INDUSTRIAL ACCIDENT AND SAFETY

PRESENTED BY:- CHANDAN SINGH

 BASIC PRINCIPLES OF ACCIDENT PREVENTION

 Industrial Safety means freedom from

accidents happening in an industry.

Accident means an unplanned, unexpected

event, which may or may not result into an
injury.
 BASIC PRINCIPLES

PRINCIPLE - ONE

An unsafe act, an unsafe condition, an accident; all these

are symptoms of something wrong in management
system.
 BASIC PRINCIPLES

PRINCIPLE - TWO

Certain sets of circumstances can be

predicted to produce severe injuries. These
circumstances can be identified and
controlled.
 BASIC PRINCIPLES

PRINCIPLE - THREE

Safety should be managed like any other

company function. Management should direct
the safety effort by setting achievable goals,
by planning, organizing, and controlling to
achieve them.
 BASIC PRINCIPLES

PRINCIPLE - FOUR

The key to effective line safety performance is

management procedures that fix
accountability.
 BASIC PRINCIPLES

PRINCIPLE - FIVE
The function of safety is to locate and define
the operational errors that allow accident to
occur
 BASIC PRINCIPLES

view the entire system in detail to define likely modes of failure, including human
error and their effects on the safety of the system.

Development
Identification
of accident Communicating Measurement
and
Prevention on of of
appraisal of
and loss – accident Effectiveness
The accident
Control information of control
problems
procedures
Feedback to be used for modification
 FUNDAMENTAL TRUTHS IN ACCIDENT
PREVENTION

There are two fundamental truths in accident prevention.

TRUTH – ONE
The accident –causes and injury –causes are different.

TRUTH - TWO
There are more than one cause for any accident
HOW TO DECIDE WHETHER A PARTICULAR
INCIDENT IS AN ACCIDENT OR NOT?

A) Injury to any Person

B) Damage to Property

C) Damage to Equipment

D) Damage to Material
 TYPES OF ACCIDENT

1.No accident even though accident potential is there

2.Near miss accident –called as incident

3.Accident –No damage or injury

4.Accident –Damage or injury

5.Accident-injury to person and damage to equipment,

material or property
 CHAIN OF ECVENTS

Injury

Accident

Unsafe acts
Unsafe condition

HUMAN FAILURE
Relation of Major Accidents, Minor
Accidents and Near-Miss Accidents

Serious Accidents

Minor Accidents
29

300 No Damage / Injury cases

 CAUSES OF AN ACCIDENT

Unsafe conditions
The major unsafe conditions are as below
 Improper guarding ,un-guarded

 Defective tools

 Slippery floors, work places

 Improper house keeping

THE MAJOR UNSAFE ACT ARE

 Operating without authority

 Failure to secure or warn
 Operating or working at unsafe speed
 Making safety devices inoperative
 Using unsafe equipment ,hands instead of equipment
or equipments unsafely
 Taking unsafe position or posture
 Failure to use personal protective equipment
 Cost of an accident

Every accident happening on shop floor, at home or in –

between, costs something to

 The injured person

 The family members of the injured
 The factory where he works
 The society in which he is living
 The nation
The accident costs are of mainly
two types

• Direct Cost (costs which can be seen and measured

• Indirect Cost ( Hidden cost)

Direct cost
 Compensation
 Medical expenses
 Direct expenses made by injured
The accident costs are of mainly
two types

Indirect cost
 Loss of production by the injured
 Loss of production by other workers who comes for help
 Cost of training a new worker
 Low production by the worker
 Low production by the victim for some time
The three basic steps in accident
prevention

 Discovering causes

 Eliminating unsafe acts

 Eliminating unsafe conditions

 Discovering Causes

There are five techniques to deal with discovering potential

causes of accident

a. Job safety analysis

b. Plant /site inspection
c. Accident investigation
d. Recording and tabulation of data
e. Analysis of data.
Unsafe act can be eliminated by

a. Personnel adjustment
b. Education and training
c. Supervision
d. Discipline

Unsafe condition can be eliminated by keeping a watch of it

and remove it as early as possible
 Safety in P&M Operations

Most accidents ,whether they occur in project sites, on the farm, at

home or on the highway are caused by the carelessness of some
individual or failure of plant and machinery.

Some basic and common safety rules and regulations are:

1.Know your machine in details
2.No operator should be assigned to a job until he completes the
following minimum requirement:-

a. He has been properly trained to operate the machine assigned to him.

b. He has read and understood the operator’s manual for the machine.
 Safety in P&M Operations
c .He has essential personal protective equipment and know how to use it.
d. He has the knowledge about the job requirements, any dangerous
condition which may arise and other emergency procedures

3.Maintain safe job condition and working procedure

4.Examine the work site for restricted traffic patterns, obstructive views,
congestion etc
5.Never attempt to clear oil or adjust a machine while it is in motion.
6.Attend to all fuel and oil leakage immediately and use only approved
grades of lubricating and fuel oils
7.Keep the battery terminals covered with petroleum jelly.
 Concrete Mixer

1. All gears ,chains and rollers of concrete Mixer should be adequately

guarded to prevent damage /danger
2. Concrete Mixer hopper shall be protected by side railing to prevent
workers from passing under them and operator shall make sure
before lowering the skip that all workers are safe.
3. Hopper hoisting wire rope has to be checked for its condition
periodically.
 Concrete Mixer

4. Hopper hoist and anchoring brake should be checked and adjust

while slipping occurs.

5. Nothing should be kept inside the motor enclosure.

6. Keep hoist clutch to be checked and adjusted while slipping occurs

7.Be sure that motor fan guard is secured timely

8.Be sure that wiring is properly connected and insulated

9.Ensure double earthling is done to electric mixers

 Welding Generators

1.Install the machine in a well ventilated environment with a proper Earthing.

2.Operator/welder should be well aware of sequence of operations
3.Direction of rotation is to be ensured thoroughly.
4.Adoption of correct size of supply &welding cables with lugs (sockets)
5.Insulation of machine should not fall below 2MΏ
6.Fuse rating should not exceed 50 Amps
7.Only genuine parts should be used
8.Avoid grinding work, near generator.
 Dumpers & Trucks

1.Only experienced operators with valid license should be permitted to

work
2.Allm parts and accessories should be kept in safe condition
3. All lights ,reflectors and brakes should function otherwise truck
should be removed from services until repairs are made
4.All vehicle plying on the road should abide by the provision of the
motor vehicle Act
 Dumpers & Trucks

5.No person should be permitted to remain on the truck

while being loaded by excavating equipment or crane.
6.Materila loaded should be within safe weight limit.

7. While reversing the truck /dumper ,Reverse Horn should

be used. If reverse horn is not available signalman should
be provided.
8. Never keep the PTO lever engaged while the tipper is
running on the road .PTO level should be engaged only
during the tipping operation
 Water Pump-Safety Precaution

1.Ensure proper foundation is provided for placing water pumps

to prevent possible toppling and avoid vibration
2.Ensure mounting bolts of both pump and motor /engine is
secured well
3.The coupling used should be of correct size with proper
keyway and keys and the alignment should be perfect.
4.Ensure the power supply is switched off before attending any
type of repairs on the water pump.
5.Ensure all the bolts are tightened properly and keys are placed
well before starting the pump
6. Before starting the pump ensure that there is no unwanted
tools left near the pump
 Water Pump-Safety Precaution

7.No cloth or cotton waste or paper shall be allowed to come

in contact with the shaft when the pump is in running
condition.
8.Proper cover should be provided for the motor to prevent it
from rain or any unexpected water spillage
9.No loose connection is to be allowed in the water line,
especially near the pump. The water may spill on the
motor and pump causing damage
10.Proper earthling is a must for electrically operated pumps
 Safety in Electricity
Hazards associated with electricity
1.Electric shock
2.Electric fire &explosion
3.Electric flash &burns
-Joules burns
-Flash burns

These are the other types of hazards ,which are not directly related
to electricity, but may occur .These may be termed as Secondary
Hazards. These are
1.Person falling from height
2.Dropping of tools &objects
 Safety in Electricity

3.Health hazards due to release of toxic gas and production of UV

rays
4. Psychological effect
 Emotionally anxious
 Distracted

And hence more prone to accidents.

Electric shock
It is a sudden & accidental stimulation of body’s nervous system
by the passage of electric current .Shock is felt when person
becomes part of electric circuit
 Severity of shock depends on

1.Amount of current passing through body

2. Duration of flow
3.Path of flow of current
4.Type of energy

Body resistance:
A person’s main resistance to current flow is skin’s surface.
Callous or dry skin has a fairly high resistance .A sharp decrease
in resistance takes place ,however ,when the skin is moist .Once
the skin’s resistance is broken down ,the current flows readily
through the blood and the body’s tissues.
 Effect of electric shock on human

The effects are as follows

Human voluntary and involuntary nervous system which control and co-
ordinates thought signals ,biological functions & muscles has data
transmission through neuro-humoral (chemical) transmission. This gets
disturbed due to flow of external electric current through human body cells,
muscles ,nerves, tissues etc. The interface between biological tissues and
electrical current manifest in the form of electric shock
 How shock occurs

1. By simultaneously touching the phase and neutral conductor thus

completing the circuit through his body.

2. By touching the phase conductor and standing on the ground

3. By touching the metallic part that has become live by itself being in
contact with energized wire and standing on the ground
 Shock Protection Method

Isolation:
All electrical equipment should be isolated from accidental contact & approach by
unauthorized men, providing barrier .Panel boards, generators, large motors, batteries
should be enclosed. Low & medium voltage OH lines should be kept 19”above the
ground.
Isolation Switches:
The switches should be connected in phase only. The switches should be easy and free to
operate .Body of the metallic switches should be earthed. Every DB should be provided
with a switch. It is advisable to keep switch as near as possible to the work-place. If
switch is connected in neutral, person who repairs the equipment, could get shock though
the supply is cut using the switch
 Shock Protection Method

Isolation transformer:
Power can be tapped from isolation transformer for the power
tools and for testing electric equipment (in working condition).
Avoids shock between earth and phase.

Double Insulation:
In addition to the normal insulation required for functioning of
the equipment, a second layer of insulation known as
protective insulation is interposed between functional
insulation and any accessible metal parts of appliances
 Earthing

Earthing is of two types

Neutral Earthing (System Grounding): Intentional connection of

neutral point to earth is called neutral or system earthing.If neutral
point is earthed ,the phase to ground voltages under earth fault
conditions do no arise to high value. Earth fault protection becomes
easy. Hence it is universal practice to have a neutral earthling at each
voltage level.

Equipment Earthing: If is quite different from neutral

earthing.Connecting to earth the non-current carrying metal parts of
equipment is equipment earthing.The potential of earthed body does
not reach to dangerously high value since it is connected to earth.
 The equipment Earthing is the
essential safety measure
Fuses:
Fuses are proven Safety devices for overloads conditions.
 Current Limitation
Safety is assured by purposely limiting the shock intensity from a
device (ELCB) to a value known to be reasonable safe.

Cable routing: All electrical cables should run either overhead (7 feet) or
underground .Cable routing layout map to be prepared so that it does
not cause tripping hazards. Welding and power cables not to be
overlapped. Protect cables against mechanical damages, heat.
 The equipment Earthing is the
essential safety measure
Cable joints: Staggered joints: Joints are not to be overlapped. One
primary insulation and an overall secondary insulation are to be
done. Proper insulation tapes are to be used. For high voltage cables
use jointing kits.

Manpower: Employ qualified electrician, preferably ‘B’ licence

holders. Identification of the electrician –red helmets.

Hand Lamps: Only 24 V hand lamps are to be used. Totally enclosed

and protected Hand lamps are to be used. Hand lamps used for
confined space work should be of all insulated type with no joints.
 The equipment Earthing is the
essential safety measure

Electric burns:
1. Burns from electric Flash
2. Burns from electric heat

Working near overhead lines:

Minimum height of overhead cable:

400 KV 7.3 M(24 ft)

275 KV 7.0 M(23 ft)
132 KV 6.7 M(22 ft)
33-66 KV 6.0 M(19 ft 9 in)
11-33 KV 5.2 M(17 ft)
 Fire Prevention

Fire:
Fire is a chemical reaction ,in which substance (fuel) combines with
oxygen. The reaction is exothermic and usually associated with
emission of light and heat.

Elements of fire:
 Fuel
 Heat
 Oxygen
 Explosion
 Chain reaction

Fire Triangle Fire tetrahedron (Pyramid)

Oxygen Heat Heat

Chain
Reaction

Fuel Fuel
Oxygen
 Fire Tetrahedron (Pyramid)

Fuel
Chain
Oxygen Reaction

Heat
 Classification of fire (based on
material burning)
Class “A” fire
Ordinary combustible fire
Solid combustible material normally organic in nature
(compounds of carbon) cooling effect of water is essential for
extinguishing the fire E.g. wood ,Cloth ,Paper etc which leave
carbon after combustion.

Class “B” fire

Flammable liquid fire
Flammable liquids or liquifiable solids where blanketing effect is
essential for extinguishing the fire e.g. Petroleum products ,
solvent, paints etc
 Classification of fire (based on
material burning)
Class “C” fire
Flammable gas fire: These are the fires involving gases or liquefied
gases under pressure where it is necessary to isolate the burning gas at
a fast rate with an inert gas ,powder or vaporizing liquid for
extinguishment e.g. fuel gas, hydrogen, liquefied petroleum gas etc.

Class “D” fire

Metal fires: Metals generally called Alkali Metals such as Magnesium,
Sodium, Titanium etc. Specialized techniques ,extinguishing agents
&equipments are required to control such fire.
 Classification of fire (based on
material burning)

Electrical fires
According to latest concepts ,the electrical fires do not
constitute a particular class. Any fire involving an electrical
equipment is in fact be a fire of class A,B or C. The normal
procedure in such fires is to cut off the electricity and use
an extinguishing method appropriate to the burning
material. Special extinguishing agents which are non-
conductor of electricity and non –damaging to the electrical
equipment such as dry chemical powders and carbon di-
oxide should be used.
 Principle of extinguishing fire

 Starvation -Elimination of fuel

 Smothering - Limiting oxygen supply
 Cooling - Limiting rise of temperature
 Chain inhibition
 Principle of extinguishing fire

CLASS Type of Fire Extinguisher

OF FIRE
Water Foam DCP
CO2
Not suitable ,but Not suitable, Not suitable,
Suitable but will control
A will control small but will control
fires small fires surface fires in
textile fibers

Suitable for non-polar

B Unsuitable flammable Suitable Suitable
liquids only
C Unsuitable Unsuitable Suitable Suitable
Suitable for some
D Unsuitable Unsuitable Unsuitable cases if special
type dry
chemical used
Electrical Unsuitable Unsuitable Suitable Suitable
 Fire Extinguisher-Do’s

 Keep it at its designated place

 Always use suitable extinguisher
 In case of abnormality, inform fire control room
 For electrical fires, use DCP & CO2 extinguishers only
 Avoid physical damage
Fire Extinguisher-Don’ts

 Do not misuse fire extinguisher

 Do not use water type extinguisher on electrical fires
 Do not attempt to open fire extinguisher
 Do not relocate extinguisher on your own
 Do not remove operating instruction sticker
 Do not obstruct the visibility & access.
 Safety in welding
 Body of the welding machine should be earthed.
 Terminal of the welding cables should be provided with lugs and
kept tight.
 Joint in the cables should be made with terminals, kept tight and
well insulated with heat resistance tape.
 Cable should be free from joints at least for a length of three
meters from electrode holder to avoid shock hazard.
 Other electrical cables should not be kept laid with welding
cables , to avoid insulation damage.
 For the return lead only proper cable should be used. Using
rods ,angles ,channels etc should be avoided
 Never change electrode with bare hands or wet gloves ,when
standing on wet floor
Safety while working at height

THE ARE THREE MAIN HAZARD ASSOCIATED

WITH WORK AT HEIGHT.

 Falls
 Falling objects
 Falls from collapsing structure
Risk Assessment

 First, as a part of the planning of the work, carry out a risk

assessment.
 Plan to do as much of the work as possible at low level.
 Do not work at height unless it is absolutely unavoidable
 If this is not possible, consider the following
 The activity
 Equipment to be used
 Location, e.g. near or over water, roads, under power lines ,etc
 Environment, e.g. weather, temperature, lighting
 Duration of the work.
 Condition and stability of the work surface
Precautionary Measures

1.Falls
There are four ways of preventing falls of people. They
are
i) Edge protection, e.g. Guard rails ,toe boards.
ii) Maintaining a safe distance from an edge.
iii) Safety nets.
iv) Safety harnesses
 Cont…
2.Falling objects
To prevent objects falling onto people you need a proper management
system which:
 Provides barriers, e.g. a toe boards or mesh guards to prevent items
from slipping or being knocked off the edge of a structure
 Secures object to the structure, e.g. lashing of scaffold boards
 Ensures that there are no loose objects and that any loose tools are
properly secured
 Creates an exclusion zone ,where necessary ,beneath areas where
work is taking place.

In addition, when people are working at a heights above other work

areas ,it is mandatory to provide safety helmets to protect the
workers below against falling objects.
 Cont…

3.Falls from collapsing structures

A competent person should inspect and attach a notice to a structure
after completion and before it is put into use.

LADDERS
Ladders are frequent cause of accidents. They should not be used as
a working platform-ONLY FOR ACCESS. Ladders use is only
permitted when the ladder is used for short duration and the ladder
is:
 Fixed to prevent slipping
 Placed on firm level surface with the top part of the ladder resting
against a solid surface
 Cont…

 The ladder is correctly angled ( at 75 degree to the

horizontal/one out for every four up)
 Positioned such that working on it does not require stretching
out
 Positioned so that a good handhold is available if used for
access or must protrude sufficiently above a working
platform that is to be accessed

All ladders including steps must be thoroughly inspected on a

regular basis, by a person who is qualified to judge the
suitability/safe condition of the equipment. A record of such
inspections must be recorded
Cont…

When extension ladder are used the overlap of any adjacent

sections should be as follows:

Closed length
 Less than 5 metres-11/2 rungs overlap

 5-6 metre – 21/2 rungs overlap

 Over 6 metres- 31/2 rungs

 Working platform
 Be securely footed on stable ground
 Support the weight of the personnel and equipment to be used
 Provide a stable access and will not overturn
 Be secured to an existing structure ,where necessary and
wherever possible
 Take account of the gradient of the ground, especially where
mobile platforms are used.
 Provide guard rails to the platform
 Provide barriers on open edges ,holes and openings in the
platform floor, the edges of roofs and working areas.
 Ensure that only standard /approved Personal Protection
Equipment is used for working at height
 Working on roof
Precautions for all roof work
 Is the work necessary?
 Risk assessment and method statements
 Getting on and off the roof
 Edge protection
 Work platforms
 Falls arrest equipment
 Falling material
 Prevent unauthorized access
 Avoid working on/ near fragile materials
 Training
 Weather conditions
 Short duration work
Safety nets

Safety nets are the least problematic and hence the preferred option.
Make sure that either safety net is used to protect against falls
through the gaps created as the leading edge moves forward .If
safety nets are used make sure that they:

 Are installed as close as possible beneath the roof surface.

 Are securely attached and will withstand a person falling onto them.
 Are installed and maintained by competent personnel.
Thank

You