Safety Appraisal & Control Technique

Quality Control: Safety appraisal & control

techniques, Permit to Work systems, Accident/ Safety appraisal system is a system, method, practice, & procedure to measure the safety performance of
standard for the purpose of evaluating its effectiveness and reliability, to find out drawbacks or deficiency if any
Incident/ Near-miss/ Dangerous occurrence to suggest the safety measures to raise its safety value. This is first step of any safety organisation in its march
reporting, investigations, Major Accident towards accident or loss prevention programmes.

Hazards TYPES OF SAFETY APPRAISAL SYSTEM:

(MAH) Control System, Emergency 1. QUANTITATIVE APPRAISAL: - Quantitative Appraisal is the method of computing accident frequency,
severity, incidence & their index rates and a safety activity rate. Frequency rate and severity rate are useful
Preparedness and Response Plans Industrial in comparing safety performance of different units in a given time.
Hygiene and
2. QUALITATIVE APPRAISAL: - Qualitative Appraisal is carried out to find the areas where safety
Occupational Health: Ventilation and Heat improvement is necessary. It includes safety inspection, safety audit, accident analysis etc. Safety inspection,
safety audit help to identify
Stress, Industrial Lighting & Illumination, Noise
3. PREVENTIVE APPRAISAL: - preventive Appraisal includes preventive maintenance before any accident
and
occurs. Safety sampling, safety survey, fault tree analysis, HAZOP &HAZAN studies, safety inventory, system
O C C U PAT I O N A L Vibration, Industrial Hygiene, Personal safety, safety standards, work permit system, safety tags, are used for this purpose.

S A F E T Y & H E A LT H Protective Equipment, Occupational Health, 4. CORRECTIVE APPRAISAL: - Corrective Appraisal includes corrective maintenance after any accident
Occupational takes place or any defect (crack, corrosion etc ) detected Accident investigations, analysis, application of
remedy are carried out for this objective.
Health Hazards & Occupational Diseases,
5. STATUTORY APPRAISAL: - It includes statutory inspection & testing of boilers, unfired pressure vessels,
Introduction to Ergonomics, Physiology at Work. lifting tackles & tools, hoist &lifts. It also includes work place monitoring, medical check- up etc
Permit to Work System Scope of Application: Types of safe work permits
Title: Enhancing Safety Through Permit Authorization •Industries with inherent risks due to specific hazards, such The type of safe work permit required is determined by the nature of the work to be performed and the
Definition: as chemical plants, construction sites, and manufacturing Hazards that should be controlled and eliminated. The practices for a single type of permit to be suitable
A safe work permit is a documented authorization for facilities. for all situations and examples are provided below
specific work activities conducted at a designated •Prime contractors subcontracting hazardous work to
location within a specified timeframe. external parties.
It serves as a mechanism for controlling and •Organizations with employees working in isolated areas or
coordinating work to establish and maintain safe performing non-routine tasks.
working conditions. Hazards and Safeguards:
Purpose: •All work activities entail some level of risk, necessitating
Identify and assess potential hazards associated with appropriate safeguards.
the work. •Safe work permits are crucial for maintenance tasks,
Define necessary precautions, procedures, and particularly when machinery isolation is required to prevent
safety measures. unexpected start-ups.
Ensure clear communication and agreement between •Critical work conditions requiring permits include confined
issuers and receivers regarding work conditions and space entry, handling of flammable or explosive materials,
safety protocols. exposure to harmful substances, and high-voltage electrical
work.
Components of a Permit: Additional Considerations:
•Conditions: Specific conditions under which work can be •Integration with other safety systems, such as lockout-
performed. tagout (LOTO) procedures.
•Preparations: Steps to prepare the work area and •Training and competency requirements for personnel
equipment. involved in permit issuance and execution.
•Precautions: Safety precautions and measures to •Emergency response protocols and provisions for
mitigate risks. unexpected events during the permitted work.
•Limitations: Any restrictions or constraints applicable to •Continuous review and improvement of permit processes
the work. based on feedback and lessons learned.
Ensuring Safety in Heat-Generating Work Criteria for Confined Spaces:
Definition: Safety Measures: Cold work permits are used in hazardous maintenance Large enough for an employee to enter.
A hot work permit is a documented authorization Use of portable detectors for combustible gases to work that does not involve “hot work”. Configured in a way that poses risks of death or
required for activities that generate heat or sparks, warn workers of gas entry. serious injury.
such as welding, cutting, grinding, and the use of Implementation of precautions to prevent ignition of Cold work permits are issued when there is no reasonable Not designed for continuous employee occupancy.
pneumatic tools and electrical equipment in non- flammable materials or gases. source of ignition, and when all contact with harmful
Adherence to established procedures for safe hot substances has been eliminated or appropriate Work at Height:
explosion-proof environments.
work practices, including fire watch and emergency precautions taken Any work performed at a height of 1.8 meters or more
Types of Hot Work:
response protocols. Ensuring Safety in Confined Spaces from the ground level or floor.
Welding
Definition: Includes working on transmission towers, sloped
Burning
Responsibilities: A confined space entry permit is a documented roofs, overhead tie-ins, erecting steel, and
Cutting
Issuance of hot work permits by authorized authorization required before entering limited or installing/replacing roofing.
Riveting
personnel. restricted spaces where hazardous substances or Excludes normal work on low stepladders or loading
Grinding
Training of workers in hot work safety procedures. dangerous conditions may be present. Examples platforms.
Drilling
Use of pneumatic hammers and chippers Supervision of hot work activities to ensure include tanks, vessels, silos, storage bins, hoppers, Fall Protection:
Utilization of non-explosion-proof electrical equipment compliance with permit conditions and safety vaults, pits, towers, and sewers. Necessary when working at elevated positions where
and internal combustion engines. measures. Hazardous Conditions: there is a risk of falling and no physical protection
Hazardous Situations: Lack of oxygen such as handrails.
Presence of flammable materials in equipment. Importance: Presence of toxic or combustible gases
Risk of suffocation or entrapment Types of Work Covered:
Combustible materials that burn or release flammable Working from ladders, scaffolds, mechanical lifts, or
vapors when heated. Hot work permits help prevent fire incidents and Code of Practice:
explosions in environments where heat or sparks can Used in conjunction with the permit to outline elevated platforms.
Presence of flammable gases in the atmosphere or Erecting steel structures or installing roofing
entering from adjacent areas, such as unprotected ignite flammable materials or gases. important safety aspects of the operation.
They ensure that proper precautions are taken to Describes procedures for safe entry, work, and exit materials.
sewers. Any work within 6 feet (1.8 meters) of the edge of a
safeguard workers and property during heat- from confined spaces.
generating activities. flat roof.
Electrical Isolation Permit Safety Measures: Safety Measures: Safety Measures:
Title: Ensuring Safety in Electrical Work Clearance shall be taken on the specified format for Adherence to excavation safety protocols and All access points to roofs must be secured to prevent
Definition: trip reset of HT and LT equipment. procedures. unauthorized entry.
An electrical isolation permit is required for work on Compliance with all safety protocols and regulations Implementation of appropriate measures to mitigate Plans and drawings of the roof structure should be
electrical systems where there is a risk of contact with to prevent electrical hazards and accidents. risks associated with excavation work, such as cave- available to authorized personnel for reference.
energized electrical conductors. This includes, ins and utility strikes. Training and Awareness:
•Installation or repair of electrical equipment. Excavation Permit Examples: Personnel accessing roofs must receive appropriate
•Accessing panels containing electrical components. Title: Ensuring Safety in Excavation Work Excavation for utilities installation or repair. training on safety procedures and hazards associated
•Work on instrumentation, instrument panels, or Definition: Construction of foundations for buildings or with fragile roofs.
telecom equipment. An excavation permit is a critical component of the structures. Awareness of safe practices and precautions is
•Removal of a part of the circuit outside normal excavation procedure and is mandatory for any Trenching
Working for pipeline
on Fragile Roofsinstallation or maintenance. essential to prevent accidents and falls.
operating conditions. excavation work. Title: Ensuring Safety in Roof Access
Scope of Application: Scope of Application: Restricted Access:
Applies to all work involving electrical systems where Applies to all excavation activities, regardless of Access to all roofs is restricted to authorized
contact with energized conductors is possible. size or scale. personnel due to inherent danger.
Includes both High Tension (HT) and Low Tension (LT) Essential for ensuring safety and compliance with Unauthorized access is prohibited to prevent
lines and equipment. regulatory requirements. accidents and injuries.
Permit Requirements: Permit Requirements: Authorized Personnel:
Necessary for electrical isolation and energization of Must be obtained before commencing any Only personnel with proper authorization, such as
electrical equipment. excavation work. maintenance staff or trained individuals, are allowed
Required for working on transformers, which may Ensures that proper safety measures are in place access to roofs.
contain energized circuits, capacitors, wiring, etc. to prevent accidents and injuries. Access may be granted based on job requirements,
training, or understanding of the specific area.
Lockout/Tagout (LOTO) System Components of LOTO Program: Accident/Incident/Near-Miss/Dangerous Occurrence Reportable Accidents:
Title: Ensuring Safety during Equipment Maintenance Lockout: Physically locking energy sources to prevent Reporting Any accident in a factory resulting in death or bodily
Introduction: equipment startup. Title: Promoting Safety Through Reporting and injury preventing work for 48 hours or more is
Industrial equipment can pose hazards even when Tagout: Using tags to provide additional warning and Investigation reportable to the statutory authority.
not in use due to energy sources like electricity, information about the locked-out equipment. Introduction: Management Responsibility:
natural gas, steam, pressurized water, and Specific procedures for isolating and securing energy Accidents often start with near-misses and can Management should establish a system for
compressed air. sources before maintenance work begins. escalate to minor or major injuries if not addressed identifying, recording, and investigating all accidents
Need for Safety Measures: Benefits of LOTO Program: promptly. and property damage cases.
Workers performing maintenance or repairs, or those Prevents accidental energization of equipment, Reporting and investigating every incident or accident Accidents register and health register must be kept
working near equipment, must be aware of potential reducing the risk of injury or death. is crucial for accident prevention. updated with accurate information.
hazards. Provides clear communication and guidance for Accident Reports:
It's crucial to take steps to protect workers from workers, regardless of their familiarity with the Accidents should be documented in detail, starting
unexpected energization of machinery. equipment. from near-misses to major incidents.
OSHA Requirements: Ensures compliance with OSHA regulations, avoiding Proper records should be maintained in separate
OSHA mandates a formal lockout/tagout (LOTO) potential fines and penalties. registers for reportable and non-reportable cases.
program to ensure worker safety during equipment Accident reports must include detailed investigation
maintenance. findings and causes analysis reports.
This program involves specific procedures to control Importance of Reporting:
hazardous energy sources and prevent accidental Reporting every incident allows for early identification
startup. of potential hazards.
Rationale for Formal Program: Helps in preventing future accidents by addressing
Different equipment may have varying safety root causes and implementing corrective measures.
practices. Enables management to track and compare
Multiple workers with varying levels of familiarity may performance year to year for continuous
need to work on the same equipment. improvement.
A formal program ensures consistency and clarity in
safety procedures, reducing the risk of accidents.
ACCIDENT RECORDS Accident Investigation Key Considerations:
Necessary to transform a hazard, costly and ineffective Title: Understanding and Preventing Accidents Accident investigations should focus on identifying
work into a planned safety program more Introduction: causes rather than assigning blame.
specifically. Accident investigation is crucial for identifying causes Objectivity and factual analysis are essential, without
To create interest in accident prevention and preventing future incidents. letting personal feelings influence the report.
To provide up to date information on the accident It is the responsibility of department supervisors to Primary and secondary causes of accidents should
To provide information on frequent unsafe investigate all accidents, regardless of size. be identified, not just symptoms.
practice/unsafe conditions. Investigation Responsibility: Slide: Unsafe Acts and Conditions
To measure the effectiveness of safety program. Department supervisors are responsible for Title: Identifying Root Causes of Accidents
FIVE BASIC DOCUMANTS investigating accidents to promote accountability for Unsafe Conditions:
1. Personal injury record safety actions. Unguarded or inadequately guarded dangerous parts
2. Damage control records for property & equipment In some cases, safety officers and supervisors of machinery.
3. Register of injuries (progressive & monthly) collaborate on investigations, while major accidents Poor design and construction of equipment or
4. Register of damage to equipment (progressive & may require a dedicated investigation committee. workplace.
monthly) Statutory Reportable Accidents: Faulty equipment contributing to hazards.
PERSONAL INJURY RECORD Serious or fatal accidents are investigated by factory Unsafe Acts:
They tell who keeps getting hurt inspectors, who provide detailed reports on the Improper operating procedures or unsafe
Enable grouping injuries quickly incident, including facts, any breaches of law, and performance.
Provide details of accurate costing recommended remedial measures. Engaging in horseplay or inappropriate behavior.
Provide quick reference for analysis Inspectors may order the prohibition of equipment or Failure to wear appropriate personal protective
CONTENTS OF PERSONAL Nature of injury:
INJURY RECORD processes posing imminent danger. equipment.
Name: Token No: Type of injury: Disobeying instructions or neglecting to inform
Occupation: Age: Description of incident: supervisors about activities.
Dept: Date of occurrence:Signature of witnesses: Ignoring warnings or being inattentive to job tasks.
Signature of supervisor
Situational Factors: Investigation Technique: Major Accident Hazards (MAH) Factory Statutory Requirements:
Physical environment factors like temperature, Steps include site observation, interrogation, findings, Title: Understanding Major Accident Hazards Notification of major accidents to statutory authorities
lighting, and working hours can contribute to and recommendations. Definition of Major Accident: within 4 hours using Form SC3.
accidents. Objective questions should be asked and answered According to "The Maharashtra Factories (Control of Submission of written reports and On-site Emergency
Physical characteristics of employees, such as age to determine key details of the accident. Industrial Major Accident Hazards) Rules, 2003," a Preparedness Plans (as per Schedule 4 and
and experience, may also influence accident rates. Initial information should be collected promptly from major accident involves: Schedule 6, respectively).
Psychological characteristics and environmental eyewitnesses and coworkers. Loss of life inside or outside the factory. Conducting mock drills every six months and
factors, such as safety consciousness and job Preserve the scene and gather evidence like Ten or more injuries inside and/or one or more maintaining records.
mobility, play significant roles in accident prevention. photographs, sketches, and notes. injuries outside. Submission of Safety Reports and periodic safety
Purpose and Technique of Accident Investigation Classify causes according to severity and Release of toxic chemicals, explosion, fire, or audits.
Title: Ensuring Safety Through Investigation Techniques responsibility for preventive action. spillage of hazardous chemicals resulting in on- Control Measures for Toxic Chemicals
Purpose of Investigation: Provide recommendations for prevention, focusing on site or off-site emergencies or equipment Title: Ensuring Safety in Handling Toxic Chemicals
Identify accident causes to prevent future incidents. engineering controls before human responsibilities. damage leading to process stoppage or adverse Control Measures:
Raise awareness of hazards among management, environmental effects. Dyke walls with proper slope and drain valves.
workers, and supervisors. MAH Factory Definition: Anticorrosive paints for pipelines and tanks.
Determine changes or deviations that led to accidents A MAH factory refers to an industrial activity handling Proper support and earthing for pipelines.
for systems safety analysis. hazardous chemicals equal to or exceeding specified Level, pressure, and temperature indication/alarm
Compare injury rates for safety performance threshold quantities outlined in Schedule 2 of "The systems.
evaluation. Maharashtra Factories (Control of Industrial Major Fire protection systems and suitable personal
Use records for job safety analysis and safety rule Accident Hazards) Rules, 2003." protective equipment.
development. Example: A factory storing 50 tons of toxic chemicals Connection of vents to scrubber systems and spill
such as Ammonia falls under the MAH unit category. control procedures.
Statutory Provisions for MAH Units Display of safety instructions and training/education
Title: Compliance Requirements for MAH Units for employees.
Control Measures for Flammable Chemicals Occupational Health and Safety Audits •Audit Procedure:
Title: Implementing Safety Measures for Flammable Title: Ensuring Workplace Safety through Audits •Constitution of Audit Team: Led by a lead auditor, the
Chemicals •Introduction to Safety Audits: team includes at least two members.
Control Measures: •Safety audits conducted by experts not associated •Constitution of Auditee Representatives:
Flameproof electrical fittings and proper earthing. with industrial activities are essential for maintaining Representatives from the audited industry must be
Bond wires and fencing for pipelines. safety standards. involved.
Anticorrosive paints and fire protection systems. •According to IS-14489, a safety audit report must be •Study of Industry: Identification and brief history of the
PV valves, flame arrestors for vents, and spill control submitted within 30 days after completion. audited industry are recorded.
procedures. •Need of Safety Audit: •Setting Audit Goals: Objectives and scope of the audit
Statutory inspection and testing of pipelines and •Safety Requirement: Regular safety audits ensure a are defined.
tanks. safe working environment by identifying and rectifying •Planning: An audit plan with a time schedule is
Emergency action plans and workplace monitoring. deficiencies. developed.
Control Measures for Pressure Vessels
•Legal Requirement: Compliance with regulations •On-Site Activities:
Title: Safety Precautions for Pressure Vessels
such as Rule 12-C & 68-O of the Gujarat Factories •Opening Meeting: Held with the auditee to discuss
•Control Measures:
Rules 1963 and Rule 10 & 12 of the Manufacture, objectives.
[Link] of safety valves, stop valves, and
Storage, and Import of Hazardous Chemicals Rules •Process Study: Understanding the industry
excess flow valves.
1989 mandates submission of safety audit reports. processes and safety standards.
[Link] electrical fittings and proper earthing.
•Plant Inspection: Observations noted during a
[Link] wires and proper support for pipelines.
thorough plant inspection.
[Link] paints, fire protection systems, and
•Document Examination: Reviewing records and
suitable personal protective equipment.
documents for compliance.
[Link] control procedures and statutory
•Checklists: Utilizing audit points checklists such as
inspection/testing of pipelines and tanks.
Annexure A, B & C of IS-14489.
[Link] action plans and workplace monitoring.
•Closing Meeting: Discussing audit findings with the
auditee and recommendations for improvement.