diploma in industrial safety UNIT-3

NATIONAL SAFETY ACADEMY

DIPLOMA IN INDUSTRIAL SAFETY


CHAPTER-3

WORK PROCEDURES

CONTENTS:

1. INTRODUCTION

2. INDUSTRIAL PSYCHOLOGY

3. EMPLOYEES TRAINING IN SAFETY

4. DIFFERENCE BETWEEN EDUCATION AND TRAINING

5. ASSESSMENT OF TRAINING NEEDS

6. METHODS OF TRAINING

7. RISK ANALYSIS

8. RISK ASSESSMENT CONCEPTS


9. HAZARDS CONTROL

10. QUANTITATIVE RISK ANALYSIS PROCEDURES

11. RISK TOLERABLITY

12. EMERGENCY CONTROL PLAN

13. DISEASTER MANAGEMENT

14. ON SITE EMERGENCY PLAN

15. OFF SITE EMERGENCY PLAN

16. GAS CYLINDERS

INTRODUCTION

INDUSTRIAL PSYCHOLOGY:INDUSTRIAL PSYCHOLOGY IS STUDY OF HUMAN BEHAVIOUR AND IS CONCERNED WITH THYE DISCOVERY OF INFORMATION RELATING TO HUMANBEHAVIOURAND IS CONCERNED WITH THE DISCOVERY OF INFORMATION RELATING TO HUMAN BEHAVIOURIT IS CONCERNED WITH PHYSICAL ASPECTS OF WORK ENVIRONMENT LIKE LIGHTING TEMPERATURE AND THEIR EFFECT ON OUTPUT AND SAFETY OF THE WORKER


SCOPE OF INDUSTRIAL PSYCHOLOGY:TO INVESTIGATE IN AN UNBIASED MANNER THE WAYS IN WHICH PSYCHOLOGICAL PROBLEMS ARE HANDLED AT PRESENTTO DEVELOP[ NEW METHODS AND TO MODIFY THE METHODS WHICH HAVE BEEN TRIED OUT AND EVALUATE THEM.TO FORMULATE CERTAIN PRINCIPLE THIS WILL HELP IN THE SOLUTIONS OF HUMAN RELATIONS PROBLEMSIT OMITS MANY OF THE ROUTING ADMINISTRATIVE DETAILSINDUSTRIAL PSYCHOLOGY EMPHASIZES THE SCIENTIFIC AND RESEARCH ASPECTS OF PEOPLE AT WORK

ADVANTAGES OF TAINTING IN SAFETY ARE:

1. TRAINING HELPS TO DEVELOP SAFETY CONSCIOUSNESS AMOUNT THE EMPLOYEES AND BUILD UP FAVOURABLES ATTITUDES ON THEIR PART TOWARDS SAFETY MEASURES AND SAFETY PRECAUTIONS


1. TRAINING IMPARTS KNOWLEDGE AND SKILL WHICH IMPROVE PRECEPTIONS ANDLEADS TO SAFE WORK PERFORMANCES ON THE PART OF THE EMPLOYEES

2. TRAINING ACTIVITIES INDIRECTLY DEMONSTRATE COMPANY INTEREST IN EMPLOYEES WHICH LEADS TO GOOD HUMAN RELATIONS AT WORK.

LEVEL:

3. HELPERS(1 DAY) NEED FOR SAFETY AT WORK HAZARDS CONDUCTED WITH THEIR TASKS AND WAYS TO SAFEGUARD SAFETY IN HANDLING AND STORAGE STEPS IN HANDLINGS AND STORAGE STEPS TO BE TAKEN IN EMERGENCY

2. OPERATORS(3 DAYS) INTRODUCTION TO SAFETY AND COMPANYS POLICY COMMON CAUSES OF ACCIDENTS


ACCIDENTS PREVENTIONSAFETY REQUIREMENTS IN THE JOBROLE OF WORKMEN IN SAFETYSAFETY IN HANDLING AND STORAGEINDUSTRIAL HYGIENE AND OCCUPATIONAL HEALTHPERSONAL PROTECTIVE EQUIPTMENTSSTEPS TO BE TAKEN IN EMERGENCY AND FIRST AID

SUPERVISORS(5 DAYS)SAFETY AND COMPANYS POLICYSAFETY AND THE LAWPLANT HOSUEKEEPINGCOMMON CAUSE OF ACCIDENTS IN THE PLANTACCIDENTS INVESTGATION AND ANALYSISPLANT SAFETY INSPECTIONFIRE PREVENTION AND CONTROLPERSONAL PROTECTIVE EQUIPTMENTS


EMPLOYEES EDUCATION AND MOTIVATIONROLE OF SUPERVISORS IN SAFETY

MANAGERS:INTRODUCTION TO SAFETY AND HEALTH AND COMPANYS POLICYLEGAL RESPONSIBILITY OF THE EMPLOYERIDENTIFICATRION AND CONTROL OF HAZARDSELEMNTS OF INDUSTRIAL HYGIENE AND ENVIRONMENTAL MONITORINGOCCUPATIONAL HEALTHACCIDENTS AND ASSOCIATED COSTS.MANAGING SAFETYROLE OF MANAGERS IN SAFETYPREVENTIVE AND CONTROL MEASURES


ASSESSMENT OF TRAINING NEEDS:

a. WHAT ARE THE CURRENT SAFETY PROBLEMS OF THE ORGANIZATION(I.E ACCIDENTS/ OCCUPATIONAL DISEASE ETC)?

b. WHAT ARE AREAS OF SAFETY TRAINING?

c. WHEN TRAINING SHOLUD BE IMPARTED?

d. WHO SHOULD BE GIVEN TRAINING?

e. WHEN AND HOW TO EVALUATE EFFECTIVENESS OF TRAINING?

METHODS OF TRAINING:

f. ON THE JOB INSTRUCTIONS BY THE SUPERVISOR OR A SENIOR WORKER AT THE TIME OF ALLOCATIONS OF THE JOB TO THE WORKER

g. LECTURE ON SAFETY BY EXTERNAL INTERNAL FACULTY UTILIZING SUITABLE BLEND OF ORAL INSTRUCTIONS AND AUDIO VISUAL AIDS

h. DISCUSSIONS LED BY EXPERT FACULTY MEMBERS COVERING RELEVANT SAFETY ISSUES.


RISK ANALYSIS HAZARDS IDENTIFICATIONCAUSE CONSEQUENCES ANALYSISHAZARDSAND OPERABILITY STUDIESFAULT TREE/EVENT ANAKYSIS FOR FREQUENCE ASSESSEMENTSAFETY AUDIT STUDIESINDIVIDUAL AND SOCIETIES RISK ASSESSMENTRISK CONTOUR MAPPING

THE REQUIREMENTS OF QRA ARE:SYSTEMS ARE IN PLACE TO IDENTIFY HAZRADS ANALYZE RISKS FROM THE HAZARDS AND EVALUTE WAYS EITHER TO ELIMINATE HAZARDS OR TO MANAGE RISKS.APPROPRAITELY REVIEW OF RISKS TOBE CONDUCTED AT LEAST ONCE IN THREE FOR EXISTING UNITS PIPELINES AND MARKETING INSTALLATIONS FOR ONGOING OPERATIONS BASED ON


1. MULTI DISCIPLINARY INETRNAL SAFETY AUDITS

2. OISDS EXTERNAL SAFETY AUDITS

3. REGULATORY COMPLIANCES

4. WALK THROUGH ASSESSMENT

5. HAZOP

6. PREVIOUS RISK ASSESSMENT

7. PREVIOUS QUANTITIES RISK ANALYSIS APPROPRIATE RISK ANALYSIS ANSD ASSESSEMENTS ARE CONDUCTED FOR

NEW PROJECTS THAT INCLUDE

1. PHILOSOPHY REVIEW

2. PLANT REVIEW PLANT LAYOUT PROCESS TECHNOLOGY ETC.

3. INHERENT SAFETY

4. PROCESS DESIGN SAFETY

5. HAZOP

6. QUANTITATIVE RISK ANALYSIS

7. CONSTRUCTION RISK SAFETY


RISK ANALYSIS INVOLVES:THE DEFICATION OF RISKS HOWVERE THEY MAY ARISE AND WHOEVER THEY MAY AFFECTTHE ASSESSMENT OF THE RISKS AS TO THEIR PROBABILITY OF OCCURING AND THE IMPACT THEY WOULD HAVE IF THEY DID OCCURTO ALLOCATE SUCH RISKS BETWEEN THE MAN PROJECT PARTIES.

PROJECT MANAGEMENT STRUCTURE: WHATEVER THE CONTRACTING PHILOSOPHY, A STRONG PROJECT MANAGEMENT STRUCTURE AND CULTURE IS REQUIRED IN ORDER TO DEAL WITH THE COMPLEX ISSUES INVOLVED IN DELIVERING A FUNCTIONING PLANT TO TIME AND BUDGET. IT IS PARTICULARLY IMPORTANT IN MINIMIZING THE CONSEQUENCES OF THE PROBLEMS WHICH OCCUR IN EVERY PROJECT.

SCOPE AND BASIS OF TURKEY CONTRACT: IDEALLY, THE TURNKEY CONTRACT SHOULD COVER THE ENTIRE SCOPE OF THE PROJECT, BUT OFTEN THE INFRASTURCTURE REQUIREMENTS BEYOND THE ISTE BOUNDARY WILL BE OUTSIDE THE SCOPE.SINCE EVERY ADDITIONAL


GROUND CONDITION AND GEOLOGICAL RISK: IT IS USUALLY THE CASE THAT TURNKEY CONTRACTORS WILL ACCEPT GROUND CONDITIONS AND GEOLIGICAL RISK ONCE THEY HAD THE OPPURTUNITY TO CARRY OUT A SURVEY.IN THE ABSENCE OF SUCH A SURVEY, OF IF THE SITE CHOSEN AS OBVIOUS GEOLOGICAL DRAW BACKS THE TURKEY CONTRACTS PRICE IS UNLIKELY TO BE FIRM

RISK ARISING FROM DESIGN: WHERE THE TURNKRY CONTRACT HAS BEEN PLACED ON THE BASIS OF A FUNCTIONAL SPECIFICATION, THEY WILL CLEARLY RESPONSIBLE FOR THE DESIGN OF THE PLANT. BUT IF THE DESIGN HAS BEEN ESTABLISHED BY TH PROJECT

CONSTRUCTION RISKS: THE PRINCIPAL RISKS ASSOCIATED WITH THE CONSTRUCTIONS OF THE PLANT ITSELF SHOULD BE TRANSFERRED TO THE TURNKEY CONTRACTOR

CLIMATE AND WEATHER RISKS: CLEARLY THE MONSOON CREATES GREAT DIFFICULTIES OR OUTDOOR CONSTRUCTIONS, WHICH HAS TO BE PROGRAMMED WITH PERIOD OUTSIDE THEN MONSOON SEASON, WITH WEATHYER TIGHT STRUCTURES COMPLETED BEFORE THE RAINS ARRIVE. ANY PROJECT DELAYS CAN


HAZARDS CONTROL

i. ADMINISTRATIVE CONTROL MEASURES(PERSONAL HOUSE KEEPING, MAINTENANCE ETC.) AND

ii. ENGINEERING CONTROL MEASURES (ISOLATION, DESIGN FEATURES, OPERATING PROCEDURES, WORKING, WORKING EQUIPTMENTS,ETC.) HUMAN CAPABILITIES AND LIMITATIONS MUST BE GIVEN DUE CONSTRUCTIONS IN ANY TYPE OF CONTROL MEASURES.

EMERGENCY CONTROL PLAN:

OBJECTIVES OF DISASTER MANAGEMENT RAPID CONTROL AND CONTAINMENT OF THE AFFECTED PERSONSMINIMIZING THE ISK AND IMPACT OF EVENT/ACCIDENTS ON PEOPLE, PROPERTY AND ENVIRONMENTEFFECTIVE REHABILITION OF THE AFFECTED PERSONSMANUFACTURING PROCESSLOCATION OF THE INDUSTRYPLANT LAYOUT AND MATERIALS HANDLING


1. ON SITE EMERGENCY PLAN EMERGENCY ORGANIZATION PLANT RISK EVALUATION MEDICAL FACILITIES EMERGENCY EQUIPMENT AND FACILITIES CONVEYANCE SYSTEMS NOTIFICATION AND COMMUNIACTION SYSTEMS SAFETY TRAINING DRILLS AND EXERCISES TESTING AND EVALUTIONS OF THE EMERGENCY PLAN

OFF SITE EMERGENCY PLAN

EMERGENCY ORGANIZATIONS:SELECTING PERSONS IN CHARGE/ALTERNATESSPECIFYING THE FUNCTIONS OF EACH KEY INDIVIDUAL AND GROUPMAINTAINING TELEPHONE NUMBERS(OFFICE AND HOE) OF KEY PEOPLE ALTENATES


RISK EVALUATION:DETAILS OF HAZRADOUS MATERIALSQUANTITY OF HAZRADOUS MATERIALSLOCATIONS OF HAZARDOUS MATERIALSPRPERTIES OF EACH (MSDS SHEET) HAZARDOUS MATERIALSHANDLING MATERIALS REQUIREMENTS SPECIAL FIRE FIGHTING PROCEDURES(IF ANY)

EMERGENCY EQUIPTMENTS AND FACILITIES:FIRE FIGHTING EQUIPTMENTSEMERGENCY MEDICAL SUPPLIESSELF CONSTRAINED BREATHING APPARATUSGOOGLES, BOOTS, RUBBER GLOVES, HELMETSOTHER PERSONAL PROTECTIVE EQUIPTMENTS


SAFETY TRAINING: INDUCTION TRAINING FOR NEW EMPLOYEESSAFE HANDLING OF CHEMICALS/INFLAMMABLE EQUIPTMENTSPROCEDURES FOR REPORTING EMERGENCIESKNOWLEDGE OF ALARM SYSTEMSUSE OF FIRE FIGHTING EQUIPTMENTSPERMIT PROCEDURES USE OF PERSONAL/PROTECTIVE EQUIPTMENTSEVACUATION PROCEDURES

DRILLS AND EXERCISES: OBJECTIVESPROVIDE HAND ON EXPERIENCE WITH THE PROCEDURES TO BE IMPLEMENTED DURING AN EMERGENCY DURING AN EMERGENCYTEST THE VALIDITY OF THE PLAN AND PROCEDURESFAMILIARIZE THE RESPONSE PERSONNEL WITH EQUIPTMENTS


TESTING AND EVALUATING AN EMERGENCY PLANASSESS OF EFFECTIVENESS OF THE PLAN AND ITS RESPONSEESTABLISH CRITERIA FOR CORRECTIVE AND PREVENTIVE ACTIONSTEST KNOWLEDGE AND SKILL OF PARTICIPATING PERSONNELIDENTIFY TRAINING NEEDS OF RESPONSE PERSONNELTEST THE COMMUNICATIONS NETWOORK AND COOPERATIVE RESPONSE SKILLS.

OFF SITE EMERGENCY PLAN REQUIRE ATTENTION TO THE FOLLOWING ACTIVITIES:EMERGENCY ACTIONSCOMMUNICATIONS WITH AUTHORITIES CONCERNEDEVACUATION SHELTERING PLAN

GAS CYLINDERS

1. CYLINDERS MANUFACTURED IN INDIA ARC FITTED WITH SAFETY RELIEF DEVICES. SUCH DEVICES SHLL BE MANUFACTURED AND MAINTAINED IN ACCORDANCE WITH INDIAN STANDARD 5903


HANDLING STORAGE

1. CYLINDERS SHALL BE ADEQUATELY SUPPORTED DURING HANDLING

2. TROLLEYS AND CRADLES OF ADEQUATE STRENGHT SHALL BE USED WHEN MOVING THE CYLINDERS

3. SLIDINTHE CYLINDERS SHALL BE HANDLED CAREFULLY AND NOT BE ALLOWED TO ALL UPON ONE ANOTHER OR OTHERWISE SUBJECTEDTO ANY UNDUE SHOCK

4. LIQUEIFIED PETROLEUM GAS CYLINDERS AND CYLINDERS CONTAINING LIQUEFIED GASES SHALL ALWAYS BE KEPT IN AN UPRIGHT POSITION AND SHALL BE SO PLACE THAT THEY NOT BE KNOCKED OVER

5. OPEN FLAMES LIGHTS, LIGHING OF FIRES WELDING AND SMOKING SHALL BE PROHIBITED IN CLOSE PROXIMITY TO ANY CYLINDERS CONTAINING CLAMMABLE GASES EXCEPT THOSE WHOLE IN USE FOR WELDING CUTTING AND HEATING

6. G,DROPPING, OR PLAYING WITH CYLINDERS PROHIBITED


JOB SAFETY ANALYSIS

JOB SAFETY BREAK DOWN SHEET CONSISTING OF THE FOLLOWING:

1. NAME OF OPERATION FOR JSA

2. DESCRIPTION OF THE OPERATION

3. HAZARDS(POTENTIAL/EXISTING)

4. PRECAUTION/REMEDIES

JSA: A PERSON WELL CONVERSANT WITH THE JOB OPERATION SHOULD DO JSA A SUPERVISOR IN ASSOCIATION WITH SENIOR PERSONNEL OR OFFICER CAN DO IT OR A SMALL COMMITTEE CAN DO IT.

ADVANTAGES :

i. HELPS TO IDENTIFY HAZARDS AND PREVENT ACCIDENT

ii. HELPS TO ESTABLISH SAFE WORK METHOD WORKING CONDITONS SUITABLE PLANT SAFETY RULES,PPE REQUIREMENTS ETC.

iii. HELPS TO ESTABLISH IN PLANT SAFETY INSPECTION HELPS TO ACCESS THE REQUIREMENTS INCLUDING SAFETY TRAINING OF NEW WORKERS/EXISITING WORKERS.


A LIST GUIDED WORDS ARE GIVEN BELOW

1. NO OR NOT

2. MORE

3. LESS

4. AS WELL AS

5. PART OF

6. REVERSE

7. OTHER THAN

A SIMPLE EXAMPLE IS GIVEN BELOW

i. SUPPLY TANK IS EMPTY

ii. PUMP FAILS TO TURN

iii. MECHANICAL ELECTRICAL FAILURE

iv. PUMP IS SWITCHED OFF

v. PIPE LINE IS FRACTURED

vi. ISOLATION VALUE IS CLOSED.


DEVIATION IS LESS PASSED INOT THE REACTION VESSEL THE CAUSES MAY BE

1. ISOLATION VALVE IS SLIGHTLY CLOSED

2. THE PUYMP IS PARTLY BLOCKED

3. THE PUMP FAILS TO PRODUCE FULL FLOW-BECAUSE THE IMPELLERS ARE ERODED BECAUSE VALVE IS WORN ETC.

PRINCIPLE OF TOTAL LOSS INCIDENT CONTROL: TRY TO INVESTIGATE ALL ACCIDENTS, FIND OUT THE CAUSES INCLUDING

CONTRIBUTING CAUSES AND WORK OUT REMNEDIAL MEASURES TO PREVENT RECURRENCES OF SUCH ACCIDENTS.

ANTICIPATE POTENTIAL ACCIDENTS UNDER CERTAIN CIRCUMSTANCES AND WORK THEIR CONTROL PREVENTION E.G.UNUSUAL NON ROUTINE WORK AND PRODUCTION ACTIVITIES MAINTENANCE WORK SOURCES OF HIGH ENERGY WHICH MAY LEAD TO EXPLOSION FIRE TO TOXIC RELEASE ETC.,


3.SAFETY SHOULD BE CONSIDERED AS ANOTHER NORMAL ACTIVITY OF THE FACTORY MANAGEMENT SHOULD REALIST THAT SAFETY IS ANALOGOUSS TO COST QUALITY AND QUANTITY OF PRODUCTION MANAGEMENT MAY SET GOALS FOR SAFETY PLANNING COORDINATING AND CONTROLLING TO ACHIEVE THE GOALS/OBJECTIVES FAULT TREE ANALYSIS IS A BIOGRAPHICAL REPRESENTATION OF THE LOGICAL RELATION BETWEEN A PARTICULAR SYSTEM ACCIDENT(TO PREVENT)AND THE PRIMARY CAUSE EVENTS.

4.THE KEY TO EFFECTIVE LINE SAFETY PERFORMANCE LIES IN THE ESTABLISHMENT OF PROCEDURES BY MANAGEMENT FOR FIXING ACCOUNTABILITY FOR SAFETY.IF WE ENSURE #4,#3 WILL BW EFFECTIVE SINCE #3,#4 ARE COMPLEMENTARY. LOSS CONTROL MANAGEMENT INVOLVES CONTROL OVER AVAILABLE LOSSES LIKE MEN, MATERIALS AND WORKING ENVIRONMENT.


COURSES:

Diploma in occupational Health And Safety Diploma in industrial safety Diploma in electrical safety Diploma in fire fighting Diploma in construction safety Certificate in fire and safety engineering Diploma in fire and safety engineering PG diploma in fire and safety engineering Certificate in oil and Gas safety Diploma in oil and Gas safety Diploma in health ,safety and Environment PG diploma in Health ,safety Environment


JOB PLACEMENT :

NSA will give100% job placement assistance to all successful candidates. Some of the Industries are listed below.

Oil Refineries,

Port trust, Airport, Chemical Industries, Insurance, Construction and service industries are main job providers.

Students passed out from this institute can find job opportunities as Safety Supervisor, Safety Inspector, Safety Officer, Safety Manager, Fireman and Fire Officer.


Contact us:

No. 714, 1st Floor, M.T.H Road, Mannurpet, Chennai – 600 050. +91 7667442300 Ph: 26242038 ,26242318

Mobile No:8643055672

Website – http://safetyacademy.in/

Email : [email protected]

Education

diploma in industrial safety UNIT-3