Personal protection in the work environment

• Personal protective equipment (PPE) is protective clothing, helmets, goggles, or other

garments or equipment designed to protect the wearer's body from injury or infection.
• The hazards addressed by protective equipment include physical, electrical, heat, chemicals,
biohazards, and airborne particulate matter.
• About 0 to 40% of total accidents can be prevented or controlled by the proper use of
personal protective equipment.
• The PPE provides good defense against hazards of toxic exposure, oxygen deficiency,
dusting,
• chemical splashes, steam, water and liquids, flying particles, hot substances, radiation, sharp
edges, welding, cutting, grinding, striking against and stepping over objects, glare, personal
falls and injury due to falling bodies, noise, scarp cleaning, material handling, the opening of
pipelines or any hazardous work, electric shocks, burn and firefighting.
• Protective equipment may be worn for job-related occupational safety and health purposes
and other activities.
• The purpose of personal protective equipment is to reduce employee exposure to hazards
when engineering controls and administrative controls are not feasible or effective to reduce
these risks to acceptable levels.
• PPE has the serious limitation that it does not eliminate the hazard at the source and may
result in employees being exposed to the hazard if the equipment fails.
• Protective clothing is applied to traditional categories of clothing, and protective gear applies
to items such as pads, guards, shields, or masks, and others. PPE suits can be similar in
appearance to a cleanroom suit.
• Any item of PPE imposes a barrier between the wearer/user and the working environment.
This can create additional strains on the wearer, impair their ability to carry out their work
and create significant levels of discomfort. Good ergonomic design can help to minimise
these barriers and can therefore help to ensure safe and healthy working conditions through
the correct use of PPE.
Need for PPE:
1. Chances of failure of engineering controls, materials, process, equipment, and safety devices cannot
be denied and, in those circumstances, the PPE can act as a barrier between the man and hazard and
save from the injury.
2. There are certain operations or accidental situations where engineering controls are less possible
and PPE becomes necessary. For repair or maintenance or to enter into a toxic or oxygen-deficient
atmosphere, or while working at height or doing jobs like welding, cutting grinding, chipping, PPE
gives good protection.
3. It effectively avoids the contact of dangerous substances, noise, vibration, and radiation.
4. It protects from atmospheric contaminants.
5. It is a legal as well as moral duty to provide suitable PPE.
Types of PPEs
• Personal Protective Equipment (PPE) means any device or appliance designed to be worn or
held by an individual for protection against one or more health and safety hazards.
• It could include safety glasses, gloves, face shields, protective clothing or footwear. There are
two types of PPE these include simple and complex.
Simple personal protective equipment this refers to equipment that has a basic design model, it
protects against lower risk hazards. It is reasonable to assume with this type of PPE that the user is
aware of the hazards, can see the risk gradually increasing and is able to make an assessment and
safely identify the need for PPE to be worn.
Complex personal protective equipment this refers to equipment that it more of a technical design
and provides protection against fatal or serious risk. With this type of PPE the user cannot identity the
hazard in sufficient time and is immediately exposed to hazards that have irreversible effects.

Respiratory Protective Equipment (RPE)

• Respiratory Protective Equipment (RPE) is a particular type of Personal Protective
Equipment (PPE), used to protect the individual wearer against the inhalation of hazardous
substances in the workplace air.
• Employers are required to firstly attempt to eliminate the hazard at source.
• RPE should only be used after all other reasonably practicable control measures have been
taken.
• PPE is considered a last resort because it only protects individual workers, is prone to failure
or misuse, such as wearing the wrong RPE for the job, and employees wearing RPE may get a
false sense of security when using RPE.
• Respiratory Protective Equipment (RPE) not worn or selected appropriately is totally
ineffective and may give the user a false sense of protection.
Types of RPEs:
I. Respirator (filtering device) uses filters to remove contaminants in the workplace air, there are
two main types:
a. Non-powered respirators rely on the wearer's breathing to draw air through the filter Eg:
Disposable filteing half mask, Half mask, full face mask
b. Powered respirators use a motor to pass air through the filter to give a supply of clean air to the
wearer eg: Half mask , full face mask, helmets, hoods, visors
II. Breathing apparatus (BA) needs a supply of breathing-quality air from an independent source
(eg air cylinder or air compressor)
Different styles of RPEs
Tight-fitting facepieces (often referred to as masks) - rely on having a good seal with the wearer's
face. These are available as both non-powered and powered respirators and BA. Examples are
filtering facepieces, half and full-face masks.
Loose-fitting facepieces rely on enough clean air being provided to the wearer to prevent
contaminant leaking in (only available as powered respirators or BA). Examples are hoods helmets,
visors, blouses and suits.

Non-Respiratory PPEs
Eye protection (e.g. goggles) (RPE)
Head protection (e.g. safety helmets)
Ear protection (e.g. earplugs)
Foot protection (e.g. steel toecap boots)
Hand and arm protection (e.g. gloves)
Body protection (e.g. high-visibility clothing)
Skin protection (e.g. protective clothing)
Fall protection (e.g. safety harnesses)
 1. Eye Protection
This help protect the mucus membranes of the eyes, as well as help to reduce the risk of foreign
objects entering the eyes and damaging them.
Needed when an employee work with Machines, Lasers, Impacts, Heat, Tools, Flying Particles/Dust,
Electrical work, Chemical handling have the potential causing eye injury from physical, chemical, or
radiation agents.
Three main types of eye protection
Safety glasses: These are effective for flying objects heading straight towards the face, but they are
not effective for vapours and dust that can enter the eyes.
Goggles: They are effective at protecting the eyes from all angles, as the rim is in contact with the
face
Face shields and visors: These can be worn with prescription glasses underneath, and they help to
protect the whole face.

2. Head protection
Head protection can protect the head from physical hazards, they can also protect other parts of the
upper body, such as the neck, hair, nose and ears.
Firefighter helmets are similar to industrial safety helmets; however, they cover more of the head and
give greater protection against impact, heat and flames.
Types of head protection:
Industrial safety helmets: These protect the head from falling objects such as tree-felling, building
and construction and blasting at a quarry.
Bump caps: These protect the head from being bumped, they are useful for maintenance personnel
working under machinery and plumbers working under pipework. However, the do not offer adequate
protection from the risk of a falling object.
Head Protection: Care Considerations
• Remove and replace hard hats if they have
• Perforation, cracking, or warping of the brim or shell
• Indication of exposure to heat, chemicals or UV light (loss of surface gloss, chalking or
flaking)
• Always replace a hard hat if it sustains an impact
• Suspension can be changed if excessive wear is noticed
• Never drill holes, paint or apply labels to headgear
• Do not store headgear in the rear window shelf of a car: sunlight and extreme heat can
damage them
Classes of head protectors:
Class A hard hats: these provide impact and penetration resistance along with limited voltage
protection (upto 2,200 volts)
Class B hard hats: These provide the highest protection against voltage shock protection (upto 20,
000 volts). Also, provide protection from impact and penetration hazards by flying objects
Class C hard hats: These provide light weight comfort and impact protection but offer no protection
from electrical hazards

3. Ear protection
Exposure to noise level over 85 dB cause hearing loss. So, hearing protection required at 90 dB.
Types of ear protection
Ear defenders (ear muffs): The cups are lined with a sound absorbing material, this helps to reduce
the level of noise to the ears
Ear plugs: These fit into the ear canal and form a seal, they also can have a cord on them, that can be
put behind the back of the neck, to help prevent them from becoming lost.
Canal caps: These are similar to ear plugs, however they offer less protection they are suitable for
operations where earplugs would be frequently taken out and put back in.

4. Foot protection
• Toe and foot injuries account for 5% of all disabling workplace injuries. Workers not wearing
safety shoes have 75% of all occupational foot injuries. Safety footwear must meet ANSI
minimum compression and impact performance standards in ANSI Z41-1991 (American
National Standard for Personal Protection-Protective Footwear)
Situations where employees should wear foot / leg protection include:
• Heavy objects might roll or fall in feet
• Sharp objects such as nails or spikes that can pierce ordinary shoes
• Exposure to molten metal that might splash on feet or legs
• Working on or around hot, wet or slippery surfaces
Working when electrical hazards are present
Types of foot protection:
Safety boots and shoes: They come with slip-resistant soles, penetration-resistant midsoles,
protective toe caps.
Wellington boots: These are suitable for people who work in wet conditions, they are normally made
from rubber, they also come with slip-resistant soles, penetration-resistant midsoles, protective toe
caps.
Special Purpose Shoes
Safety shoes: these designed to be electrically conductive to prevent the buildup of static electricity in
areas with the potential for explosive atmospheres or nonconductive to protect workers from
workplace electrical hazards.
Electrically conductive shoes: provide protection against the buildup of static electricity. Workers in
explosive and hazardous locations such as explosives manufacturing facilities or grain elevators must
wear conductive shoes to reduce the risk of static electricity buildup.
Electrical hazard, safety-toe shoes: et from completing an electrical circuit to the ground. These
shoes can protect against open circuits of up to 600 volts in dry conditions.
Foundry Shoes: insulate the feet from extreme heat and keep hot metal from lodging in shoe eyelets,
tongues or other shoe parts.

Foot and leg protection choices

• Leggings protect the lower legs and feet from heat hazards such as molten metal or welding
sparks. Safety snaps allow leggings to be removed quickly.
 • Metatarsal guards protect the instep area from impact and compression. Made of aluminum,
steel, fiber or plastic, these guards may be strapped to the outside of shoes.
• Toe guards fit over the toes of regular shoes to protect the toes from impact and compression
hazards. They may be made of steel, aluminum or plastic.
• Combination foot and shin guards protect the lower legs and feet, and may be used in
combination with toe guards when greater protection is needed.
• Safety shoes have impact-resistant toes and heat-resistant soles that protect the feet against
hot work surfaces common in roofing, paving and hot metal industries. The metal insoles in
some safety shoes protect against puncture wounds.

5. Hand and arm protection

Hand and finger injuries account for 18% of all disabling injuries and about 25% of all industrial
work place accidents.

Types of hand and arm protection

Gloves: These protect the hands, they can prevent blisters from occurring, people from burning
themselves or getting splinters in their hands.
Gloves with cuffs: These protect both the hand and the wrists
Gauntlets, sleeves and long gloves: These provide protection for the hands, wrists and parts of
the forearms.
Sleeves and arm protection: These can provide protection for the whole forearms and upper
arms.

Factors that influence selection of protective gloves:

• Type of chemicals handled.
• Nature of contact (total immersion, splash, etc.).
• Area requiring protection (hand only, forearm, arm).
• Grip requirements (dry, wet, oily).
• Thermal protection.
• Size and comfort.
• Abrasion/resistance requirements.

Gloves materials groups

• Leather, canvas or metal mesh
• Fabric and coated fabric gloves
• Chemical- and liquid-resistant gloves
• Insulating rubber gloves

6. Skin protection

Types of whole-body skin protection

• Separates: These only cover part of the body (e.g. jackets or trousers).
• Aprons: These only cover part of the body.
• Overalls, coveralls, body suits, boiler suits and chemical suits: These cover the whole
body, and may be reusable or disposable.

For leg protection

• Knee pads.
• Gaiters these cover the shins.
• Hard fibre or metal guards, which help to protect against some impact hazards.

For effective skin protection

• Protective clothing must be suitable for the hazard (e.g. chemical resistance and protection
against physical hazards can vary widely).
• Manufacturer’s instructions must be followed (Do not use chemical resistance for longer than
the recommended breakthrough times, and clean as to not damage its effectiveness).
• Worn or contaminated clothing must be stored separately from clean clothing.
 • Check for surface damage, which could reduce its effectiveness.
• Do not wear loose clothing near moving machinery, if there is a chance that it could get
caught.

High visibility clothing is required to protect the body against certain hazards such as moving
vehicles
• Jackets
• Tops
• Trousers
• Vests

7. Fall protection systems

These can be used by individuals when they are working at height.

Types of fall protection systems

Work restraint systems: These prevent the user from reaching zones where the risk of a fall exists,
this means they will be protected from falling and hurting themselves
Work positioning systems: These are similar to work restraint systems and allows the user to
have both hands for working. If using this system, you must always have a backup system in place.

Personal Protective Equipment (PPE) Standards

The existing Occupational Safety and Health Administration (OSHA) personal protective
equipment (PPE) standards are found in 29 Code of Federal Regulations (CFR) Part 1910.
• 29 CFR 1910.133 Eye and Face Protection: Employers must provide suitable eye/face
protection against hazards like flying particles, molten metal, chemicals, and harmful light.
Protection must comply with ANSI/ISEA Z87.1 standards.
• 29 CFR 1910.134 Respiratory Protection: Employers must provide and maintain respirators
when necessary to protect employee health. A respiratory protection program must be
established and managed by the employer.
• 29 CFR 1910.135 Head Protection: Protective helmets must be used where there is risk of
head injury from impact, falling objects, or electrical hazards. Helmets must meet ANSI
Z89.1 standards.
• 29 CFR 1910.136 Occupational Foot Protection: Protective footwear must be worn where
foot injuries from falling/rolling objects or electrical hazards are possible. Footwear must
meet ASTM F-2412 and F-2413 standards.
• 29 CFR 1910.137 Electrical Protective Equipment: Specifies requirements for insulating
equipment like gloves, sleeves, mats, and blankets to protect workers from energized
electrical parts. Covers design, testing, and safe use.
• 29 CFR 1910.138 Hand Protection: Employers must ensure workers use gloves against
hazards like cuts, burns, punctures, and chemical or thermal risks. Selection depends on
hazard type and work conditions.
• 29 CFR 1910.140 Personal Fall Protection Systems: Employers must provide fall
protection systems (such as harnesses or lifelines) where fall hazards exist. Equipment must
meet performance and safety standards.
• 29 CFR 1910.132 General Requirements:
o Provide adequate protection against the particular hazards for which they are
designed
o Be of safe design and construction for the work to be performed
o Be reasonably comfortable when worn under the designated conditions
 o Fit snugly and not unduly interfere with the movements of the wearer
o Be durable
o Be capable of being disinfected
o Be easily cleanable
o Be distinctly marked to facilitate identification only of the manufacturer

Monitoring Safety Performance:

Frequency rate: How often do injuries occur. It is defined as the disabling (lost time)
injuries per 106 man-hours worked.

Number of lost time in jur y x 1000000

F A=
Man − hours worked
Number of repor table lost time in jur y x 1000000
FB=
Man − hours worked
FB is frequency rate reportable to authorities
FA is frequency rate used for comparison purpose

Example 1. Using the following data calculate the frequency rate of accident in an industrial
plant.
Number of workers=500
Number of disabling injuries per year= 5.
Average number of hours worked by worker per year=2000.

Sol.
Frequency rate=numbers of disabling injuries/number of man-hours worked x 1000,000
= [5/500×2000)] x 1000000=5

Severity rate: How serious are the injuries occur. It is defined as the number of days of lost
time per 106 man-hours worked.

Man d ays lost due to lost time in jur y x 1000000

S A=
Man − hours worked
Man d ays lost due to repor table lost time in jur y x 1000000
SB=
Man − hours worked
Standard number of days lost is correlated to the nature of injury, as for example, standard
number of days lost in 35days, the nature of injury being cutting of the tip of a finger,
whereas standard number of days lost in 6000 days for a total disability case.

Example 2. Using the following date calculate the severity rate of accident in an industrial
plant where only one accident occurred during the year, the type of injury being cutting of the
tip of a finger.
Number of workers =2000.
Number of days lost in a year due to accidents =100
Average number of hours worked by worker per year =2000.

Sol. Severity rate =days lost in year due to accidents/number of man-hours worked x
1000,000
Number of man-hours worked in this case =2000 X 2000.
Days lost in year due to accidents =100+35 =135.
Severity rate = (135/2000 x 2000)x1000000 =33.75

Example 3: Using the following data calculate the severity rate of accident in an industrial
plant where only one accident occurred during the year involving total disability of a worker.
Number of workers=2000.
Number of days lost in a year due to accident=100.
Average number of hours worked by worker per year=2000.

Sol. Severity rate= days lost in year due to accidents/number of man hours worked x
1000000.
Number of hours worked in this case=2000×2000.
Total disability; days lost=100+6000=6100 days.
Severity rate =6100/2000x2000x1000000= 6100/4=1525

Severity rate: It is the ratio of the number of injuries to the number of employees during the
period under review. It is defined as the number of days of lost time per 106 man-hours
worked.

Man Number of lost time in jur ies x 1000

Lost-time injury incidence rate =
Average number of persons employed

Reportable Lost-time injury incidence rate =

Number of repor table lost time in jur ies x 1000
Average number of persons emplyed

Activity rate: The safety activity rate is the overall safety promotional & awareness activity
which including safety training & safety inspection conducted in a year with respect to total
employees present & man hours worked in a year.
This emphasizes the cost of accident prevention activities against the cost of accident
occurrences incidents.
Safety activity rate
Sa fet y activit y number x 5000000
=
Man hours worked x total number of employes present in a year

Housekeeping
• Housekeeping means managing household tasks like cleaning, cooking, shopping,
maintenance, and bill payments.
 • These tasks may be performed by members of the household, or by other persons
hired for the purpose.
• The term may also refer to money set aside for such duties, office/organizational
upkeep, and even computer storage system maintenance.
• Good housekeeping reduces hazards, prevents slips, trips, and fire risks, and ensures
safety.
• It involves waste removal, proper storage, clear walkways, orderly work areas, and
maintenance.
• Effective housekeeping is ongoing, not a one-time cleanup. Poor practices often lead
to accidents.
• Though it requires effort and planning, it improves safety, prevents incidents, and
creates an efficient environment.

Responsibilities of Management & Employees

• Train employees to recognize hazards such as wet or messy floors, equipment in
walkways, and improper lifting.
• Provide training on safe chemical handling, PPE use, material handling, and
prevention of slips, trips, and falls.
• Prepare a safety manual for new employees and display safety rules at key locations.
• Reinforce safety rules in daily briefings and organize regular safety training with
expert involvement.
• Implement preventive maintenance for all equipment.
• Store toxic chemicals in closed, labelled cupboards and ensure safe, sanitary waste
disposal.
• Keep locker rooms clean, dry, and equipped with proper washing and sanitation
facilities.
• Ensure employees consume food only in designated canteens.
• Provide rest breaks during shifts to reduce fatigue.
• Keep corridors, staircases, and fire exits clear of obstructions at all times.
• Ensure hot/cold water taps are clearly marked.
• Maintain swimming pool pH and chlorine levels, with visible “No Diving” signage.
• Cover bed corners for safety and maintain “No Smoking” zones.
• Provide safety shoes for engineering/kitchen staff and gumboots for stewarding staff.
• Ensure smoke detectors function properly with indicator lights blinking.

Advantages of good housekeeping:

1. Creates a cleaner, safer, and well-organized workplace.
2. Reduces slips, trips, falls, and fire hazards.
3. Ensures smooth workflow with less material handling.
4. Leads to better use of space and organized storage.
5. Provides improved control of tools, materials, and inventory.
6. Minimizes wastage of materials and reduces property damage.
7. Allows easier equipment cleaning and maintenance, lowering breakdowns.
8. Improves health and hygiene by reducing exposure to dusts, vapors, and hazards.
9. Boosts employee morale and makes the workplace pleasant.
10. Increases productivity and efficiency, as tools and materials are easy to locate.
Poor housekeeping can cause:
1. Slips, trips, and falls due to loose objects, spills, or clutter.
2. Being struck by falling objects from poorly stacked materials.
3. Caught in-between objects because of disorderly storage.
4. Hit by moving objects in congested or cluttered work areas.
5. Striking against projecting items like tools, materials, or equipment.
6. Cuts, punctures, or injuries from nails, wires, or sharp materials.
7. Fire hazards from waste accumulation, flammable materials, and poor cleanliness.
8. Blocked emergency exits or escapes routes, delaying evacuation.
9. Reduced efficiency and workflow due to disorganized tools and materials.
10. Higher accident risks overall, leading to injuries, downtime, and losses.

Elements of housekeeping and cleanliness at workplace

Dust and Dirt Removal – Regular sweeping keeps the workplace hygienic and prevents slips; avoid
using compressed air for cleaning as it can cause dirt and dust particles to be embedded under the skin
or in the eye.
Employee facilities: Adequate employee’s facilities such as drinking water, wash rooms, toilet
blocks, and rest rooms etc. are to be provided for the employees at the workplace so that employees
can use them when there is a need.
Flooring: Floors are to be cleaned regularly and immediately if liquids or other materials are spilled
as that can cause of accidents in the workplace. Areas such as entranceways which cannot be cleaned
continuously are to have mats or some type of anti-slip flooring. It needs to replace if worn, ripped or
damaged.
Lighting: Adequate lighting reduces the potential for accidents. It is to be ensured that inoperative
light fixtures are repaired and dirty light fixtures are cleaned regularly so that the light intensity levels
are maintained at the workplace.
Aisles and stairways: Aisles and stairways are to be kept clear and not to be used for storage.
Warning signs and mirrors can improve sight lines in blind corners and help prevent accidents. It is
also important to maintain adequate lighting in stairways. Further stairways need to have railings
preferably round railings for adequate grip.
Spill control: Prevent spills with proper maintenance; clean spills immediately using correct
materials and disposal methods.
Waste disposal: Placing containers for wastes near the place where the waste is produced encourages
orderly waste disposal and makes collection easier. All recyclable wastes after their collection are to
be transferred to their designated places so that the waste materials can be dispatched to the point of
use or sold.
Tools and equipment: Tools and equipment are required to be inspected prior to their use. Damaged
or worn tools are to be taken out of service immediately. Tools are to be cleaned and returned to their
storage place after use. This keeps buildings, equipment and machinery in safe and efficient working
condition.
Storage All storage areas need to be clearly marked. Flammable, combustible, toxic and other
hazardous materials are to be stored in approved containers in designated areas which are appropriate
for the different hazards that they pose. The stored materials are not to obstruct stairs, exits, fire
equipment, emergency eyewash fountains, emergency showers, or first aid stations.
Clutter control: Cluttered workplace can lead to issues which including ergonomic and injuries. It is
important to develop practices where items like tools, chemicals, cords, and containers are returned to
their appropriate storage location when not in use. Danger to the employees increases if the
established exit routes and doors are blocked.
Individual workspace: Individual workspace needs to be kept neat, cleared of everything not needed
for work. This space is often overlooked when conducting general housekeeping and cleanliness
inspections. It is necessary to make a check list which is to be used by the employees to evaluate their
workspace.

5 s of housekeeping
• 5S is a system for organizing spaces so work can be performed efficiently, effectively, and
safely.
• This system focuses on putting everything where it belongs and keeping the workplace clean,
which makes it easier for people to do their jobs without wasting time or risking injury.
• 5S is a systematic approach to good housekeeping.

1. Sort
• The first step of 5S, Sort, involves going through all the tools, furniture, materials, equipment,
etc. in a work area to determine what needs to be present and what can be removed.
• Go through everything; throw away rubbish, archive old stuff you may need, decide what you
need in that area on a daily and weekly basis.
• Everything else must be removed. Sentiment cannot play a part here this is a manufacturing
environment
• When a group has determined that some items aren't necessary, consider the following
options:
o Give the items to a different department
o Recycle/throw away/sell the items
o Put items into storage
2. Set in Order
keeping only the things, you need daily or weekly in their right places, marking or labelling them
clearly so anyone can easily find and return them.
3. Shine & Clean as you are setting a location for each item, give it a wipe and check it is is
good
working order. Any broken item needs to be fixed. If your working area is particularly dirty, more
time
needs to be set aside so a thorough clean can be completed.
• These first three steps will get you well on your way to visually improving your factory.
When our factories look better, our people feel better about working in them suddenly there is
more space to move and those little annoying things are easier to find.
• The Challenge is to Maintain this New Level of Organisation
• This is where the “Standardization” and “Sustaining” come into play, which we will delve
into below.
• The first part of 5S is the easy part, once you get going we understand how to sort and tidy, as
we do it all this time at home, in our cars, in our garages, for our tax returns (although some
people are better at it than others), The challenge is to maintain the new level of cleanliness
and improve on it as time progresses, not to let it naturally let is slip back. This is where the
last two S’s come into the process.
4. Standardisation- the new arrangement and level of cleanliness is our new standard for each
area. Take photos and display in the area; talk about the 5S activities in your toolbox talks and
daily meetings; share ideas across the factory. This helps to create your new 5S standards and
brings consistency across the factory.
5. Sustain- if the first 4S’s have been done well, sustaining the cleanliness and origination
becomes simpler as it is clear where everything goes and each person working in an area
knows where to return things at the end of the job or end of the shift. Using simple audits, we
 can track how we are going to maintaining our 5S baseline on a weekly basis and to also note
the areas of improvement we need to make in the week ahead. Where ever you are in your
Lean Manufacturing implementation, using 5S as your housekeeping tool ensures you are
keeping on track and involving every person in your factory. If you are a little lost or have
fallen behind, then start the process again; get back to Sorting and Setting in order. This is the
foundation of your Lean production system and you can make it work.

Work permit system

The work permit specifies the conditions and procedures for safe execution of the work and allows
the work to be carried out under controlled risk conditions.
Aim:
The purpose of the work permit system is to ensure that:
1. Only authorized persons are allowed to work in hazardous area which is clearly notified.
2. The person permitted for work are being aware of the various safety issues involved and knows
that necessary safety precautions have been taken.
3. Work permit is legal documents between issuer and executor for commencement of job inside
refinery.
4. Client has implemented the work permit system to distribute the equal responsibilities of job
being performed.

Purpose & Objective:

The purpose 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.

The objectives of the Work Permit System are to exercise control over the maintenance, repair and
construction activities by assigning responsibilities, ensuring clear cut communication between
interested functions & safety considerations to the job, its hazards & the precautions required. It
ensures
that the work is properly defined, authorised, operating personnel are aware what is going on,
precautions to be taken are specified and the persons executing the job understand the nature and
extent
of hazards involved.

A hot work and cold work permits

• Hot work and cold work permits are work permits that authorize controlled work in
nonstandard, potentially hazardous conditions.
• They consist of specific instructions regarding the nature of the job, time and place, and
communicate information regarding safety procedures.

Cold work permit (Green color)

• It is required for any job which does not involve or use of any source of ignitions, spark, and
fire.
• Cold work permits are green colored permits issued for hazardous maintenance work that
does not involve the ignition hazards found in hot work.
• Cold work situations are determined by conducting a risk assessment for the task and the
working environment. If no flammable or explosive risks are identified, a cold work permit is
sufficient for carrying out the work.
Hot work permit (Red color)
• It is required for any job which involves or use of source of ignition, spark, and fire.
• Hot work permits are red-colored permits used to authorize work that will generate heat or
sparks, such as: Welding, Drilling, Grinding, Riveting, Cutting, Use of internal combustion
engines
• Hot work involves working with a source of ignition in an environment with a potentially
flammable or explosive atmosphere.
• Hot works takes into account the presence of flammable and combustible materials as well as
combustible gas in the vicinity of the work.

Entry into confined spaces

• Confined spaces can be below or above ground. A confined space, is not necessarily small.
Examples of confined spaces include silos, vats, hoppers, utility vaults, tanks, water supply towers,
sewers, pipes, access shafts, truck or rail tank cars, aircraft wings, boilers, manholes, pump stations,
digesters, manure pits and storage bins.
Ditches, wells, and trenches may also be a confined space when access is limited
Barges, shipping containers and fish holds are also considered as possible confined spaces.
• Entry into confined spaces means going into an area that is not meant for continuous human
occupancy, has limited or difficult entry and exit points, and may create challenges for rescue,
evacuation, or emergency response.
• All hazards found in a regular workspace can also be found in a confined space. However,
they can be even more hazardous in a confined space than in a regular worksite.

It may cause risk due to following factors:

o its design, construction, location or atmosphere
o the materials or substances in it
o work activities being carried out in it, or the
o mechanical, process and safety hazards present

Hazards in confined spaces can include:

• Poor air quality:
o Insufficient amount of oxygen for the worker to breathe.
o Toxic gases that could make the worker ill or cause the worker to lose consciousness.
o Simple asphyxiants are gases like argon, nitrogen, or carbon monoxide that replace oxygen in the
air, lowering it below safe levels. Low oxygen can quickly cause dizziness, nausea, unconsciousness,
and even death within minutes.
• Chemical exposures due to skin contact or ingestion (as well as inhalation of toxic gases).
• Fire hazard - An explosive or flammable atmosphere due to flammable liquids and gases and
combustible dusts which, if ignited, would lead to fire or explosion.
• Process-related hazards - such as residual chemicals, or release of contents of a supply line.
• Physical hazards noise, heat/cold, radiation, vibration, electrical, and inadequate lighting.
• Safety hazards - such as moving parts of equipment, structural hazards, engulfment,
entanglement, slips, or falls.
• Vehicular and pedestrian traffic.
• Shifting or collapse of bulk material (engulfment).
• Barrier failure that results in a flood or release of free-flowing solid or liquid.
• Visibility - such as smoke particles in air.
 • Biological hazards viruses, bacteria from fecal matter (waste from body) and sludge, fungi,
or moulds.

What should be done when preparing to enter the confined space?

• Before entering any confined space, a trained and experienced person should identify and
evaluate all the existing and potential hazards within the confined space.
• Ensure the confined space hazard assessment and control program has been followed.
• Evaluate activities both inside and outside the confined space.
• Air quality testing: Air quality in confined spaces should be tested from outside before entry,
checking all areas top to bottom and side to side. Continuous monitoring is needed if
conditions may change, such as leaks or ongoing work. A trained worker with properly
calibrated detection equipment should perform the testing using remote probes and sampling
lines.
The sampling should show that:
o The oxygen content is within safe limits - not too little and not too much.
o A hazardous atmosphere (toxic gases, flammable atmosphere) is not present.
o Ventilation equipment is operating properly.
o The results of the tests for these hazards are to be recorded on the Entry Permit along with the
equipment or method(s) that were used in performing the tests.

How are hazards controlled in confined spaces?

The traditional hazard control include engineering controls, administrative controls and personal
protective equipment. Engineering controls are designed to remove the hazard while administrative
controls and personal protective equipment try to minimize the contact with the hazard.
The engineering control commonly used in confined spaces is mechanical ventilation. The entry
permit system is an example of an administrative control used in confined spaces. Personal protective
equipment (such as respirators, gloves, hearing protection, etc.) is commonly used in confined spaces
as well. However, wearing of PPE sometimes may increase heat and loss of mobility. Those situations
should be carefully evaluated. When using PPE, always use as part of a PPE program and be sure to
evaluate all possible hazards and risks associated with PPE use.

How is air quality maintained?

• Natural ventilation (natural air currents) is usually not reliable and not sufficient to maintain
the air quality. Mechanical ventilation (e.g., blowers, fans) is usually necessary to maintain air
quality.
• If mechanical ventilation is provided, there should be a warning system in place to
immediately notify the worker in the event of a hazard or a failure in the ventilation
equipment. Care should be taken to make sure the air being provided by the ventilation
system to the confined space is 'clean' throughout the entire space.
• Ease of air movement throughout the confined space should be considered because of the
danger of pockets of toxic gases still remaining even with the use of mechanical ventilation.
• Do not substitute oxygen for fresh air. Increasing the oxygen content will significantly
increase the risk of fire and explosion.
• The use of mechanical ventilation should be noted on the entry permit.
• Ensure air being removed from the confined space is exhausted away from workers on the
outside.

How are fire and explosion prevented?

Work where a flame is used or a source of ignition may be produced (hot work) should not normally
be
performed in a confined space unless:
• All flammable gases, liquids and vapors are removed before the start of any hot work.
Mechanical ventilation is usually used to
1. Keep the concentration of any explosive or flammable hazardous substance less than 10% of its
lower explosive limit
2. Make sure that the oxygen content in the confined space is not enriched. Oxygen content should be
less than 23% but maintained at levels greater than 19.5.
• Surfaces coated with combustible material should be cleaned or shielded to prevent ignition.
• Do not bring fuel or fuel containers into the confined space (e.g., gasoline, propane), if
possible. Ensure welding equipment is in good condition.
• Where appropriate, use spark-resistant tools, and make sure all equipment is bonded or
grounded properly.
• During hot work in confined spaces, oxygen and combustible levels must be monitored to
stay within safe limits, with flammables below 10% of the Lower Explosive Limit. If hazards
are found, the space should be purged, ventilated, and retested, as purging gases themselves
can be dangerous; entry is only allowed once conditions are safe.

How are energy sources controlled?

All potentially hazardous energy sources such as electrical, mechanical, hydraulic, pneumatic,
chemical, or thermal must be de-energized (or isolated) and locked out prior to entry to the confined
space so that equipment cannot be turned on unintentionally accidentally. If lock out or tag out is not
possible, the hazardous energy must be controlled in a way that eliminates or minimizes worker
exposure to the hazards before workers are allowed to enter the confined space. It is important that
any method of control other than isolation and lockout must be evaluated and the effectiveness for
controlling the hazardous energy must be demonstrated.

What are other safety precautions?

• Any liquids or free-flowing solids should be removed from the confined space to eliminate
the risk of drowning or suffocation.
• All pipes should be physically disconnected or isolation blanks bolted in place. Closing
valves is not sufficient.
• Use two blocking valves, with an open vent or bleed valve between the blocking valves when
isolating pipelines or similar conveyances to prevent entry of materials and hazardous
contaminants.
• A barrier is present to prevent any liquids or free-flowing solids from entering the confined
space.