
to compulsory disclosure of
information by occupier, specific
responsibility of occupier or right of
workers to work imminent danger.
PENALTIES
 Imprisonment upto 2 years or fine upto
Rs.1,00,000 or both
 Not less than Rs.25000 in case of
death.
 Imprisonment upto 6 months or fine
upto Rs.10,000 or both.
 Imprisonment upto 6 months or fine
upto Rs.10, 000 or both.
 Imprisonment upto 7 years with fine
upto Rs.2,00,000 and on continuation
fine @ Rs.5,000 per day.
 Imprisonment of 10 years when
contravention continues for one year.
 Frequent/Common Industrial Hazards
1. Power Tools
2. Flying/Falling Objects
3. Moving machinery
4. Eye Injuries
5. Electrical hazards
6. Minor Cuts/Bruises/Abrasions/Slips
7. Dust Inhalation
8. Burns and/or frostbite
9. Chemical Spills/Caustic Chemicals
10. Ergonometric injuries
 Personal Protective Equipment (PPE)
What is PPE?
Equipment that employers/workers wear to protect
themselves from hazards in their work environment.
Examples
lab coats/ aprons
safety goggles
hard hats
gloves
safety shoes
hearing protection
respirators
 When is PPE Necessary?

Hazard Example Common related tasks

Impact Flying objects such as large Chipping, grinding, machining, masonry
chips, fragments, particles, work, wood working, sawing, drilling,
sand and dirt. riveting, etc.
Heat Anything emitting extreme Furnace operations, pouring, casting, hot
heat. dipping, welding, etc.

Chemicals Splash, fumes, vapors, and Acid and chemical handling, degreasing,
irritating mists. plating, etc.
Dust Harmful dust. Woodworking, buffing, and general dusty
conditions.
Optical Radiant energy, glare, and Welding, torch-cutting, -brazing,
intense light -soldering and laser work.
Radiation
 When is PPE Necessary?
 Safety goggles are intended to
shield the wearer's eyes from
impact hazards such as flying
fragments, objects, large chips,
and particles.
 Goggles fit the face immediately
surrounding the eyes and form a
protective seal around the eyes.
This prevents objects from
entering under or around the
goggles.
When is PPE Necessary?
 Impact hazards
 Falling objects or potential for dropping
objects.

 Penetration Hazards
 Objects or machinery that may cause
punctures, cuts, or abrasions.

 Compression Hazards
 Machinery/heavy objects that may roll
over and crush or pinch feet.
 When is PPE Necessary?
 Chemical Hazards
 Chemical exposures from inhalation or
contact with the skin and eyes.
 Harmful Dust
 Dust from sandblasting, sawing,
grinding, or other generation of airborne
dust.
 Heat/Cold Hazards
 Hot/cold work areas and sources of
high/low temperature that could result in
burns.
 When is PPE Necessary?
 Noise Hazards
 Excessive noise (louder than a hair
dryer).

 Electrical Hazards

 Optical Radiation: Lasers

 Workers with exposure to laser beams
must be furnished with suitable laser
safety goggles which will protect for
specific wavelength of the laser.
Prevention of the Frequent Hazards
1. Power Tools – Training (Limited Access)
2. Falls/Falling Objects – Training (PPE-hardhats)
3. Moving machinery – Training (Lockout)
4. Eye Injuries – (PPE- safety goggles)
5. Electrical hazards – (Trained Staff)
 Prevention of the Frequent Hazards
6. Minor Cuts/Bruises/Abrasions/Slips – Safety Awareness,
Housekeeping
7. Dust Inhalation – (PPE - dust masks)
8. Burns and/or frostbite – (Training & Awareness, PPE)
9. Chemical Spills/Caustic Chemicals – Training &
Awareness, PPE)
10. Ergonometric injuries (strains, sprains) - Awareness
 Lockout Tag & Hot Work Permit

Image courtesy: Google Images

Summary

 Hazards are related to the properties of the compound

(or activity)
 Risk is related to the chance of an accident happening
and the hazard involved
 Chemical Hazard Symbols
 Incompatible chemicals
 Fire classification and fire extinguisher
 OSHA and Factories Act
 Personal Protective Equipment