BASIC SAFETY ORIENTATION Basic Safety Orientation General Safety rules Environment, Health & Safety...
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Transcript of BASIC SAFETY ORIENTATION Basic Safety Orientation General Safety rules Environment, Health & Safety...
Basic Safety Orientation• General Safety rules
• Environment, Health & Safety Policy
• Onsite Emergency Preparedness
• Fire protection & prevention system
• Safety in Hazardous chemicals
•Personnel protective equipment
• Work permit system
• Basic First Aid
• Accident reporting system
GENERAL SAFETY INSTRUCTIONS Smoking or carrying of cigarettes / bidis, matchboxes, lighter etc. is prohibited
inside the factory premises. These should be deposited at the Security Office
near the Plant main gate before entering the plant.
Any job Inside / Outside Plant battery Limit should be executed after
authorization of safety work permit.
Wearing of Safety Helmet and Safety Shoes is compulsory while moving inside
the plant Battery Limit.
Appropriate Personnel Protective Equipment (PPE’s) should be used while
executing any type of Job or doing normal operational activities.
Safety belt should be used for working at elevated heights, roofs or at places
where there are no guards.
GENERAL SAFETY INSTRUCTIONS In case of Emergency, On site Emergency Plan should be followed by all Personnel
present inside the factory premises.
For an employee working in shift duty, respective area operator / Engineer should not
leave designated work place till the shift reliever reports the work place. Never take and
hand over charge other than work place as this leaves the plant unmanned.
Do not tamper with any type of equipment parts, electric switches or any other devices
without proper operating knowledge of it.
Charging of steam line should be done with grate care to avoid accidental leakage due to
hammering.
If a person is affected by chemical splash, the splashed part should be washed
immediately with plenty of water from nearest Safety Shower.
Hose used for any utility connections must be properly clamped. It should not be
connected with loose wires.
Protective valve caps must be place on all gas cylinders except when in use. Gas
cylinders should never be dropped especially from trucks or platforms while unloading or
loading into vehicles.
GENERAL SAFETY INSTRUCTIONS
FOR CONTRACTORS Contractor is allowed to work at Nirma LAB plant in accordance with rules and
regulations prescribed as per Gujarat Factories Act with Valid Labor License.
Contractor has to follow the Safety Work Permit system as described in Safety
Manual Chapter number Three.
It is contractor’s responsibility to provide adequate Personal Protective
Equipment required for executing the job. Contractor ensures that proper
PPE’s are used mentioned in the Safety work permit.
In case of any minor / major accident, contractor has to provide accident
details to Site Incharge, Nirma Limited within 24 Hrs of the time of an
accident.
In case of an emergency, all contractor persons have to immediately
assemble at any one of the Assembly points depending upon the wind
direction.
GENERAL SAFETY INSTRUCTIONS FOR TRAINEES Trainees are allowed for entering inside Plant Battery limit after getting permission
from HOD-Production / Production Shift Incharge.
For plant visit, all trainees should be accompanied by Training Center personnel. In
absence of Training Center personnel, they will be accompanied by Production
personnel. No trainees are allowed inside plant battery limit alone.
All trainees / vocational trainees have to wear Safety helmet during plant visit.
Touching or operating any part of the Plant equipment is not allowed during plant
visit.
Wearing of loose cloths are not allowed inside the plant battery limit.
In case of an emergency, all trainees, vocational trainees have to immediately
assemble at one of the Assembly points depending upon the wind direction.
GENERAL SAFETY INSTRUCTIONS FOR VISITORS
Visitors are allowed only after obtaining Visitor Pass from the Main GateSecurity Office.
Visitor has to display visitor pass during the visit inside the plant main gateno. 1.
Wearing of Safety Helmet is compulsory while visiting Inside plant batterylimit.
Safety helmet is issued on returnable basis from Time office security gate. Touching or operating any part of the Plant equipment is not allowed during
plant visit. In case of an emergency, visitor has to immediately assemble at one of the
Assembly points depending upon the wind direction. Even if visitor is present at outside plant battery limit area, he/she has to
assemble at assembly point. Following assembly points are designatedinside factory premises:
- Near Time office Gate- Near Cake building gate- Near Administration building main entrance
Carrying of Mobile phone is not allowed beyond the Time office Gate.
SAFETY & HEALTH POLICY• Productivity with safety is our motto. Safety and health aspects will be considered in
process design, selection of equipments and implementation of programmes.• Health and safety of the workers is an asset of the company. Continuos improvement
in performance by training and rewarding will be ensured for maintaining a vigilant workforce.
• The management and workforce equally share the responsibility of maintaining a healthy and safe workplace. Necessary institutional mechanism will be evolved to maintain and improve the safety, health & environment of the workplace by representative participation with checks and balances.
• To fulfill our social responsibility, we will conduct programmes, seminars, celebrations, and put up hoardings to make the general public aware, so as to react timely, safety and intelligently in case of emergency.
• We will encourage our associates, contractors and suppliers to implement safe and healthy practices in their establishments.
• Above all, we commit to fulfill all statutory provisions under the guidance of regulatory agencies.
Date : KALPESH A. PATEL EXECUTIVE DIRECTOR
MEDICAL HEALTH CENTRE
• Medical Officer - Full time• Male Nurses - 4 Nos. (One in each shift)• Ambulance Drivers - 4 Nos. (One in each
shift)• Contact No. 120• Location : Beside Canteen &
In front of Fire & Safety Dept. Outside the plant battery limit.
Facilities at Medical Health Centre• All Medical Treatment Facility• All Medicines Available• Indoor Facility• Emergency Treatment Room - 2 beds.• Special Room - 2 beds.• General Room - 2 beds.• Minor Surgical Treatment Facility• 19 Nos. First Aid Boxes in the Plant
Area
Emergency Preparedness Emergency Flow Chart
EMRGENCY ALARM
PANEL ENGINEER
PUBLIC ANNOUNCEMENT SYSTEM
DECLARATION OF INCIDENCE & LOCATION
REPEATER PANELF & S PANEL
INCIDENCEAREA
CHIEF EMERGENCY CONTROLLER TEAM LEADERS
SEARCH &RESCUE
ROLL CALL REPAIRSECURITYMEDICALCOMMUNICATION
PLANTPROTECTIONTEAM
TASK FORCE
Officer F&S–1Fireman–4Tech(Inst)–1Tech(Mech)–1Tech(Elect)-1Sec. Guard-4
Panel Engr-2Area Optr-1SIC(Ele)-1Tech(Ele)-1
Tech(Inst)-1 Male nurse-1Amb. Driver-1Tech(Lab)-2
Head Guard-2Sec. Guard-4
Sec. Guard-1 Sec. Guard-1 Tech (Mech)-1Manual WeighBridge Optr-1
SEC.OFFICERSIC TIME O. SIC - MECHSEC.OFFICERSIC Q & ASIC – INST.SIC – PROD.SIC – PROD.
TEAM
TEAMLEADER
MEMBERS
L & UL OPTR.
FIRE WATERPUMP HOUSE
NONEMERGENCYTEAMTECHNICALPERSONS
MAINCONTROLROOM
NON TECHNICAL/CONTRACT/VISITORS
ASSEMBLYPOINTS 1/2/3
1.Ensures availabilityof operator at WPhouse2.Cordens off area withthe help of securityteam.3.Containment ofemergency at the placeof occurrence.4. co- ordinates withthe repair team forattending any repair tocontain the emergency.
1.Mobilises thetechnical manpower toprotect the plant in allrespects.2.Decides shutdown ofthe plant & safeevacuation ofpersonnel.
1.Prepares a list ofpersons to becommunicatedinternally & externally.2.Establishes internalcommunication withfollowing priority:HOD (Prod)HOD (F &S)DGM (Opern)3.Ensures all telephonelines are free.4.Refrain externalcommunicationwithout permission ofexecutives.
1.Team leader/Member willaccompany the injuredto Medical HealthCentre.2.If required, injuredperson would betransferred toContractual Hospital.3. Mobilizes additionaltransport, if required.4. List out names ofinjured persons.
1.Closes main gatesand restricts themovements.2 Provides securitycoverage at main gate,near time office andarea of emergency.3.Cordons off theemergency area andevacuate theunauthorized.4.Permits Fire-tender,Ambulance.5.Provides details ofcontract worker/visitorinside to rollcall team5
1.Team will receiveinstructions from CEC& immediately attendrepair work.2. Help of contractemployees to assist therepair team may be
arranged, if required.
1. Reports to CEC &take instructions.2. Mobilizes team,establishes contactwith the Roll CallTeam from time totime.3. Informs CEC, if anyperson is missing, thenstarts searching ofmissing person.4.Uses necessaryPPE’s while searchingmissing person.
1Eensures list ofcompany employeesfrom T.O.& Contract -Workers and Visitorsfrom security.2. Takes head count ofthe persons reportingnear T.O.(Asse.Point)3. Establishescommunication withCEC to pass oninformation aboutmissing personnel.4. Arranges food &extra vehicle with thehelp of P&A Dept.
ROLE/FUNCTIONS
Testing of Effectiveness of On - Site Emergency Plan• Types of Mock - Drill1. Planned Mock - Drill 2. Surprised Mock - Drill • Frequency of Mock - Drill
Statutory Requirement - Once in Three Months.
• Debriefing Meeting after Every Mock - Drill to evaluate deficiency in the resources or training. The deviation of the On - Site Emergency Plan may be corrected on this basis.
WHAT IS FIRE
• A FIRE is voluntarily advancing process:
combustion of one or more inflammable materials & releasing energy
• Fire is a chemical reaction between oxygen and carbon (or even hydrogen and carbon) in which heat and light energies are also released.
• combination which may be defined as a chemical reaction of rapid oxidation accompanied with evolution of light & heat.
FUEL + HEAT ENERGY + OXYGEN/ AIR = FIRE
FIRE TRIANGLE
• THREE BASIC ELEMENTS - PRODUCTING FIRE:
• Presence of FUEL VAPOUR
• Presence of OXYGEN
• Presence of HEAT/ SOURCE OF IGNITION
• THIS COMBINATION CAUSING COMBUSTION IS REFERRED AS FIRE TRIANGLE AND ILLUSTRATED IN ADJOINING FIGURE.
FIRE TRIANGLE
AIR/OXYGEN FUEL
IGNITION SOURCE / TEMPERATURE /HEAT
CHEMISTRY OF FIRECHEMISTRY OF FIRE
CLASSIFICATIONCLASSIFICATION OF FIRES & OF FIRES & SUITABLE FIRE EXTINGUISHERSSUITABLE FIRE EXTINGUISHERS
Classification Coding Material Extinguisher to be used
Wood, rubber,
cloths, paper etc..
Water type / Soda Acid extinguishers
Flammable liquid & solids
Foam, CO2, DCP
Flammable
Gases & EElectric Fire
CO2 & DCP
Metal fire (Mg. Na)
Special DCP
Fire Extinguisher Facility• Types of Fire Extinguisher at Nirma
1. DCP Type Fire Extinguisher 5 kgs., 10 kgs. & 50 kgs.Sodium Bicarbonate + CO2 Gas
Cartridge
2. CO2 Type Extinguisher
4.5 kgs., 9 kgs. & 22.5 kgs.Pressurised Carbon Dioxide (Gas +
Liquid)
FIRE WATER PUMP HOUSE
• Fire water reservoir capacity is -11850 M 3
•Pump-house is equipped with 2 H .T. Pumps with the
capacity of 410 m3/h, each. 2 Jockey pumps to make
up pressure and three Diesel pumps to compensate H.T.
Pumps in case of power failure. All electrical pumps can
also run on power back up by emergency power
generator.
Fire protection & prevention
Pump house pressure setting
• Description Capacity set pressure
• jockey pump - A 40 m3/hr 8.5 Kg/cm2• jockey pump - B 40 m3/hr 8.5 Kg/cm2• H.T.Pump - A 410 m3/hr 8.0 Kg/cm2• H.T.Pump - B 410 m3/hr 7.2 Kg/cm2• Diesel Pump - A 410 m3/hr 6.6 Kg/cm2• Diesel Pump - B 410 m3/hr 6.1 Kg/cm2• Diesel Pump - C 410 m3/hr 5.5 Kg/cm2• Header pressure should be maintain minimum 10.5 kg/cm2
Fire protection & prevention TAC approved Fire water System.
Fire Hydrant having capacity is 1180 Liters/Minutes
The hydrant are located at 30 meters distance.
Water Monitor having Capacity is 1800 Liters/Minutes
Medium Velocity Water Spray System (MVWS)
The above system always remains pressurized with
water. Pressure should be maintain 10.5 kg/cm2
Fire protection & prevention
Two Combination type mobile fire tenders are available to
handle the emergency.
Fire Tender - 01 and Fire Tender - 02
Fire Tender - 01:
Fire Tender - 01 is having 3500 lits capacity of water tank,
2000 lits capacity of Foam tank, 2 nos of CO2 fire
extinguisher (22.5 Kg) and 500 kgs DCP vessel kept
inside.
•The Fire Tender - 01 is provided with two stage centrifugal
pump. The capacity of pump is 210 m3/hr at 7 kg/cm2
discharge pressure
Fire protection & prevention
Fire Tender - 02:
Fire tender - 02 is having 2000 lits capacity of water tank,
2500 lits capacity of Foam tank,
The Fire tender - 02 is provided with single stage
centrifugal pump. The capacity of pump is 2250 LPM at 7
kg/cm2 discharge pressure
A very sensitive fire alarm system of TATA HONEYWELL is installed. The total fire –protection area is divided in to 9 zones. These nine loops have, in all, 146 Manual Call Points, and 17 Hooters. Breaking of glass of MCP will result in actuating the siren and also displaying emergency in audio-visual mode at Fire Control Room as well as in Main Process Control Room. The exact area and location of the emergency can be learnt from that communication and responding to that emergency;
Fire Alarm System
Fire protection & prevention
Hazard Communication
• MSDS -Identify the Chemicals used -Ensure MSDS for every material -Ensure training for usage of MSDS -Update MSDS
• Labeling -Label all containers, vessels, discharge and
transfer points
-Make appropriate signs on storage containers
• Training
Chemical Hazards• Flammable/Explosion
– Flash point– LEL
• Toxic/Poison– Acute / Chronic– Local / Systemic– Routes of entry
• Reactive• Corrosive
Chemical Hazards- Harmful effects Injuries
Burns in eyes, skin and other organs; fires and explosions
AllergyBreathing problems, skinrash and coughing
IllnessShort & long exposures can cause immediate or delayed illness
FatalityPoisonous chemicals can even cause death
Chemical Hazards- Basic Causes of Accidents
Hurrying, Overconfidence, horse playing, carelessness Spills and leaks of chemicals if not wiped out immediatelyWorking conditions like contamination of atmosphere with harmful dust, vapors and gases -leading to respiratory problemsExposures of inflammable chemicals to heat, sun - fire and explosion hazardsContact of two or more incompatible material- can prove to be detrimental.Neglect or failure of chemical disposal in a proper way -can become a source of fire or explosion
MECHANICAL SAFETY
Crushed hands and arms, severed fingers, blindness - the list of possible machinery-related injuries is as long as it is horrifying. Safeguards are essential for protecting workers from needless and preventable injuries.
A good rule to remember is: Any machine part, function, or process which may cause injury must be safeguarded.
Where the operation of a machine can injure the operator or other workers, the hazard must be controlled or eliminated.
Causes of Machine Accidents
• Reaching in to “clear” equipment
• Not using Lockout/Tagout• Unauthorized persons doing
maintenance or using the machines
• Missing or loose machine guards
Where Mechanical Hazards Occur
• Point of operation• All parts of the machine which move,
such as:– flywheels, pulleys, belts, couplings, chains,
cranks, gears, etc.– feed mechanisms and auxiliary parts of the
machine
• In-running nip points
Point of Operation
That point where work is performed on the material, such as cutting, shaping, boring, or forming of stock must be guarded.
Safe Handling and Storing Materials
• Involves diverse operations:
• Manual material handlingCarrying bags or materialsUnpacking materials
• Material handling via machineForkliftCraneRigging
• Stacking or storing drums, barrels, kegs, lumber, • loose bricks or other materials
Injuries
Lifting objects is a major cause of back injuries in the work place
Improper storing and handling of material and equipment can cause struck by and crushed by injuries
Hazards of material handling•Improper manual lifting or carrying loads that are too large or heavy
•Being struck by materials or being caught in pinch points
•Crushed by machines, falling materials or improperly stored materials
•Incorrectly cutting ties or securing devices
Manual Handling
• Seek help:
• When a load is too bulky to properly grasp or lift
• When you can’t see around or over the load
• When you can’t safely handle the load
• Attach handles to loads to reduce the chances of getting fingers smashed.
Safe Lifting • Break load into parts
• Get help with heavy or bulky items
• Lift with legs, keep back straight, do not twist
• Use handling aids - such as steps, trestles, shoulder pads, handles, and wheels
• Avoid lifting above shoulder level
Summary- Material Handling•Manually handling materials
– When lifting objects, lift with your legs, keep your back straight, do not twist, and use handling aids
•Using cranes, forklifts, and slings to move materials– Watch for potential struck by and crushed by dangers– For slings, check their load capacity, inspect them, and
remove them from service when they display signs of stress or wear
•Also -– Keep work areas free from debris and materials– Store materials safely to avoid struck by/crushed by
hazards
Personal Protective Equipment(PPE)
• Required when engineering or administrative controls are inadequate.
• Must be properly selected and worn.
• Training is required.• Pre-Job analysis
– Hazard Assessment
PPE may be divided into two broad groups
I. Non-Respiratory equipmentII. Respiratory equipment
Types of PPE’s:
Non-Respiratory Equipment
Head protection Eye and Face protection Hand and Arm protection Foot and Leg protection Body protection Ear protection Fall proof protection
Respiratory Protection• Air-Purifying (APR)
– Chemical Filters• Canister Mask• Cartridge Mask (Half and
Full Face)
– Mechanical Filters• Dust Mask• Micro Filters
– Combination of Chemical and Mechanical Filters
• Supplied Air (SAR)– Air-line
• Hood style• Facepiece style
– Half Face– Full Face
• Escape Provision– Blower
– Self Contained Breathing Apparatus (SCBA)
Work Permits - Why?Work Permits - Why?Work permit is meant by document evidence of responsibility.We handle innumerable flammable, toxic and corrosive chemicals - poses special risks.Maint. Personnel are not adequately familiar with process conditions.Operation will determine that it is safe to perform the designated job.Basic purpose of permit system is to prevent injuries to personnel.Protect property from damageAvoid fireEnsure that all work is carried out in safest possible manner.permit specifies the conditions and procedure for safe execution
WORK PERMIT REQUIRMENT Permit is required for the following
jobs :• Major & Minor Maint. work.• Inspection.• Construction.• Boxing up Permit• Process Equip. cleaning• Entry into confined space.• Excavation• Electrical Isolation Work
Excavation Permit
Work Permits - Work Permits - Requirement?Requirement?
Major & Minor Maint. work.- Cold work, Hot workConstruction - Hot work, excavation, Cold workProcess Equip. cleaning- Cold workEntry into confined space- Confined space/ Vessel EntryExcavation- Excavation/DiggingChemical unloading - Cold WorkElectrical Isolation: Lock out/ tagout permit
TYPES OF PERMITS Types of work permit with specific colors.
HOT WORK/VESSEL ENTRY/BOXING-UP (Red, light green & white)
For Inside & Outside of the Battery Limit Area.
NLBA/F&S/FMT/002
COLD WORK PERMIT (Red, Blue & White)
NLBA/F&S/FMT/001
(For all general maint. works (no ignition source)
EXCAVATION PERMIT(Yellow ,light green, light gray & white)
NLBA/F&S/FMT/004
Digging work, civil work etc.
ELECTRICAL LOCKOUT/TAGOUT PERMIT
NLBA/F&S/FMT/003
Cold Work Permit
Basic First Aid• Shock
– Lay victim down – Keep victim warm– Keep victim calm– Get assistance
• Bleeding– Use clean bandage– Apply pressure– Elevate wound
• Burns– 1st Degree - redness
only, flush with cool water
– 2nd Degree - blisters, place damp bandage, use no ointments
– 3rd Degree - white or charred, use dry bandage
– 2nd or 3rd - get medical attention
Basic First Aid
A. The back of the tongue may obstruct the airway.
B. Lift the jaw forward to help open it.
C. Pinch the nose shut. Take a deep breath. Open your mouth wide and put it over the victim's mouth. Make a tight seal. Blow to fill the lungs. Watch the chest rise.
D. Listen carefully for air to come out. Watch the chest fall. Repeat steps C and D over and over every five seconds until the victim starts to breathe.
What is an Accident?
• Accident is an unplanned event that results in personal injury or in property damage.
• Unsafe act - 88 %• Unsafe condition - 10 %• Natural - 2 %
Type of AccidentFirst Aid –
Accidents which does not require any special medical / surgical procedure.
Minor –
Accident which requires special medical / surgical procedure but injured can resume duty within 48 Hrs from the time of an accident.
Major -
Accident which requires special medical / surgical procedure / reference to tertiary care hospital and injured can not resume duty within 48 Hrs from the time of an accident.
Achieving safety at workplace ...
NEAR ACCIDENTS
MINOR INJURIES
MAJOR ACCIDENT
Safety committeeTeam work
300
29
1
HEINRICH PRINCIPLE Ratios
PREVENTION IN ADVANCE BY
INVESTIGATING ACCIDENTS AND NEAR ACCIDENTS
Accident Investigation
•Investigation is not intended to find fault but to find the fact, to eliminate the re-occurrence.
The Three Basic CausesPoor Management Safety Policy & Decisions
Personal FactorsEnvironmental Factors
Unsafe ActUnsafe
Condition
Unplanned release of energyand/or
Hazardous material
Basic Causes
Indirect Causes
Direct
Causes
ACCIDENTACCIDENTPersonal Injury
Property Damage
Good Safety Practices
• Inspect work area daily• Observe - be alert• Housekeeping, Housekeeping, Housekeeping• Use your best safety device - THINK• If you’re not sure - ASK someone!!• Report Injuries/Incidents/Illnesses immediately• Report safety issues to the safety committee
Based on the nature of injury, accidents are dived into mainly three categories:
– First aid – Accidents which does not require any special medical / surgical procedure.
For First Aid injuries accident records are kept in the Medical Center’s register.
Upon receiving the accident report, investigation is done by HOD Fire & Safety / Fire & Safety SIC for understating the unsafe condition / act happened causing an accident to happen.
HOD Fire & Safety communicates the accident details to GM-Works, DGM- Technical, DGM – M&S and HOD-Production for all kinds of accidents.
Minor Accident – Accident which requires special medical / surgical procedure but injured can resume duty within 48 Hrs from the time of an accident.
If the person requires further treatment, which is not available at Medical Centre, he/she is referred to outside contractual hospital.
In case of Minor accident, Injured person / respective SIC / HOD fills up the Work Injury Report as per LAB / FS / FMT / 5 (in English) or LAB / FS / FMT / 6 (in Gujarati) and sends original copy to Medical Officer and duplicate copy to HOD Fire & Safety. Originator retains file copy.
Upon receiving the accident report, investigation is done by HOD Fire & Safety / Fire & Safety SIC for understating the unsafe condition / act happened causing an accident to happen.
Major Accident - Accident which requires special medical / surgical procedure / reference to tertiary care hospital and injured can not resume duty within 48 Hrs from the time of an accident.
In case of Major accident, Injured person / respective SIC / HOD fills up the Work Injury Report as per LAB / FS / FMT / 5 (in English) or LAB / FS / FMT / 6 (in Gujarati) and sends original copy to Medical Officer and duplicate copy to HOD Fire & Safety. Originator retains file copy.
Upon receiving the accident report, investigation is done by HOD Fire & Safety / Fire & Safety SIC for understating the unsafe condition / act happened causing an accident to happen. In case of Major accident, Injured person / respective SIC / HOD fills up the Accident investigation Report as per LAB / FS / FMT / 7 (in English) or LAB / FS / FMT / 8 (in Gujarati) and sends original copy to HOD Fire & Safety, duplicate copy to Personnel Dept. and Triplicate copy to Medical Officer. Originator retains file copy.
If the injured leaves the work place and takes treatment from outside doctor without reporting injury to Medical Center, then such an accident is not treated as an Industrial Accident.
For Major / Minor category of an accident, Fitness Certificate is issued by Medical Officer as per LAB/FS/FMT/09 before injured resumes the duty.
Cases which are refereed to outside contractual hospital, the communication regarding the condition of victim, treatment given and the advice for the necessary rest required if any, should be communicated immediately or as early as possible to the Medical Officer by the injured person or his/her relative.
In case of major accidents when an injured can not resume duty within 48 Hrs from the time of an accident, as per the Factories Act & GFR 103, Form no. 21 is filled up and sent to "Factories Inspector" as soon as possible.