INDUSTRIAL

HAZARDS and plant safety

PRESENTED BY GAURAV R. BHALKAR 1st year M. Pharm(Pharmaceutics)

INDUSTRIAL HAZARD

Industrial hazards may be defined as any conditions produced by industries that may cause injury or death to personnel or loss of product or property.

Industrial hazards are of various types

• Fire and explosion

hazards

• Electrical hazards

• Chemical hazards

• Gas hazards

• Mechanical hazards

• Dust hazards

FIRE AND EXPLOSION HAZARDS

CAUSES

Electrical systems that are overloaded,

resulting in hot wiring or connections

Combustibles near equipment that

generates heat, flame, or sparks.

Flammable liquids and aerosols

Electrical wiring in poor condition

Batteries

Smoking in the factory premises by

workers.

PREVENTIVE MEASURES

Not exceeding the maximum 

occupancy  within any part of the

building.

Maintaining proper fire exits and

proper exit signage (e.g., exit signs

pointing to them that can function in a

power failure).

Prohibiting flammable materials in

certain areas of the facility.

Smoking is prohibited in industrial

premises.

Don’t wear nylon cloths at work place .

Each and every section of the industry should have fire extinguisher .

Make sure that all employees are familiar with fire extinguisher.

HOW FIRE OCCURS ?

• Fire naturally occurs when the elements are present and combined in the right mixture.

• The elements are heat, fuel, and an oxidizing agent (usually oxygen).

• These elements comes together and form a model called FIRE TRIANGLE. And hence fire is formed.

FIRE CLASSES

Class A fires involve organic solids such as paper and

wood.

Class B fires involve flammable or combustible liquids,

including petrol, grease, and oil.

Class C fires involve flammable gases.

Class D fires involve combustible metals.

Class E Fires involving ELECTRICAL APPARATUS

Class F fires involve cooking fat and oil.

SAFETY MEASURES

1.Fire extinguisher Types of fire

extinguisher

Water fire extinguisher

Foam fire extinguisher

Dry chemical powder

co2 fire extinguisher

wet chemical fire extinguisher

metal fire extinguisher

Use of fire extinguisher

Types of fire extinguisher

CLASS A

CLASS B

CLASS C

CLASS D

CLASS E

CLASS F

WATER √

FOAM √ √

DCP √ √ √ √

co2 √ √ √

WET CHEMICAL √ √

METAL √

2. Fire tendersTypes of fire tenders

Water fire tender

Carbon dioxide fire tender

Dry chemical fire tender

ELECTRICAL HAZARDS

CAUSES

The improper use of machinery or

apparatus

The improper use of electrical

outlets

The improper use of electrical

equipment, such as cables and power

cords

The improper maintenance of

apparatus, outlets, and electrical

equipment

An overloaded circuit

The improper joints of two wires.

PREVENTIONS

Use extension cords only for

temporary purposes.

Do not use any equipment or

cords that have splices.

Do not use three-to-two prong

adapters.

Don't overload outlets.

Because of the chemicals, check

the connection and power cords are

not degrading.

Indication of DANGER SIGN at

every high voltage terminal.

Proper maintenance of wiring

and equipment.

Never use the power cord to

move or carry apparatus.

Effect of the shock

Current Reaction

1 Milliampere Perception level

5 Milliamperes Slight shock felt; not painful but disturbing

6-30 Milliamperes Painful shock; "let-go" range

50-150 Milliamperes Extreme pain, respiratory arrest, severe muscular contraction

1000-4,300 Milliamperes Ventricular fibrillation

10,000+ Milliamperes Cardiac arrest, severe burns and probable death

Safety measure

• Electric gadgets should be repaired only by a qualified person.

• Disconnect electrical gadgets when not in use.

• Never touch electrical equipment with wet hands.

• Electric wires or cords, if faulty, should never be used until repaired.

• Avoid contact with energized electrical circuits.

• Place rubber mats in front of electrical switch boards.

• Make sure that all employees are familiar with the location and use of fire fighting apparatus

• Use sand or blanket to control fire caused due to electrical accidents

CHEMICAL HAZARDS

CAUSES

Irritants are materials that can cause

inflammation of the body surface with

which they come in contact. Common

irritants substances such as: NITROGEN

DIOXIDE, OZONE ETC.

Chemical asphyxiants render the body

incapable of maintaining an adequate

oxygen supply. Examples include: CARBON

MONOOXIDE ETC.

Depressant effect upon the central nervous

system, particularly the brain. Examples

include: CHLOROFORMS, ALCOHOLS ETC.

Hepatotoxic agents can cause damage to

the liver. Examples include: CARBON

TETRACHLORIDE, METYLENE CHLORIDE ETC.

Nephrotoxic agents can damage the

kidneys. Examples include: URANIUM

COMPOUND.

PREVENTIONS

Train employees to follow safe handling

and application procedures for maintenance

or pesticides chemicals.

Do not use excessive grease or lubricants

on equipment.

Regularly re-evaluate all procedures to

ensure they effectively remove chemicals.

Store chemicals in designated areas away

from food, ingredients and packaging.

Ensure chemical container are clearly

labeled or colour coded, and that they are

used only for chemicals.

Receive raw ingredients from reputable

suppliers that effectively control chemical

hazards.

Ensure restricted ingredients and

additives are correctly measured.

e.g Hexachlorophene. Because of its

toxic effect it penetrate human skin. So

it used only when an alternative

preservative has not been shown to be

as effective.

Safety measures

Respirator must be used in all the gas storage places.(specifically chemical gas)

Body should be fully covered whenever people are interacting with hazardous chemicals.

When skin burn happens due to chemicals use alkaline solution always instead of water.

GAS HAZARDS

THREE MAJOR TYPES OF GAS HAZARDS

1. Flammable

Risk of fire and / or explosion e.g. Methane, Butane, Propane

2. Toxic

Risk of Poisoning e.g. Carbon Monoxide, Hydrogen, Carbon Dioxide, Chlorine

3. Asphyxiant

Risk of suffocation e.g. Oxygen deficiency. Oxygen can be consumed or displacedby another gas.

Gas Safety at Work

The Gas Safety (Installation and Use) Regulations 1998 require the following:

All gas appliances, pipe work and safety

devices must be maintained in a safe

condition and be inspected by a competent

person.

When a gas appliance is installed, it must

be located in a position that is easily

accessible for use, inspection and

maintenance.

Employers, the self-employed, or anyone

responsible for business premises, must not

allow a gas appliance to be used it may be

dangerous.

BHOPAL GAS TRAGEDY

• It occurred on the night of 2–3 December 1984 at the Union Carbide India Limited (UCIL) pesticide plant in Bhopal, Madhya Pradesh.

• The official immediate death toll was 2,259. The government of Madhya Pradesh confirmed a total of 3,787 deaths related to the gas release.

THE RELEASE OF GAS

• In November 1984, most of the safety systems were not functioning and many valves and lines were in poor condition.

• Several vent gas scrubbers had been out of service.

• The reaction was sped up by the presence of iron from corroding non-stainless steel pipelines. The resulting exothermic reaction increased the temperature inside the tank to over 200 °C (392 °F) and raised the pressure. This forced the emergency venting of pressure from the MIC holding tank, releasing a large volume of toxic gases. About 30 metric tons of methyl isocyanate (MIC) escaped from the tank into the atmosphere in 45 to 60 minutes.

MECHANICAL HAZARDS

Work Equipment Examples

Hand tools Hammers, Knives, Screwdrivers etc.

Power tools powered screw drivers, drill machine etc.

Machinery Photocopiers, food production line etc.

Apparatus Bunsen burners

Other Ladders etc.

EXAMPLE OF WORK EQUIPMENT

CAUSES AND PREVENTIONS

Rotating Machinery causes

Machinery with rotating parts can catch loose clothing, hands or hair, potentially causing serious injuries. Prevention Ensure rotating shafts, belts and pulleys are covered by guards, lids or covers.

ToolsCauses

Careless use of tools or use of tools in poor condition can cause injuries to the hands, eyes, head and limbs.

Prevention regularly check tools for defects or damage

MagnetsCauses

Large, powerful magnets or electromagnets can attract other magnets or iron/nickel objects which can cause painful pinching of fingers or hands if caught between the two.

Preventioninform peoples of this hazard before such magnets are used.

Glassware Causes

Any kind of glassware has the potential to break, thus creating the risk for cuts.

Preventions• wear goggles for eye protection.• use heat-resistant glassware.• clean up any broken glass immediately and

dispose of in a special waste bin.

DUST HAZARDS

How does dust hurt you?

Chronic Obstructive Pulmonary Disease (COPD) :-

‘Obstructive’ lung conditions which reduces airflow out of the lungs.

Asthma :-Another obstructive lung disease, which can be caused by exposure to irritants at work place and causes shortness of breath.

Cancers :-Tumours, particularly of the lung and nose, are related to substances commonly encountered at work including asbestos, silica, nickel, cadmium and wood dust.

Heart disease :- Dust-affected lungs put extra strain on the heart, which can lead to right-sided heart failure.

Extrinsic allergic alveolitis (EAA) :-

An allergic condition, which affects workers exposed to biological dusts, causing conditions including farmers’ lung.

PREVENTIONS

Safe machinery and equipment :-• Dusty work processes should be

isolated if possible.• An exhaust ventilation system is

often needed to suck dust away.

Safe procedures :-• Standardised working procedures are

needed in areas where dust can be a problem.• Information and training is

important.• Warning signs may be needed.

Respirators If steps 1 and 2 are not completely effective then an approved respirator is needed. Make sure that(A) It fits properly and is the right

kind of respirator(B) Training in how to use it is

provided and(C) Maintenance checks are carried

out.

INDUSTRIAL POLLUTION

AIR POLLUTION

CAUSES :-

1. Emissions from industries and

manufacturing activities.

2. Burning Fossil Fuels.

3. Household and Farming Chemicals.

COMMON AIR POLLUTANT :-

Carbon monoxide

Lead

Nitrogen dioxide

Sulfur dioxide

Effect on health :-

Acidification

Asthma

Cancer (like lung cancer)

COPD

Effect on children(risk of asthma,

pneumonia etc)

How to avoid air pollution ?

Practice

• Recycling

• Reusing

• Waste minimisation

• Mitigating

• Preventing

• Compost

Pollution control devices

1. Dust collection systems

• Baghouses

• Cyclones

• Electrostatic precipitators2. Scrubbers

• Baffle spray scrubber

• Cyclonic spray scrubber

• Ejector venturi scrubber

• Mechanically aided scrubber

• Spray tower

• Wet scrubber

WATER POLLUTION

CAUSES

Industrial waste

Sewage and waste water

Ocean and marine dumping

Oil Pollution

Effect on health

Diseases like Cholera

Malaria

Typhoid (spread during the rainy

season )

Aquatic life gets destroyed

Control of water pollution

Pollution control devices

Sewage treatment• Sedimentation (Primary treatment)• Activated sludge biotreaters (Secondary treatment;

also used for industrial wastewater)• Aerated lagoons• Constructed wetlands (also used for urban runoff)

Industrial wastewater treatment• API oil-water separators• Biofilter• Dissolved air flotation (DAF)• Powdered activated carbon treatment• Ultrafiltration

Throw waste material only in dust bin.

Use water wisely. Do not keep the tap running when not in use.

Do not throw chemicals, oils, paints and medicines down the sink.

don’t overuse pesticides and fertilizers in farm.

Rivers should not be used for washing clothes or bathing animals in.

SOIL POLLUTION

CAUSES

• Application of pesticides and fertilizers

• Mining

• Oil and fuel dumping

• Disposal of coal ash

• Leaching from landfills

• Drainage of contaminated surface water into

the soil

• Discharging urine and faeces in the open

Effects by soil pollution

• Causes problems in the human respiratory

system.

• Causes problems on the skin.

• Causes various kinds of cancers.

• Very bad smell and odour in the town.

• Landfills breed rodents like rats, mice and

insects, who in-turn transmit diseases.

Prevention on soil pollution

• More and more land should be brought under

farming.

• Trees should be planted everywhere.

• Waste matter should be disposed

immediately.

• Avoid using more fertilizers and Pesticides.

• Don’t dump oil and fuel on the ground.

REFERENCES

Pharmaceutical And Production Management

C.V.S Subrahmanyam

www.wikipedia.com