QUESTIONS ON SAFETY

1.What factors lead to the injury of a worker?

Dangerous Materials ii) Hazards of Pressure Vessels iii) Hazardous Chemical Reactions
iv) Hazardous of Unit Operations v) Flammable Gases, Vapours And Dust Hazards
vi) Health Hazards vii) Hazards due to corrosion viii) Entry in To Confined Spaces ix)
Working with Pipelines x) Plant Alteration and modification xi) Sampling and Gauging xii)
Hazards due to Instrument Failures.
2.Give two examples of unsafe act
All moving parts, flywheels, Head race and trail race of water turbine, electric generator,
motor, transmission machinery and other machines are to be fenced.
Work on or near moving machinery: This has to be done by trained adult with tight fitting
clothing
3.What is meant by chronic toxicity?
It is the development of adverse effects as the result of long term exposure to a toxicant
Use of C6H5CH3 and CHCl3
4.List few toxic chemicals.
There are generally three types of toxic entities; chemical, biological, and physical: Chemical
toxicants include inorganic substances such as, lead, mercury, hydrofluoric acid, and
chlorine gas, and organic compounds such as methyl alcohol, most medications, and poisons
from living things.
5.Name two major industrial accidents that were catastrophic in nature.
Fire accident and poisonous gas leakage
Bhopal Tragedy of leakage of methyl isocyanade from a battery manufacturing chemical
industry.
(ii). Leakage of radio active radiations from an atomic power plant in Chernobyl in Russia.
6.What is meant by periodic advice?
Advices regarding (i) The conditions of all types of equipments (ii). General behaviour of the
workers and whether there is any need for counseling, training or so. (iii). General house
keeping.
7.What are remedial measures for safety.
Prompt and reasonably through corrective action should follow the inspection findings. If
this does occur, the blame is on the management only. Each report should be kept active
until every item on it has received considerable and proper disposal.
8.What are accident spots?
Moving equipments, belt conveyors, chain pulley, etc (ii). High temperature and high
temperature equipments (iii). All electrical installations (iv). Storage of flammable and toxic
materials.

9.List the industrial health hazards.

Industrial hazards are hazards that are associated with different industries depending upon the
nature of operation and equipments, coupled by faulty behavior of people working over there.

10.What is vocational guidance?

Vocational guidance is a scientific method of selecting workers. Guidance aims at finding out
what type of job will suit a particular workers and selection aims at searching out what type
of worker from various applicants will fit in the job, as employment of unfit workers is a
wastage to industry.

Part B
11.a. Discuss the importance of safety consciousness in chemical industries
Safety Consciousness: Safety Consciousness is defined as the complete knowledge possessed
by the workers regarding different types of Hazards that are associated with Process
conditions and equipments in a working environment

Statistical evidence clearly demonstrates that different individuals can have different rates of
accidents from one another; for example, young male drivers are the group at highest risk for
being involved in car accidents. There also seems to be substantial variation in personal
accident rates between individuals.

However, a number of studies have cast doubt on whether accident-proneness actually exists
as a distinct, persistent and independently verifiable physiological or psychological
syndrome. Although substantial research has been devoted to this subject, there still seems to
be no conclusive evidence either for or against the existence of accident proneness in this
sense.
Nature and causes
The exact nature and causes of accident-proneness, assuming that it exists as a distinct entity,
are unknown. Factors which have been considered as associated with accident-proneness
have included absent-mindedness, carelessness, impulsivity, predisposition to risk-taking, and
unconscious desires to create accidents as a way of achieving secondary gains.

11.b. Discuss the importance of safety training at various levels of operation.

Inspection as a check on quality of product is an essentiality f production. Inspection to
discover conditions that if uncorrected may be the cause of accidents and injuries is essential
to first rate safety performance. A person working in the plant would have a considerable
advantage when he is asked to undertake an inspection of his own establishment. Most of the
discussed points on the one call inspection are valid for the continued inspection work also.
Inspection schedule: In theory at least safety inspection should be added only where
inspection incidental to production is not adequate for safety

Safety inspection check list for a chemical plant.

(i). Pessure vents.
(ii). Relief Valves.
(iii). Control Valves.
(iv). Sparger – To disperse a gas through a liquid.
(v). Heat Exchangers and condensers.
(vi). Pressure vacuum stills.
(vii). Reactors.
(viii). Lagging.
(ix). Recorders, meters, gauges.
(x). Heating coils.
(xi). Drains,
(xii). Exhaust equipments.
(xiii). Manhole.
(xiv). Escape facilitates during emergencies.
CORRECTIVE ACTION:

Prompt and reasonably through corrective action should follow the inspection findings. If
this does occur, the blame is on the management only. Each report should be kept active
until every item on it has received considerable and proper disposal.

12.a. Define hazard. classify the hazards and its effects according to chemical properties
A hazard is a situation that poses a level of threat to life, health, property, or environment.
Most hazards are dormant or potential, with only a theoretical risk of harm; however,
once a hazard becomes "active", it can create an emergency situation.
Most of the chemical and physical agents in the industry are potentially harmful to man.
Prolonged regular exposure at some air-borne contain can give chronic occupational
diseases. Brief contact may cause acute diseases. Examples of adverse effects on human
body are given below.
Respiratory system:
 Sulfur dioxide, aerolein, chromic acid mist and other chemical
causes coughing initially and chronic bronchiotis on prolonged
periods.
 Chlorine, phosgene, nitrogen oxides will cause damages to
tissues of respiratory system resulting in accumulation of
fluids in lungs.
 Repeated inhalation of fumes form coal tar pitch, nickel
refining, fibres of asbestos may result in lung cancer.

SKIN:
 Prolonged contact of acid and alkali causes skin irritation.
 Original solvents cause dermatitis by their irritant action.
 Unrefined mineral oils, coal tar pitch and arsenic compounds
causes skin cancer.

EYE:
 Eyes are vulnerable to attack by all air-borne contaminants.
Eye surface is more sensitive to mild compounds.
 BLOOD:
 Lead and benzene causes anemia by affecting blood forming
process in bone marrow.
 Carbon dioxide and some nitrates react with hemoglobin and
reduce the capacity if blood to transport oxygen.
LIVER:
 Carbon tetrachloride, selenium compounds have toxic effect
on the liver, which may lead to jaundice.
 Vinyl chloride on prolonged exposure induces liver cancer.

KIDNEYS:
 Heavy metals can produce injury to the kidneys.

BLADDER:
 Aromatic amines like naphthylamine and benzedine cause
bladder injury.

NERVOUS SYSTEM:
 Organic chemicals like hexane, methyl butyl ketone and tri-
cresylphosphate damage nerves.
 Some organ phosphorous compounds interfere with nerve
impulses.

12.b. What are the factors to be considered in the plant layout?

It is the arrangement of machines within a factory, so that each operation is performed at a
point of greatest convenience.
Objectives: (I). Minimum Utilization of floor area
(ii). Lighting and ventilation of area.
(iii). Minimizing accidents.
(iv). Space for future developments.
(v). Safety of equipments, and personnel.
(vi). Better working conditions.
(vii). Easy supervision.
(viii). Neatness.
A good plant planning and layout is a big help in promoting safe working
environment. Site choice and planning, transportation facilities, layout etc., should normally
receive detailed consideration at the early stages of planning a new project. Safety requires
constant attention to .,
(i). Storage and handling facilities for explosive and flammable substances as raw materials,
intermediate products and finished product stages.
(ii). Electrical equipment, wiring and installation lighting power supply including emergency
stand by power.
(iii). Boiler and other pressure equipments.
(iv). Ventilation, heating and air Conditioning.
(v). Fire protection.
(vi). Waste and effluent disposal.
(vii). First aid, medical facilities, personnel protective equipments, noise and sanitation etc.
The important points to be remembered in lay out are.,
(i). Segregation of hazardous process areas.
(ii). Provision of a separate area for storage of flammable and hazardous materials.
(iii). Provisions of separate location for furnaces, heaters etc.,
(iv). Using flame at a safe distance from areas where flammable and volatile materials are
housed.
(v). Ventilation and lighting.

13.a. What are personal protective equipment? Discuss the importance

Biological hazard protection
Protective equipment for biological hazards includes masks worn by medical personnel
(especially in surgery to avoid infecting the patient but also to avoid exposing the personnel
to infection from the patient.) Gloves, frequently changed, are used to prevent infection but
also transfer between patients. One measure to reduce the risks of transmitting skin
microorganisms from one person to another is in the use of single use disposable blood
pressure cuff covers. Reports of hospitals reducing their hospital acquired infection rate by
nearly 50% through the use of disposable protective covers for blood pressure cuffs have
been reported.
Ballistic
Ballistic personal protective equipment (or armor) is used in combat by military personnel
and in lesser conflicts by law enforcement.
Chemicals
A hazmat suit is an impermeable garment that covers the whole body, worn as protection
from hazardous substances. It is generally combined with breathing apparatus, and may be
used by firefighters, emergency personnel responding to toxic spills, researchers, specialists
cleaning up contaminated facilities, or workers in toxic environments, where there is
exposure to hazardous materials.
Flying debris or splashing liquids
A face shield protects from flying debris such as produced by cutting, welding, chipping, or
sanding, and protects against splashes or spray of liquids. Safety glasses provide protection
for the eyes and may additionally be tinted to block UV or laser light. Goggles seal tightly
about the eyes and provide superior protection from dust, dirt, and fumes.
Sharp injuries
Meat packers and others who routinely use hand-held knives in their work may use mail
gloves to protect the hands from cuts. Those in other professions where sharps injuries are a
concern often utilize cut and puncture resistant protective gloves, and hand held safety tools
that offer critical stand-off distance between themselves and whatever they may come into
contact.
Blunt trauma
Law enforcement and Corrections officers wear for crowd management, civil disturbances,
cell extractions, riot control, violent disturbances, and other emergency response operations.
To assure their equipment is safe, end-users and industry refer to standards:

13.b.How chemical poisoning occurs in chemical plant. What are the treatments.
ammonia - Ammonia is a volatile compound that can irritate the respiratory system and
mucous membranes if inhaled, can cause a chemical burn if it is spilled on skin, and will
react with chlorinated products (e.g., bleach) to produce deadly chloramine gas.
antifreeze - Antifreeze is ethylene glycol, a chemical which is poisonous if swallowed.
Breathing it can cause dizziness. Drinking antifreeze can cause serious brain, heart, kidney,
and other internal organ damage. Ethylene glycol has a sweet flavor, so it is attractive to kids
and pets. Antifreeze typically contains a chemical to make it taste bad, but the flavor is not
always a sufficient deterrent. The sweet smell is enough to lure pets.
bleach - Household bleach contains sodium hypochlorite, a chemical that can cause irritation
and damage to the skin and respiratory system if inhaled or spilled on the skin. Never mix
bleach with ammonia or with toilet bowl cleaners or drain cleaners, as dangerous and
possibly deadly fumes may be produced.
drain cleaners - Drain cleaners typically contain lye (sodium hydroxide) or sulfuric acid.
Either chemical is capable of causing an extremely serious chemical burn if splashed on the
skin. They are toxic to drink. Splashing drain cleaner in the eyes may cause blindness
Alternative / Treatments
The hazardous chemicals can be substituted.
Ex: Use of C6H5CH3 instead of C6H6
CHCl3 instead of CCl4
Chalk instead of talc.
2). Segregation: (a). Segregation by time:
The hazardous operations can be conducted when the minimum numbers of workers
are present.
(b). By placing hazardous operation at one end of a workshop in a separate room or in a
separate building minimizes the number of workers at risk.
3). Providing complete enclosures:
Hazardous operations can be completely enclosed with the operators operating for
outside the enclosures.

14.a. How the fire occurs in chemical industries. What are the fire prevention and
protection methods.
Fire is a chemical reaction in which a combustible material combines with oxygen in the
atmosphere to give out heat and flame. The chemical change is called oxidation, and the
process is referred as ‘combustion’.
Rate of combustion varies from substance to substance and is described as slow,
rapid or spontaneous.
(i). Slow combustion is accompanied by slow evaluation of heat but not light. Eg: Cotton
waste burning.
(ii). Rapid Combustion is accompanied by rapid evolution of heat and appreciable amount of
light. Eg: Petroleum Products.
(iii). Spontaneous combustion is due to result of heat by the absorption of the atmospheric
oxygen at ordinary temperature and due to chemical reaction. Eg: Coal, paint, Phosphorous in
contact with wood
:
Fire protection is the study and practice of mitigating the unwanted effects of potentially
destructive fires.[1] It involves the study of the behaviour, compartmentalisation, suppression
and investigation of fire and its related emergencies, as well as the research and development,
production, testing and application of mitigating systems. In structures, be they land-based,
offshore or even ships, the owners and operators are responsible to maintain their facilities in
accordance with a design-basis that is rooted in laws, including the local building code and
fire code, which are enforced by the Authority Having Jurisdiction. Buildings must be
constructed in accordance with the version of the building code that is in effect when an
application for a building permit is made. Building inspectors check on compliance of a
building under construction with the building code. Once construction is complete, a building
must be maintained in accordance with the current fire code, which is enforced by the fire
prevention officers of a local fire department. In the event of fire emergencies, Firefighters,
fire investigators, and other fire prevention personnel called to mitigate, investigate and learn
from the damage of a fire. Lessons learned from fires are applied to the authoring of both
building codes and fire codes.
14.b.Explain the procedure of analysis of injury to men.
Some individuals prefer to expand the analysis into all aspects of the job, not just safety. This
approach is known as total job analysis. Methodoly is based on the idea that safety is an
integral part of every job and not a separate entity. In this document, only health and safety
aspects will be considered.
The terms "job" and "task" are commonly used interchangeably to mean a specific work
assignment, such as "operating a grinder," "using a pressurized water extinguisher," or
"changing a flat tire." JSAs are not suitable for jobs defined too broadly, for example,
"overhauling an engine"; or too narrowly, for example, "positioning car jack."
One of the methods used in this example is to observe a worker actually perform the job. The
major advantages of this method include that it does not rely on individual memory and that
the process prompts recognition of hazards. For infrequently performed or new jobs,
observation may not be practical.
One approach is to have a group of experienced workers and supervisors complete the
analysis through discussion. An advantage of this method is that more people are involved in
a wider base of experience and promoting a more ready acceptance of the resulting work
procedure. Members of the joint occupational safety and health committee must participate in
this process.
Initial benefits from developing a JSA will become clear in the preparation stage. The
analysis process may identify previously undetected hazards and increase the job knowledge
of those participating. Safety and health awareness is raised, communication between
workers and supervisors is improved, and acceptance of safe work procedures is promoted.
A JSA, or better still, a written work procedure based on it, can form the basis for regular
contact between supervisors and workers. It can serve as a teaching aid for initial job training
and as a briefing guide for infrequent jobs. It may be used as a standard for health and safety
inspections or observations. In particular, a JSA will assist in completing comprehensive
accident investigations.

15.a. Discuss the hazard of commercial chemical operation in a chemical plant

Areas of Concern
i) Dangerous Materials ii) Hazards of Pressure Vessels iii) Hazardous Chemical Reactions
iv) Hazardous of Unit Operations v) Flammable Gases, Vapours And Dust Hazards
vi) Health Hazards vii) Hazards due to corrosion viii) Entry in To Confined Spaces ix)
Working with Pipelines x) Plant Alteration and modification xi) Sampling and Gauging xii)
Hazards due to Instrument Failures.
Dangerous Materials
i)Explosives ii) Gases iii) Inflammable Liquids iv) Inflammable Solids v) Oxidising
substances
vi) Toxic and Infectious substances vii)Radio Active Substances viii)Corrosive Substances
ix)Miscellaneous Dangerous Substances
Hazards Of Pressure Vessels
1.Leakage or Bursting of Pressure Vessels 2.Design defects 3.Failure of Relief Systems
4.Lack of hydraulic testing. 5. Lack of Proper Instrumentation or Instrumentation Failure
6.Lack of N.D.Tests 7.Corrosion of Vessels. 8. Lack of routine inspections 9. Attempt of
Pneumatic testing
Hazardous Chemical Reactions
Understanding about the behaviours of reactions and adopting precautionary and emergency
measures.
15. b.Discuss factories act and workmen compensation act
Work men compensation act
This act protects the workers as for as possible form hardship arising form accidents. The
object of awarding compensation is to replace the actual loss suffered by the workmen.
DEFINITIONS:
1. Dependent: Wife or minor legitimate son, Unmarried legitimate daughters, and widowed
mother.
2. Partial disablement: This is Temporary nature, by which earning capacity is reduced, due
to disablement of permanent nature.
3. Total disablement: This is one which incapacities a workmen form all work he was capable
of performing at the time of accident resulting in such disablement.
4. Wages: Includes any benefit capable of being estimated in money other than a traveling
allowance.
5. Workmen: A person who is employed in any capacity

FACTORIES ACT:
The factories act, which regulates the safety, Health and welfare, was enacted in 1948. But
amendments were made to the act in 1954, 1976 and 1987. These amendments were based
on the potential hazards associated with chemical industry.
DEFINITIONS: Adult: Above 18. Adolescent: Between 15 and 18.
Child: Below 15. (iv). Calendar Year:12 months from Jan 1.
Young Person: Either child or Adolescent.
Week: 7 Days form midnight on Saturday.
Power: Electrical or other form of energy, which is mechanically transmitted and is not
generated by human or animal agency.
Prime Mover: Any engine, motor or other appliance, which generates or otherwise provides
power.
Transmission Machinery: Any shaft, wheel, drum, pulley, coupling, clutch, driving belt or
any other device by which the motion of a prime mover is transmitted to or received by any
machinery.
Manufacturing Process: Making, altering, repairing, ornamenting, finishing, packing, Oiling,
washing, Cleaning, breaking up, demolishing, treating or adopting any article or substance
with a view to its use, sale, transport delivery or disposal.
Worker: A person employed directly or through any other agency whether for wages or not
in any manufacturing process or in cleaning any part of the machinery or premises or used for
manufacturing process or in nay other kind of work incidental to or Connected with the
manufacturing process.
Factory: (i). Wherein 10 or more workers are working or were working on nay day of the
preceding 12 months and in any part of which a manufacturing process is being carried on
with the aid or power.
(ii). 20 or more workers are working or were working on any day of the preceding 12 months
and in any part of which a manufacturing process is being carried out with out the aid of
power.
Occupier: The person who has ultimate control over the affairs of the factory and where the
said affairs are entrusted to a managing agent such agent shall be deemed to be occupier of
the factory.