BASIC SAFETY ORIENTATION

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BASIC SAFETY ORIENTATION
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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

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GENERAL SAFETY RULES
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GENERAL SAFETY INSTRUCTIONS
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GENERAL SAFETY INSTRUCTIONS
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GENERAL SAFETY INSTRUCTIONS
FOR CONTRACTORS
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GENERAL SAFETY INSTRUCTIONS
FOR TRAINEES
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GENERAL SAFETY INSTRUCTIONS
FOR VISITORS
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SAFETY HEALTH POLICY
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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

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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.

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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

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Emergency Preparedness
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Emergency Preparedness
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Testing of Effectiveness of On - Site Emergency
Plan

• Types of Mock - Drill
• 1. 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.

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What is Fire ?
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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

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FIRE TRIANGLE
CHEMISTRY OF FIRE

• 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

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CLASSIFICATION OF FIRES SUITABLE FIRE
EXTINGUISHERS
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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)

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Fire Protection Prevention Facility at Nirma
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Fire protection prevention

• 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.

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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

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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

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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

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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
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Fire protection prevention
Fire Alarm System

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
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How to identify the HAZARD ?
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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

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Chemical Hazards

• Flammable/Explosion
• Flash point
• LEL
• Toxic/Poison
• Acute / Chronic
• Local / Systemic
• Routes of entry
• Reactive
• Corrosive

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Chemical Hazards- Harmful effects
Injuries Burns in eyes, skin and other organs
fires and explosions Allergy Breathing problems,
skinrash and coughing Illness Short long
exposures can cause immediate or delayed
illness Fatality Poisonous chemicals can even
cause death
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Chemical Hazards- Basic Causes of Accidents
Hurrying, Overconfidence, horse playing,
carelessness Spills and leaks of chemicals if
not wiped out immediately Working conditions like
contamination of atmosphere with harmful dust,
vapors and gases -leading to respiratory
problems Exposures of inflammable chemicals to
heat, sun - fire and explosion hazards Contact 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
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Mechanical Safety
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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.
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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

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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

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Point of Operation
That point where work is performed on the
material, such as cutting, shaping, boring, or
forming of stock must be guarded.
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Rotating Parts
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In-Running Nip Points
Rotating cylinders
Belt and pulley
Chain and sprocket
Rack and pinion
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Safe Material Handling
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Safe Handling and Storing Materials

• Involves diverse operations
• Manual material handling
• Carrying bags or materials
• Unpacking materials
• Material handling via machine
• Forklift
• Crane
• Rigging
• Stacking or storing drums, barrels, kegs, lumber,
  
• loose bricks or other materials

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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
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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

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Manual Handling

• Seek help
• When a load is too bulky to properly grasp or
  lift
• When you cant see around or over the load
• When you cant safely handle the load
• Attach handles to loads to reduce the chances of
  getting fingers smashed.

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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

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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

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Personal Protective Equipment
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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

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Types of PPEs
PPE may be divided into two broad groupsI.
Non-Respiratory equipmentII. Respiratory
equipment
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Non-Respiratory Equipment

• Head protection
• Eye and Face protection
• Hand and Arm protection
• Foot and Leg protection
• Body protection
• Ear protection
• Fall proof protection

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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)

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Work Permit System
Hot Work Permit
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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 damage Avoid fire Ensure that all
work is carried out in safest possible
manner. permit specifies the conditions and
procedure for safe execution
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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
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Work Permits - Requirement?
Major Minor Maint. work.- Cold work, Hot
work Construction - Hot work, excavation, Cold
work Process Equip. cleaning- Cold work Entry
into confined space- Confined space/ Vessel
Entry Excavation- Excavation/Digging Chemical
unloading - Cold Work Electrical Isolation Lock
out/ tagout permit
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TYPES OF PERMITS
Cold Work Permit

• 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/FS/FMT/002
• COLD WORK PERMIT (Red, Blue White)
• NLBA/FS/FMT/001
• (For all general maint. works (no ignition
  source)
• EXCAVATION PERMIT(Yellow ,light green, light
  gray white)
• NLBA/FS/FMT/004
• Digging work, civil work etc.
• ELECTRICAL LOCKOUT/TAGOUT PERMIT
  
• NLBA/FS/FMT/003

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First Aid Treatment
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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

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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.
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What is an Accident ?
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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

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Type of Accident

• First 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.

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Achieving safety at workplace ...
Ratios
HEINRICH PRINCIPLE
NEAR ACCIDENTS
MINOR INJURIES
MAJOR ACCIDENT
PREVENTION IN ADVANCE BY INVESTIGATING
ACCIDENTS AND NEAR ACCIDENTS
1
29
300
Safety committee
Team work
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Accident Investigation

• Investigation is not intended to find fault but
  to find the fact, to eliminate the re-occurrence.

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The Three Basic Causes
Poor Management Safety Policy
Decisions Personal Factors Environmental Factors
Basic Causes
ACCIDENT Personal Injury Property Damage
Unsafe Condition
Unsafe Act
Indirect Causes
Unplanned release of energy and/or Hazardous
material
Direct Causes
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Good Safety Practices

• Inspect work area daily
• Observe - be alert
• Housekeeping, Housekeeping, Housekeeping
• Use your best safety device - THINK
• If youre not sure - ASK someone!!
• Report Injuries/Incidents/Illnesses immediately
• Report safety issues to the safety committee

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Accident Reporting System
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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 Centers 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 MS
  and HOD-Production for all kinds of accidents.

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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.
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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.
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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.
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