INDUSTRIAL HAZARDS DUE TO FIRE AND MECHANICAL EQUIPMENT SATYANARAYANA.V ( M.Pharm I sem ) Department...
45
INDUSTRIAL HAZARDS DUE TO FIRE AND MECHANICAL EQUIPMENT SATYANARAYANA.V ( M.Pharm I sem ) Department Of Pharmaceutical Sciences UNIVERSITY COLLEGE OF PHARMACEUTICAL SCIENCES, KAKATIYA UNIVERSITY, WARANGAL-500609.
INDUSTRIAL HAZARDS DUE TO FIRE AND MECHANICAL EQUIPMENT SATYANARAYANA.V ( M.Pharm I sem ) Department Of Pharmaceutical Sciences UNIVERSITY COLLEGE OF PHARMACEUTICAL
INDUSTRIAL HAZARDS DUE TO FIRE AND MECHANICAL EQUIPMENT
SATYANARAYANA.V ( M.Pharm I sem ) Department Of Pharmaceutical
Sciences UNIVERSITY COLLEGE OF PHARMACEUTICAL SCIENCES, KAKATIYA
UNIVERSITY, WARANGAL-500609.
Slide 2
CONTENTS INTODUCTION Types of hazards in a pharmaceutical
industry Fire Classification of fires Classification of hazardous
areas Potential cause for a fire Prevention of fire Mechanical
Hazards with equipment Safety aspects in the pharma industry
Disaster management plan Conclusion References
Slide 3
Introduction HAZARD is a term associated with a substance that
is likely to cause an injury in a given environment. INDUSTRIAL
HAZARD is any condition produced by industries that may cause:
injury to a personnel, (or) One which may lead to loss of property,
products etc; (or) A substance that might proove fatal to the
personnel
Slide 4
TYPES OF HAZARDS IN AN INDUSTRY Fire Chemicals Electrical
Mechanical Miscellanious Pharmaceutical Biological Personnel
Environmental
Slide 5
CHEMICAL HAZARDS Volatility of solvents Flammability
Explosivity Stability Corrosivity Reactivity Radioactivity
Slide 6
ELECTRIC HAZARDS BASED over protective devices Short circuit
fault protectve device Open circuit fault protective devices
Ratings and sizes of surge protective capacitors
Slide 7
Measures to be taken Use of high quality electricals Electrical
equipment maintanance Proper handling of chemicals CHEMICAL SAFETY
CARDS Experts Retailer
Slide 8
CHEMICAL DATA SHEET A chemical safety data sheet provides the
following basic information about the chemical: Identification :
Name of the substance or preparation Name, address and telephone
number of the company/supplier/undertaking Composition and
information on ingredients Hazards identification First-aid
measures Fire-fighting measures Spillage, accidental release
measures Handling and storage Exposure controls and personal
protection
Slide 9
Physical and chemical properties Stability and reactivity
Toxicological information Ecological information Disposal
considerations Transport information National regulations and
references Other information
Slide 10
Chemical safety data sheets are published under several names
such as: INTERNATIONAL CHEMICAL SAFETY CARD, ICSC CHEMICAL SAFETY
CARD CHEMICAL INFO-SHEET MATERIAL SAFETY DATA SHEET, MSDS PRODUCT
SAFETY DATA SHEET HEALTH AND SAFETY DATA SAFETY DATA SHEET.
FIRE HAZARDS Fire: The self-sustaining process of rapid
oxidation of a fuel which produces heat and light Fire is an
exothermic chemical reaction between oxygen and fuel at certain
temperature. Three things essential for the combustion of fire are;
Fuel (any combustible material) Oxygen ( At concentrations above 23
% in air, the situation becomes dangerous due to the increased fire
hazard) Temperature
Slide 13
Classification of fires Most fires that occur will fall into
one or more of the following categories Class A: Fires involving
ordinary combustible materials, such as paper, wood, and textile
fibers, where a cooling, blanketing, or wetting extinguishing agent
is needed. Class B: Fires involving flammable liquids such as
gasoline, thinners, oil-based paints and greases. Extinguishers for
this type of fire include carbon dioxide, dry chemical* and
halogenated agent types.
Slide 14
Class C: Fires involving energized electrical equipment, where
a nonconducting gaseous clean agent or smothering agent is needed.
The most common type of extinguisher for this class is a carbon
dioxide exinguisher Class D: Fires involving combustible metals
such as magnesium, sodium, potassium, titanium, and aluminum.
Special dry powder* extinguishing agents are required for this
class of fire, and must be tailored to the specific hazardous
metal.
Slide 15
Class K: Fires involving commercial cooking appliances with
vegetable oils, animal oils, or fats at high temperatures. A wet
potassium acetate, low pH-based agent is used for this class of
fire.
Slide 16
Classification of hazardous areas Zone 0: an area in which a
atmosphere is present continously or is present for long periods.
Zone 1: an area in which a flammable atmosphere is likely to be
present periodically or occasionally during normal operations. Zone
2: an area in which a flammable atmosphere is likely to be present
peridically or occur in normal operations.
Slide 17
POTENTIAL CAUSE FOR A FIRE Improper design or layouts lack of
proper work design process Electricity Chemicals Housekeeping
Improper Storage Flammable Liquids Combustible materials Equipment
Lack of proper ventilation Carelessness
Slide 18
Actions in the event of fire Fire detection Raising the alarm
Calling the local fire brigade First aid fire fighting practice
evacuation
Slide 19
PREVENTION OF A FIRE Well planned design and layout Proper
ventilated systems Chemical data sheets Proper training of
personnel Proper maintenance of surroundings use of fire
extinguishers, alarms,sensors, detectors Fire fighting equipment
Sprinkler systems
Slide 20
Extinguishment Theory Removing Heat Removing Fuel Reducing
Oxygen WILL Inhibit Chemical Chain Reaction
Slide 21
FIRE EXTINGUISHERS The fire extinguishing agents are classified
into Water and water based agents portable extinguishers soda acid
extinguishers antifreeze extinguishers foam Dry chemical Carbon
dioxide Halon 1301 ( bromo tri fluoromethane) Vaporizing liquid Dry
powders for combustible metals
Slide 22
FIRE EXTINGUISHERS Non-Magnetic stored pressure deionized water
mist fire extinguisher Halotron 1 Fire extiguisher. ABC Dry
chemical fire extinguisher Carbon dioxide (CO2) Portable fire
extinguisher K Class Wet chemical extinguisher.
Slide 23
Characteristics of extinguishers Water extinguisher 30-40 ft.
60 sec. Dry chemical 5-20 ft. 8-25 sec. CO2 extinguisher 3-8 ft.
8-30 sec.
Slide 24
Quick-Check Is It Ready To Use ? 1.Check the gauge. The
pressure indicator should be in the green zone. (CO2 extinguishers
do not have pressure gauges.) 2.The extinguisher should have a
current inspection tag. 3.The pin and handle should be secured with
a plastic tab seal. 4.The extinguisher and hose should be free of
any visible damage.
Slide 25
The P.A.S.S. Method Pull the pin. Aim the hose or nozzle.
Squeeze the lever. Sweep the agent.
Slide 26
FIRE EXTINGUISHERS Dry Chemical - Works on class A, B, and C
fires (Multipurpose). Carbon Dioxide - Works on class B and C
fires. Water - Works on class A fires. Foam - Works on class A and
B fires. Halogenated - Works on class A, B, and C fires. Dry Powder
- Works on class D fires. Wet Chemical - Works on class K
fires.
Slide 27
FIRE ALARMS
Slide 28
Smoke detector Fire sensors Spinkler systems Heat
detectors
Slide 29
Mechanical hazards INTRODUCTION: Mechanical hazards may occur
due to the large numbers and different designs of equipment,
crowded workplace conditions and frequent interaction between
workers and equipment Hazardous electrical, pneumatic and thermal
energy must be released or controlled before working on active
equipment and utilities Workers are protected from sources of
hazardous energy by Implementing lock out / tag out procedures.
Interlocked guards, control switches, emergency stop devices and
operator training are important means of reducing mechanical
hazards.
Slide 30
HAZARDS WITH MECHANICAL EQUIPMENT WAREHOUSING RAW MATERIAL
WEIGHING GRANULATE PREPARATION SUPPOSITORY AND PESSARY PRODUCTION
OINTMENT PASTE CREAM GEL PRODUCTION TABLET & CAPSULE PRODUCTION
SOLUTION PREPARATION CONTAINER STERILIZATION CONTAINER FILLING
INSPECTION FREEZE DRYING PACKAGING PALLETIZATION
WAREHOUSING:FINISHED PRODUCTS SHIPMENT CONTAINER FILLING
Slide 31
WAREHOUSING WORK PHASE DESCRIPTION Incoming and out going goods
store (raw materials, excipients, labels, printed information
materials) The raw materials and excipient store is generally
located close to the production areas. Products are stored on
multi-level racks and shelves. Manually operated trolleys and
electrical pallet handlers are used to move boxes/containers.
EXPECTED INJURIES Muscular-skeletal complaints. Cutting
injuries
Slide 32
Electronic and/or mechanical weighing scales The pharmaceutical
industry uses the classic single/twin platter mechanical scales.
The more modern electronic scales are characterised by a metal box
enclosing the apparatus and by a weighing system generally
including a platter. Electronic scales are fitted with local
powder/dust exhaust devices or laminar flow exhaust hoods. RISK
FACTORS: Exposure to dust EXPECTED INJURIES: Allergic asthma,
contact dermatitis
Slide 33
Work performed in the presence of moving machinery parts
DESCRIPTION Manual cleaning of certain machine may entail the
operator being snagged, dragged or crushed by the machines parts in
motion. By way of an example, an operator may clean a mixer/blender
by pouring the cleaning fluid in the vat and starting the machine
in order to better clean the internal surfaces. Other operators may
accidentally start the machine while staff is cleaning the machines
internal parts. EXPECTED INJURIES Lesions and bruises. PREVENTIVE
MEASURES Hazardous zones must be shielded by fixed guards or fitted
with interlocking safety devices to reduce the risk of operators
being snagged and dragged. Machinery must be fitted with emergency
shut down and accidental start-up lockout devices such as safety
devices blocking machine start up when power is restored after a
temporary blackout.
Slide 34
PROCESSING OF SEMI-SOLID PHARMACEUTICAL FORMS RISK FACTORS:
Fatiguing tasks and work postures DESCRIPTION Careful cleaning of
plant systems especially where processing of semi- solid
pharmaceutical forms particularly rich in lubricating agents such
as suppositories, ovules and ointments takes place, require manual
operations involving fatiguing tasks and anomalous work postures.
EXPECTED INJURIES Muscular-skeletal complaints. PREVENTIVE MEASURES
- Consider the feasibility of employing built-in, closed-cycle
automatic washing and/or sterilization systems (cleaning in place).
- Accurate task organization and operator information and
training.
Slide 35
GRANULATE PREPARATION EQUIPMENT AND MACHINERY Miller/grinders
Compactor Twin Whisk Blender Planetary or crown wheel Blender
Rotating Tub Blender Fluid Bed Granulator-Dryer Dynamic Tunnel
Dryer System Dynamic Revolving Drum Dryer System Vacuum Dryers RISK
FACTORS : Exposure to dust DESCRIPTION Operators may be exposed to
dust during miller/grinder loading/unloading, compacting, blending
and granulation operations. ESTIMATE Field assays have yielded
ambient air dust concentration levels ranging from 342 to 3.462
g/m3 in the blender shop, from 307 to 1.884 g/m3 in the granulator
shop. EXPECTED INJURIES Allergic asthma, contact dermatitis.
Specific pharmacological effects due to active principles.
PREVENTIVE MEASURES Use of completely automated load/unload
systems. Use of protective hoods fitted with absolute filters.
Slide 36
EXPOSURE TO NOISE DESCRIPTION The sources of noise in this work
phase are: miller/grinders, compactors, blenders and granulators.
Notwithstanding the use of sound dampening devices, noise levels
may be quite high. EXPECTED INJURIES Continuous exposure to
medium-high noise levels may cause hearing injuries (noise-induced
hypoacusia) and extra-hearing complaints. Injuries and complaints
may result also from exposure to noise levels lower than the
thresholds for which legislation prescribes the use of specific
preventive measures. In addition to communication and work
performance-related complaints, the following disorders may also
arise: cardiovascular effects (high blood pressure, etc.); psychic
disorders (asthenia, irritability, depression, insomnia); digestive
tract disorders. PREVENTIVE MEASURES Preventive measures
established in cases of employee noise exposure exceeding 80 dB(A).
Decrease the exposure time
Slide 37
MANUAL LOAD HANDLING DESCRIPTION Machine hopper loading
operations in this phase may be performed manually. EXPECTED
INJURIES Muscular-skeletal complaints PREVENTIVE MEASURES Use of
mechanical/electrical handling devices or automated loading
systems. Two operator handling of heavy loads. Manual load handling
is permitted for loads up to 30 kgs.(males) and 25kgs.(females).
Handling of loads exceeding these limits shall be performed using
appropriate devices and/or shall be performed by two operators.
Operator information and training.
Slide 38
OINTMENT, PASTE, CREAM AND GEL PRODUCTION EQUIPMENT AND
MACHINES Turbo-emulsifier (blender-homogeniser) Manually operated
trolleys Bulk storage tanks Risk factors: Exposure to dust
DESCRIPTION Loading active principles into the emulsifiers is
typically performed manually. Operators insert a suction nozzle
connected to the emulsifier into the bins containing the active
principles or excipients. ESTIMATE: Field data typically reports
that an operator performs approximately two active principle and
excipient emulsifier loading cycles per 8 hour working shift.
Loading operations total 90 minutes resulting in 0,76 mg/m3. mean
operator dust exposure levels. TLV-TWA threshold values reported by
firms are 0.5 mg/m3 for active principles and 10 mg/m3 for gelling
excipients. EXPECTED INJURIES Active principle-specific induced
injuries. PREVENTIVE MEASURES - Use of automated loading
systems
Risk factors: Manual load handling ESTIMATE: Load handling data
furnished by a drug company may be broken down as follows: - empty
tube feed: package weight 5 kgs, feed frequency 3/min.; - filled
tube transfer: weight 10.8 kgs, frequency 2/min.; - labeller feed:
weight 7 kgs, frequency 1/min. EXPECTED INJURIES: Muscular-skeletal
complaints. PREVENTIVE MEASURES Use of electric powered or
mechanical devices or automated systems. Manual load handling
operations are limited to loads up to 30kgs for men and 25 kgs for
women. Heavier loads shall be handled employing appropriate means
and/or shall be performed by two operators. Contd
Slide 41
SAFETY ASPECTS IN THE PHARMA INDUSTRY Standard operating
procedures Handling of hazardous materials Water supply and
drainage Floors and floor coverings Emergency exits Back up plan if
anything goes wrong Specially trained personnel Health polices and
insurance Written procedures Safety audits Risk analysis
Appropriate training and education to employee Regular monitoring
of workplace Written documentation of policies Create awareness of
the environment Involvement of the personnel Contingency plan
Slide 42
DISASTER MANAGEMENT PLAN Disaster management plan is essential
as it: Reduces the amount of thinking time required after the
incident occurred Contains the incident and minimizes the extent of
the damage to the resources and business. Reduces the conduct of
disaster to a set of predetermined rules and a system of orderly
procedure to make orderly and rational The success in disaster
management depends on : Reliable early detection Careful planning
Efficient personnel Proper training of all personnel concerned
Problem free communication
Slide 43
CONCLUSION From the previous discussion it is clear that the
safety aspects must be considered by the pharmaceutical industry
not only in the interest of the employees or property but also in
terms of the neighboring environment as well. The source of
possible hazards, risk analysis, control procedures,preventive
measures &contingency plan are the main five essentials for
ensuring a complete work atmosphere in the industry
Slide 44
REFERENCES G.D.Muir,Hazards in Chemical Industries, 2 nd
edition. Reigels Handbook of Industrial Chemistry, 9 th edition.
James Sward Brick, James C.Boylan, Encyclopedia of Pharmaceutical
Technology,volume-4. www.fda.gov www.friesnoop.com www.pubmed.com
www.agricum.com www.teoma.com www.altavista.com