DFS 01 - Industrial Safety Management
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1) Safety Policy
Definition of Safety
The condition or state of being freedom or protected from or unlikely to cause danger or hazard, exemption from hurt, injury or loss. “They should leave for their own safety”. Denoting something designed to prevent injury or damage like “a safety barrier”, “a safety helmet”, “a safety belt” etc. A Safety full form is “Stay Alert For Every Task You do”.
Safety Policy
The Safety Policy to improve our performance and strive for achieving zero accident, on continuous basis. It is organized efforts and procedures for identifying workplace hazards and reducing accidents and exposure to harmful situations and substances. It also includes training of personnel in accident prevention, accident response, emergency preparedness and use of protective clothing and equipment. A legal requirement on an employer to prepare and keep up to date a written statement of their policy regarding the safety of their employees. The requirement for a written statement is for 5 or more employees. A Safety Policy is an important way to specify the tasks and responsibilities of each Employee & the Employer with regard to workplace safety. It is also way to ensure that the same message is repeated consistently across the organisation.
As per factories Act 1948 – Section 7(A) & 841 (B), a written statement of the company’s safety policy is an essential step in the process of demonstrating to line management and workers. That the board determined to ensure high standards of Safety and Hygiene.
Safety Committee
What is a Safety Committee ?
A safety committee is a group of employees appointed to aid and advise management on worker safety. The committee may be composed of top management and two or three supervisors and several workers, or any other combination of supervisors and workers. It is important that top management be represented and participates in the organization and conduct of the committee meetings.
Though the scope of the safety committee's activities is advisory, the commission may find it practical to appoint an engineer, supervisor or department head to the committee with authority to correct unsafe conditions without further approval.
The safety committee should hold regular monthly meetings at which the recommendations, accidents, records and program plans are discussed; and a monthly inspection should be made of a selected area or areas with special attention being paid to the subject or aim chosen for that month.
Safety Committee
1) Production Manager
2) Mechanical Manager
3) Electrical Manager
4) Utility Manager
5) Civil Manager
6) Admin Manager
7) Security Officer
8) Safety Officer
9) Representative of Shop Floor People
What the Safety Committee Does
The successful safety committee helps plan the safety program and takes part in making the program operate. These activities will be determined by the size of the committee and the policies set out by the group. It has been found advisable to establish definite policies when the committee is organized.
Safety Committee Activities
To establish a safety committee or hold safety meetings to create and maintain a safe and healthy workplace for all employees.
Committee must : If you employ 11 or more employees on the same shift
at the same location
Then you must establish a safety committee
Committee must : Establish a safety committee.
· Make sure your committee has employee-elected
and employer-selected members.
· Determines how often, when, and where, the safety
Committee will meet.
· The number of employee-elected members must
equal or exceed the number of employer-selected
members.
· The term of employee-elected members must be a
maximum of one year.
Committee must : Cover these topics
· Review safety and health inspection reports to help
correct safety hazards.
· Evaluate the accident investigations conducted
since the last meeting to determine if the cause(s)
of the unsafe situation was identified and corrected.
· Evaluate your workplace accident and illness
prevention program and discuss recommendations
for improvement if needed.
· Document attendance.
· Write down subjects discussed.
Committee must : Record meetings.
· Prepare minutes from each safety committee and:
Preserve them for one year
· Make them available for review by safety and
health consultation personnel of the department
of Labor & Industries.
2) Work Permit System &
Vessel Entry Permit System
(Type of permit to work, Hot work permit, Cold work permit, No permit required, Supporting documents, Permit issue, Permit review, Permit duration & Cancellation, Completion of work, Log books etc.)
Work Permit System
Definition of Work Permit System:
A Work Permit is a written record issued by authorised person permitting a specific task for a specific time frame in a defined area.
A work permit system consists primarily of a standard procedure designed to ensure that potentially hazardous routine and non routine work on industrial installations can be carried out safely. Many accidents have occurred due to lack of Work Permit or non observance of its consigned safety measures. It is not one more administrative paper! Fill in and follow correctly the work permit, because….It could save your life !
Work Permit Purpose:
The purpose of this standard is to describe procedures and guidelines on work permit system to carry out jobs of inspection, testing, maintenance, alternation, repair, upkeepment and construction in safest possible manner. The implementation of this system will help in bring down the risks at work sites to acceptable level, thereby reducing possibility of any accident, fire, explosion, property damage and adverse effect on environment.
Types of Work Permit
Ø Hot Work
Ø Cold Work
Ø Radiation Work
Ø Working at Height
Ø Excavation: Any job, which requires excavation / digging of earth
Ø Confined Space
Ø Lower Explosive Limit (LEL)
Ø Upper Explosive Limit (UEL)
Ø Pyrophoric Substance
Ø Self Contained Breathing Apparatus (SCBA)
Ø Gas Safety Inspector (GSI)/Issuer
Ø Fire Permit Signatory (FPS)/Issuer
Ø Receiver (Permittee)
Ø Blanket permit
Work Permit Types with Definition:
Hot Work: An activity that can produce a spark or flame or other source of ignition having sufficient energy to cause ignition, where the potential for flammable vapours, gases, or dust exists. This includes all works, which produces spark, running of IC engine, breaking of concrete, use of ordinary torches, use of battery operated devices.
Cold Work: Cold Work is an activity that does not produce sufficient heat to ignite a flammable air- hydrocarbon mixture or a flammable substance.
Radiation Work: Any activity that is carried with a source of ionizing radiation, which does not produce sufficient heat to ignite a flammable air - hydrocarbon mixture or a flammable substance.
Working at Height: Any activity that is carried out at 2.0 meters & above on temporary structure, scaffolds or on a structure not meant to do particular job safely.
Excavation: Any job, which requires excavation / digging of earth
An Excavation is any man-made cut, cavity, trench, or depression in an earth surface that is formed by earth removal. A Trench is a narrow excavation (in relation to its length) made below the surface of the ground. In general, the depth of a trench is greater than its width, and the width (measured at the bottom) is not greater than 15 ft (4.6 m). If a form or other structure installed or constructed in an excavation reduces the distance between the form and the side of the excavation to 15 ft (4.6 m) or less (measured at the bottom of the excavation), the excavation is also considered to be a trench.
Confined Space: It is an enclosure with known potential hazards and restricted means of entrance and exit. It is not meant for normal occupancy of people and is usually not well ventilated such as vessels, boilers, storage tanks, large diameter piping etc. The excavation more than 1.2 M deep, entry into floating roof tanks, when roof is more than 3M down from the top, space located below ground level such as pits, drain channels etc shall also be considered as confined space.
Upper Explosive Limit (UEL): UEL is the maximum concentration of a vapor in air (or other oxidant) above which propagation of flame does not occur on contact with and ignition source. This is usually expressed as a volume percentage of vapors in air.
Pyrophoric Substance: Substances that ignites spontaneously in air at ambient temperature. In hydrocarbon industries iron sulphide is the most commonly observed pyrophoric substance and is called as pyrophoric iron.
Self Contained Breathing Apparatus (SCBA): It is an life saving personal protective apparatus consisting of a face mask, combined with a hose and source of fresh air generally in form of a cylinder of compressed air, to be carried by bearer.
Gas Safety Inspector (GSI)/Issuer: GSI means a designated officer authorized to perform all necessary tests before signing a work permit. He must satisfy himself by a personal inspection that the tank / vessel / line / equipment / any other confined space involved is safe for the work intended. He can independently issue Cold work permit and permit for working at height.
Fire Permit Signatory (FPS)/Issuer: FPS means a designated officer authorized to issue work permit. He is ‘Fire Permit Signatory’/‘Issuer’ in case of Hot work / Vessel entry / Excavation permit and for any other permit. He issues the permit for the particular job after addressing the checklist points of permit for the units / areas, where he is the in-charge. FPS will sign the permit after getting satisfied that GSI has carried out all the tests/checks and signed the permit.
Receiver (Permittee) : The ‘Receiver’ the designated person authorized to receive work permit. Receiver generally is the executing department officer, who has to execute the particular job for which permit has been issued. The executing officer can be Engineer In-charge / Site in-charge of the job or any other nominated officer for executing dept. (normally service dept)
No Permit Required
No permit is required where work is carried out with a SOP (Standard Operating Procedure) and does not specify a need for a PTW (Permit To Work). The Site Supervisor shall satisfy himself (via risk assessment) that the risks are As Low As Reasonably Practicable (ALARP) and that competent personnel perform the tasks.
Conditions are complied throughout the work period.
Supporting Documents (SDs) -:
Supporting documents are the documents procured to satisfy a permit issuer regarding the safety precautions taken before the start of the work. You have to remember that SDs is not Permits to Work and never, by them, authorise work to proceed.
· Isolation Confirmation Certificate
· Confined Space Entry Certificate
· Clearance for Excavation Certificate
· Clearance to Move Heavy Equipment
· List of Personnel
Work Permit Issue
Permittee i.e. under whose direct supervision the job is to be carried out shall raise the requirement for appropriate permit. All permits shall be issued in triplicate / duplicate. To obtain a Safe Work Permit, the SUBCONTRACTOR'S Supervisor responsible will complete a Permit Request and submit it to the operations control room as determined prior to 1:00 p.m. on the day before the proposed work activity is to commence.
Work Permit Review
Prior to the start of the work specified on the Safe Work Permit, the supervisor will explain to all persons involved with performing the work the conditions as outlined on the permit. The permit will then be posted / displayed at the specified work area.
To ensure that equipment can be brought to a safe condition for work to commence it is of prime importance that a review of all appropriate process flowsheets, layout and engineering drawings together with equipment and material specifications is carried out. The purpose of the review is to ensure that all the key persons involved in job planning have a thorough understanding of the job. It is recommended that drawings or sketches are used to define the limits of working areas and, where appropriate, are attached to the work permit form.
The review should include not only the equipment itself but the total process of which it is part. The following items should be considered an evaluated as part of the review.
It should include:
Ø Degree of isolation,
Ø Process fluids and materials involved,
Ø Effect of other processes,
Ø Power supply isolation,
Ø Specialist advice,
Ø Location of underground services and pipes,
Ø Location of elevated power cables,
Ø Location of elevated pipelines and walkways,
Ø Purging and lock-out requirements,
Ø Pressure, Temperature,
Ø Valve identification,
Ø Equipment specification,
Ø Operating and maintenance instructions,
Ø Materials of construction and compatibilities
Or also in case of:
Ø Manual or powered excavations
Ø Use of mobile cranes
Ø Insulation or catalysts handling
Ø Use of adapters
Ø Product conversion of stationary or mobile or portable vessels and containers
Ø Temporary or permanent changes, alterations, modification of equipment or
processes,
Ø Exposure to traffic,
Ø Exposure to moving/rotating machinery
Ø In proximity of vents, liquid of gas
Ø On process lines with gas release
Permit Duration & Cancellation
All Safe Work Permits will be valid only for the time period shown on the permit. Each site will have its own specific requirements depending, on the nature of the construction work, and the Company's existing permit procedures (e.g., the requirements for construction work within an existing petrochemical refinery will differ to those for bridge construction on a new highway). The validity of a permit will depend on several factors. Generally, permits within existing operational areas are only valid for one day, while permits on new construction sites may be longer (i.e., 'Blanket' permits). The CONTRACTOR HSE Manager will determine the exact requirements in consultation with the COMPANY. All permits will automatically become voided in the event of a general alarm or at the direction of the CONTRACTOR due to safety non-compliance. If permit(s) have become voided a new permit (s) will have to be requested and put in place before the work is resumed.
Completion of the Work
Upon completion of the shift or permitted work, the supervisor who requested the permit will sign off the permit and return it to the authority that issued it. An inspection of the o k site by the Contractor and/or the company may be required, depending on the nature of the work performed. Prior to signing off the permit, the Sub-Contractor's supervisor will ensure that the work area has been left in a safe condition and that no further work will be performed until a new permit is issued.
Log Books
The Company may utilise a log book system to record the movement of personnel in certain areas. The log book system does not replace the permit system, although it may be used to authorise entry into a specific area to perform minor tasks.
Vessel Entry Permit System
Safe work permit required for entry in to vessels a safe permit is a written read issue be athorised personnel frame in a defined area. Production or other construction activities will receive. This permission of vessel entry in the port is generally taking from the Shipping Corporation / Companies. This permit from mostly of contain lot of enquires.
1) Ship coming from which Country.
2) Purpose of Visit.
3) No. of Crews members traveling & there nationality.
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3) P.P.E.
(Identify its uses & draw various personal protective equipments)
Definition of P.P.E.
P.P.E. full form is Personal Protective Equipment. This procedure outlines the requirements and practices for the management of Personal Protective Equipment (PPE) to assist with the correct selection, supply, use, replacement, maintenance, training and storage.
Specialized clothing or equipment worn by employees for protection against health and safety hazards. PPE covers any item intended for wearing or carrying by the worker with the aim of protecting him from one or more risks likely to cause injury or jeopardize health while at work, in addition to any item or accessory having the same purpose. PPE giving greater protection against risks which may cause death or severe and / or permanent injury. Personal protective equipment is designed to protect many parts of the body, i.e., eyes, head, face, hands, feet, and ears.
Procedure
PPE shall conform to any legislative, Australian Standard and/or Industry Standard requirements or guidelines. Consideration shall be given to the need for protecting persons who are working nearby or passing close to hazardous areas. All staff required to wear using PPE shall be provided with training prior to use and ongoing training where necessary.
Types of PPE
PPE can be considered in the following categories, based on the type of protection afforded by the equipment:
1) Respiratory Protection : e.g. disposable, cartridge, air line,half or full face
2) Eye Protection : e.g. spectacles/goggles, shields, visors
3) Hearing Protection : e.g. ear muffs and plugs
4) Hand Protection : e.g. gloves and barrier creams
5) Foot Protection : e.g. shoes/boots
6) Head Protection : e.g. helmets, caps, hoods, hats
7) Protection from falls : e.g. harness and fall arrest devices
8) Skin Protection : e.g. hats, sunburn cream, long sleeved clothes
9) Other personal protective
equipment : e.g. protective clothing for cryogenic work or
environments with high temperatures.
e.g. disposable, cartridge, air line, half or full face.
Safety, hygiene and emergency response professionals need products that enhance and improve their respiratory protection programs, while wearers want comfort and performance. 3M offers the best of both worlds.
e.g. spectacles/goggles, shields, visors.
Usually enclose or protect the eye area in order to prevent particulates, infectious fluids, or chemicals from striking the eyes.
3) Hearing Protection :
e.g. ear muffs and plugs
4) Hand Protection :
e.g. gloves and barrier creams
Our hands are probably the most important part of our body when it comes to doing our work. They’re involved in almost every thing we do. Yet many of the things we do with our hands are done without any deliberate thought. Your hands have no fear. They’ll go anyplace they’re sent and they only act as wisely as the person they belong to; so before you use your hands think of their safekeeping.
5) Foot Protection :
e.g. shoes/boots
Keeping in mind the safety of your foot, Foot Protection by Shoes is ideal to protect our foot from any kind of injury due to falling or rolling objects or objects piercing the sole and where such employee's feet are exposed to electrical hazards.
6) Head Protection :
e.g. helmets, caps, hoods, hats
Our head is a very delicate part of your body. Injuries to the head are very serious. For this reason, head protection and safety are very important. Wearing a safety helmet on a site may prevent or lessen a head injury from falling objects or a person hitting their head against something.
7) Protection from Wall :
e.g. harness and fall arrest devices
When work is performed on elevated surfaces such as roofs, or during construction activities, protection against falls frequently must be considered. Fall arresting systems, which include lifelines, body harnesses, and other associated equipment, are often used when fall hazards cannot be controlled by railings, floors, nets, and other means. These systems are designed to stop a free fall of up to six feet while limiting the forces imposed on the wearer.
8) Skin Protection :
e.g. hats, sunburn cream, long sleeved clothes
The skin is the single largest organ of the body. The skin, when healthy, protects us from chemical, physical, and biological hazards.
9) Other Personal Protective Equipement :
e.g. protective clothing for cryogenic work / environments with high temperatures.
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4) Types of Emergency Planning
(Explain Energy Management, Emergency Management Elements, Development Process, Co-Ordination with outside Organisation, Review, Emergency Response Procedure, Support Documents)
Definition of Emergency Planning
An emergency plan specifies procedures for handling sudden unexpected situations. It will developed your capability for effective participation in the all hazards, emergency of creation, planning process to save Lives, Property & Environment threatened by clusters.
The objective is to reduce the possible consequences of the emergency by:
· A definite plan to deal with major emergencies is an important element of
OH&S programs.
OH&S programs.
· Preventing fatalities and injuries; reducing damage to buildings, stock and
equipment; and accelerating the resumption of normal operations.
equipment; and accelerating the resumption of normal operations.
· You should also consider potential impact to the environment and to the
community in your emergency plan.
community in your emergency plan.
Types of Emergency Plans
It may be important for an organisation to have more than one emergency plan. It is often the case that organisations have Generic plans and Specific plans.
Emergency Management is the process of preparing for, mitigating, responding to and recovering from an emergency. Emergency management is a dynamic process. Planning, though critical, is not the only component. Training, conducting drills, testing equipment and coordinating activities with the community are other important functions. To be successful, emergency management requires top management support. The chief executives sets the tone by authorising planning to take place and directing senior management to get involved.
Emergency Management Elements
An emergency plan should briefly describe the facility’s approach to the core elements of emergency management are as follows :
Ø Direction & Control
Ø Communication
Ø Life Safety
Ø Property protection
Ø Community outreach
Ø Recovery and restoration
Ø Administration and logistics
The objective is a brief the summery of the purpose of the plan; that is, to reduce human injury and damage to property in an emergency
Development Process
The normal plan development process is to assign each member of the planning group a section to workout. Establish an aggressive time limit with specific goals. Provide enough time for completion of work, but not so much as to allow assignments to linger. Establish a schedule for First draft, Review, Second Draft, Tabletop exercise, Final draft, Printing & Distribution.
Co-ordinate with outside Organisation
Determine protocols for turning control of a response over to outside agencies. Some detail that may need to be worked out are :
Ø Which gate or entrance will the responding units should use ?
Ø Where and to whom will they report ?
Ø Who will be in charge of response activities ?
Review
Distribute the first draft to group members for review. Revise as needed. For a second review, conduct a tabletop exercise with management and personnel who have a key emergency management responsibility. In a conference room setting, describe an emergency scenario and have participants discuss their responsibilities and how they would react to the situation. Based on this discussion, identify areas of confusion and overlap, and modify the plan accordingly.
Emergency Response Procedure
In an emergency, all personnel should know:
· What is my role?
· Where should I go?
Specific goals & milestones, list of tasks to be performed in case of emergency by whom and when are defined.
· Emergency escape procedures and routes.
· Procedures for employees who perform or shut down critical operations
before an evacuation.
before an evacuation.
· Procedures to account for all employees, visitors and contractors after an
evacuation are completed.
The actions required assessing the situation, Protect employees, customers, visitors, equipment, vital records and other assets, particularly during the first three days and getting back to the business is also identified.
· Warning employees and customers
· Communicating with personnel and community responders
· Conducting an evacuation and accounting for all persons in the facility
· Managing response activities
· Activating and operating an emergency operations center
· Fighting fires
· Shutting down operations
· Protecting vital records
· Restoring operations
Support Documents
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5) Elaborate The 5 Good House Keeping Practices (5 S)
5S of House Keeping
What is 5S?
5S is a set of techniques providing a standard approach to housekeeping within Lean. It is often promoted as being far more than simply housekeeping and some of the elements described below certainly have broader implications.
Lean Manufacturing Housekeeping 5S "pillars"
The individual items within 5S are known as the "pillars" and are:
Ø 1s Seiri (Sort)
Ø 2s Seiton (Set)
Ø 3s Seiso (Shine)
Ø 4s Seiketsu (Standardisation)
Ø 5s Shitsuke (Sustain)5S | Japanese | English |
1S | 1S Seiri | Sort out unnecessary items in the work place and discard them |
2S | 2S Seiton | Set necessary items in good order so that they can be easily picked for use. |
3S | 3S Seiso | Shine you work place completely so that there is no dust on floor, machine and equipment. |
4S | 4S Seiketsu | Standardisation maintain of housekeeping and work place organisation at all items. |
5S | 5S Shitsuke | Sustain people to follow good housekeeping disciplines autonomously. |
There are eight crucial points for successful implementation of 5S. They are as follows :
Ø Participation by all people
Ø The programme requires Top Management commitment
Ø The CEO should Take Leadership of the Programme
Ø The programme should be Supported by all
Ø 5S Programme should be self sustaining
Ø The CEO should make a Periodic Factory Tour in Person
Ø The programme should generate sufficient impact at the initial stage
Ø Implementation of 5S should go Hand-in-hand with other Kaizen Programme
Ø Implementation of 5S should go Hand-in-hand with other Kaizen Programme
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6) Write a brief note on HAZOP study & its procedure
HAZOP
HAZOP short for Hazard and Operability is one of the several tools of Process Safety Review (PSR). HAZOP is essentially the result of interactive sessions among HAZOP study team consisting of a very senior HAZOP study specialist along with experts directly associated with the operation, maintenance, design and training of personnel of the plant subjected to HAZOP. HAZOP study is basically a communication exercise. HAZOP study is a systematic step by step study.
PROCEDURE OF HAZOP
The HAZOP team focuses on specific portion of the process called “nodes” Generally these are identified from the P & ID of the process become the study begins. Then a serried of guide words is combined with the parameters “Flow” do great a deviation. The team then focuses on all the credible causes of a “No Flow” deviation beginning with the cause that can result in the worst possible consequence can drink of at the time.
Deviation
The keyword combination being applied (e.g. Flow/No).
Cause
Potential cause which would result in the above deviation is the blockage of the strainer 81 due to impurities in Dosing Tank T1.
Consequence
The consequences which would arise, both from the effect of the deviation is
1) Incomplete separation in V1 and,
2) Chances of empty space in Pump P1, with possible damage if
prolonged. Always be explicit in recording the consequences.
prolonged. Always be explicit in recording the consequences.
Safeguards
Any existing protective devices which either prevent the cause or safeguard against the adverse consequences would be recorded in this column.
Action
Where a cause results in a negative consequence, it must be decided whether some action should be taken. It is at this stage that consequences and associated safeguards are considered. If it is deemed that the protective measures are adequate, then no action need be taken, and words to that effect are recorded in the Action column.
Actions fall into two groups:
1. Actions that remove the cause.
2. Actions that mitigate or eliminate the adverse effect.
HAZOP Study is useful at the following stages:
New plant design
· Early checking for major hazards
· Developing a design with sufficient thoroughness for sanction purpose.
· Design freezing
· Pre-commissioning checks
· Final checking in normal operation
Existing Plants
· A quick ranking exercise, with the use of some guide lines or indexes on a
plant section to have high potential for hazards.
plant section to have high potential for hazards.
· A safety audit has shown that a detailed study is desirable.
· Unusual occurrences or accidents have taken place.
· A proposal for plant modification or operating procedure : modification is
to be critically examined before authorization.
to be critically examined before authorization.
Pre-Commissioning checks
The use of HAZOP at this stage involves ensuring that all the recommendations of previous HAZOP studies have been daily incorporated.
Post Commissioning Checks
This is a final audit, after commissioning to ensure that if any changes have been made during the commissioning and early operating stages, they do not invalidate the original design assumptions, if necessary HAZOP study may be carried out again on some of the modifications.
Modification of Existing Plant Operating Procedure
Whenever it is desired to modify an existing plant or operating procedure involving hazardous chemicals or process, it should be done after a formal authorisation and HAZOP study is to be conducted before authorisation.