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8/7/2019 JITHU THAMPI

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Indira Gandhi National Open University PGDM Industrial Safety Health and Environment (2010)

1. INTRODUCTION

SAFETY IN INDUSTRY

The modern safety movement started around 1912 with the First Cooperative Safety Congress

and the organisation of the national safety council in USA.From 1912 to the present time,

remarkable advance have been made in reducing the rate and severity of accidents.

The importance of industrial safety was realised because every year millions of industrial

accidents occur which results in either death or in temporary and permanent disablement of the

employees and involves a good amount of cost such as resulting from wasted man-hours

machine hours etc which results in low productivity ,profitability etc.

But the people do not give enough seriousness to it, again, In India, the world's worst industrial

catastrophe, Bhopal gas tragedy occurs. It occurred on the night of December 2-3, 1984 at the

Union Carbide India Limited (UCIL) pesticide plant in Bhopal , Madhya Pradesh. A leak of

methyl isocyanate (MIC) gas and other chemicals from the plant resulted in the exposure of

several thousands of people. The official immediate death toll was 2,259 and the government of

Madhya Pradesh has confirmed a total of 3,787 deaths related to the gas release. Other

government agencies estimate 15,000 deaths. The government's classification was criticizedafter the deaths of people who were classed as having minor injuries. Chemicals (~390 tons)

abandoned at the plant continue to leak and pollute the groundwater whether the chemicals pose

a health hazard is disputed.

The costs of the above two disasters are unaccountable, the main cause of the above two are

lack in safety. These points to the need of safety in the industry.

Loss of lives and accidents cost gradually led to the formation of Factories Act,Office,Shopsand Railway premises act etc.The requirement for consideration of safety by management as

part of its responsibility arises primarily from these Acts.

Safety begins on the drawing board when in the original designs of tools of work place layout;

accident hazard may be built in or eliminated.

In an industry, safety may be considered from the mechanical side (equipment tools etc) or from

legal angles of workmen’s compensation or even as a matter of training in and motivation

towards safe work practices for workers (especially newly recruited ones).

Institute of Industrial Management for Safety Health and Environment.

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Employees shall be the focus point in any industry and money, material machinery which are

the inputs of the industry can only reckoned in importance after human resource only.

Increased productivity is only possible through increased safety.

2. SAFETY MANAGEMENT





Safety Management is the implementation of a " Safety Management System" into an

organization.

Safety management system’ means the organisation and arrangements established by aninfrastructure manager to ensure the safe management of its operations;"

An effective safety management system has proved that the quality, productivity and

profitability are co-partners in business enterprises. It is very important to note that an

effective safety management system has become paramount important in industrial

activities. The effective safety management system requires an infrastructure within the

organization. Present infrastructural facilities in Medium and Small scale units are not to be

desired level. Building such an infrastructure has associated costs

In order to implement a Management System into an organization, there have to be some

procedures, processes and key documents that must be used and updated by the organization.

Key elements of a Safety Management System should contain a company policy, a safety plan ,

a hazard log, internal audits and a failure reporting and corrective actions system , a risk

estimation process etc.

THE KEY DOCUMENTS

A number of documents can be considered as "key" documents in a Safety Management system

1. The System definition: Defines the system on block diagram level.

2. The Safety Plan: Describes "Who does what and when".

3. The Hazard log: Contains all known hazards and their history.

4. The Risk analysis : Contains the risk analysis performed for each hazard.

5. The Safety Requirements : The safety requirements to the system

The Safety Case : The document that proves the system is safe.


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It is then up to the organization to adjust size, amount and complexity of these key elements

into a suitable and operative Safety Management System for the product and organization in

question.

SAFETY RESULTS

• From safe plant, process and operations and

• By educating and training workers and supervisors regarding safe practices on shop

floor.





3. VISION OF THE PROJECT

The vision of the project is to increase the productivity of the plant with reduced rate of accident

and to gain knowledge. In all workplaces the health and safety of employees is closely linked

with the company's profitability. Safety and productivity are the two sides of the same coin and

productivity without safety is not possible. Employees shall be the focus point in any industry

and money, material machinery which are the inputs of the industry can only reckoned in

importance after human resource only The onward march of industrialisation cannot stop

because we are in the need of greater employment opportunities and improved goods so that

there can be continuing rise in the standards of living. Thus the challenge before us today is to

operate our industrial activities in a safe manner and to achieve the desired economic growth.

Increased productivity is only possible through increased safety. Human resource strategies

for improving the health and safety of people in the workplace do not necessarily cost money -

in fact they usually save money.





4. OBJECTIVE OF THE PROJECT

Occupational accidents severely deteriorate human capital, and hence negatively affect theproductivity and competitiveness of countries. But despite this, we still observe a scarcity of

preventive practices, an unsatisfactory management commitment and an absence of safety

culture among firms. The result is evident in firms’ high accident rates. This situation is a

consequence of the general belief among firms that investing in safety is a cost, and hence has

negative repercussions for their competitiveness. The current work shows how Productivity and

Profitability gains through Health and Safety management system. It also creates awareness

among employees about the hazard and how accident effects the production of industry so thatthey can go hand in hand with safety management system toward the growth of industry.





5. COMPANY PROFILE

BHARAT H EAVY E LECTRICALS L IMITED

Bharat Heavy Electricals Limited (BHEL ) is one of the oldest and largest state-owned

engineering and manufacturing enterprise in India in the energy-related and infrastructure sector

which includes Power , Railways , Telecom , Transmission and Distribution , Oil and Gas sectors

and many more. It is the 12th largest power equipment manufacturer in the world. BHEL was

established more than 50 years ago, ushering in the indigenous Heavy Electrical Equipment

industry in India. The company has been earning profits continuously since 1971-72 and paying

dividends since 1976-77. 73% of the total power generated in India is produced by equipment

manufactured by BHEL . The power generating equipment including turbines, generators,

boilers and auxiliaries in the country. BHEL has already supplied thermal sets up to 500 MW

rating and has the technology to go up to 800 MW. BHEL manufactured 500/236 MW Nuclear

sets are also installed in the country.

The BHEL manufactured sets accounts for 65% of total installed capacity in India. There is

ample scope for improving the plant availability by cutting down the shut down period, by

Renovation & modernization, Rehabilitation and by timely arranging the spare parts and other services.

BHEL has more than 35 years experience in the field of Design, manufacturing, erection and

operating experience, services in steam turbine .So that BHEL is undertaking Renovation and

modernization of BHEL & NON-BHEL Thermal Power Plants. This includes, Life assessment

studies recommendation for up-rating / up gradation, also includes retrofitting, repairs,

overhauling, with improved efficiency and heat rate and performance guarantee for a reasonabletime period. BHEL has taken lead role by providing specialized services, retrofitting renovating

and supply of even such spare parts for which complete design information and manufacturing

drawings are not available from original suppliers.

It is one of India's nine largest Public Sector Undertakings or PSUs, known as the Navratnas or

'the nine jewels’. It is India’s Largest Engineering & Manufacturing Enterprise of its kind


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Committed to Enhance Stake-holder Value, one of the Major Power Plant Equipment

Manufacturers in the World and consistent dividend paying company over three decades .

M AIN M ANUFACTURING P LANTS

Bhopal (Madhya Pradesh )

Bharat Heavy Electrical Limited, Raipur , Haridwar (Uttarakhand )

Hyderabad (Andhra Pradesh )

Jhansi (Uttar Pradesh )

Tiruchirapalli (Tamil Nadu )

Ranipet (Tamil Nadu)

Bangalore (Karnataka )

Jagdishpur (Uttar Pradesh)

Rudrapur (Uttrakhand )

Goindwal (Punjab )

Bharat Heavy Plates and Vessels Limited (Vizag )

Besides these manufacturing units there are four power sectors which undertake EPC contract

from various customers. The Research and Development arm of BHEL is situated in Hyderabadand two repair shops are at HERP (Heavy Equipment Repair Plant), Varanasi and EMRP

(Electric machines repair plant) Mumbai.

P RODUCTS

• Steam Generator

• Gas Generator

• Hydro Generator • Steam turbine

• Gas turbine

• Hydro Turbines

• Transformer

• Switchgear

• Oil field equipments

• Boiler drum

• Wind mill




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BHEL B HOPAL P ROFILE

Heavy Electrical Plant, Bhopal is the mother plant of Bharat Heavy Electricals Limited, the

largest engineering and manufacturing enterprise in India in the energy-related andinfrastructure sector today. With technical assistance from Associated Electricals (India) Ltd., a

UK based company; it came into existence on 29 th of August, 1956. Pt. Jawaharlal Nehru, first

Prime minister of India dedicated this plant to the nation on 6 th of November, 1960.

BHEL , Bhopal with state-of-the-art facilities, manufactures wide range of electrical

equipments. Its product range includes Hydro, Steam, Marine & Nuclear Turbines, Heat

Exchangers, Hydro & Turbo Generators, Transformers, and Switchgears, Control gears,

Transportation Equipment, Capacitors, Bushings, Electrical Motors, Rectifiers, Oil Drilling Rig

Equipments and Diesel Generating sets.

BHEL, Bhopal certified to ISO: 9001, ISO 14001 and OHSAS 18001, is moving towards

excellence by adopting TQM as per EFQM / CII model of Business Excellence. Heat

Exchanger Division is accredited with ASME ‘U’ Stamp.

BHEL Bhopal has its own Laboratories for material testing and instrument calibration which

are accredited with ISO 17025 by NABL. The Hydro Laboratory, Ultra High Voltage laboratory

and Centre for Electric Transportation are the only laboratories of it are in this part of the world.

BHEL Bhopal's strength is its employees. The company continuously invests in Human

Resources and pays utmost attention to their needs. The plant's Township, well known for its

greenery is spread over an area of around 20 sq kms and provides all facilities to the residents

like, parks, community halls, library, shopping centers, banks, post offices etc. Besides, free

Health services are extended to all the employees through 350 bedded (inclusive of 50 floating

beds) Kasturba Hospital and chain of dispensaries.





BHARAT H EAVY E LECTRICALS L IMITED , B HOPAL

PRODUCTS

Power Utilization

AC Motors &

Alternators

Transportation

Transportation

Equipment

Power Generation

Hydro Turbines

Hydro Generators

Heat Exchangers

EXCITATION CONTROL EQUIPMENT

STEAM TURBINES

Miscellaneous

Oil Rigs

Fabrication

Power Transmission

Transformer

Switchgear

On-Load Tap Changer

Large Current Rectifiers

Control & Relay Panels

Renovation &

Maintenance

Thermal Power Stations


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6. VISION

V ISION

A world class engineering enterprise committed to enhancing stakeholder value.

M ISSION

To maintain a leading position as supplier of quality equipments, systems and services to serve

the national and international markets in the field of energy generation, transmission, utilisation

and conservation for applications in the power, industrial and transportation fields. To strive for

technological excellence and market leadership in these areas

IMAGE

To build up a high degree of customer confidence by sustaining international standards of

excellence in product quality, performance and service, particularly after sales and service.

VALUES

Zeal to excel and zest for change

Integrity and fairness in all matters

Respect for dignity and potential of individuals

Strict adherence to commitments

Ensure speed of response

Foster learning, creativity and team work

Loyalty and pride in the company





8. SAFETY PRODUCTIVITY AND PROFITABILITY

KEY DEFINITIONS





SAFETY

Freedom from whatever exposes one to danger or from liability to cause danger or harm;

safeness; hence, the quality of making safe or secure, or of giving confidence, justifying trust, insuring against harm or loss, etc.

Workers are considered employees under OSHA if you:

• Control the actions of the employee,

• Have the power to control the employee's actions, and

• Are able to fire the employee or modify employment conditions

PRODUCTIVITY

The amount of output per unit of input (labor , equipment , and capital ). There are many different

ways of measuring productivity. For example, in a factory productivity might be measured

based on the number of hours it takes to produce a good, while in the service sector productivity

might be measured based on the revenue generated by an employee divided by his/her salary.

Productivity is directly influenced by time consuming accidents which shut down a production

line; delay deliveries incapacitate skilled operators, destroy essential equipment.Less easily

measured but just as harmful to production are the loss of efficiency and morale that develops

remain after a serious accident.

P ROFITABILITY

Profitability is expressed in terms of several popular numbers that measure one of two generic

types of performance: "how much they make with what they've got" and "how much they make

from what take in. This objective refers to management desire to maximise profits or avoid

losses. Accidents and injuries cost money, thus reducing profits. Safety therefore has an impact

on profits.

P RODUCTIVITY & S AFETY


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• Safety, productivity and Quality are the vital three factors in any activity.

• They are like three sides of an equilateral triangle and mutually dependent on each other.

• It is impossible to perform any of our day to day activities without influence of these

factors in one-way of other.

W HAT IS P RODUCTIVITY ?

• Productivity is the arithmetical ratio between the amount produced and the amount of

any resources used in the course of production.

• In otherwords, productivity means goods and services produced in relation to the

resources utilised in producing the same.

• Productivity is not production.

• Production merely means volume of output.

• Production can be increase without consideration of cost, by increasing the input of labour, material and equipment.

• Productivity is not merely volume of output, but output in relation to the resources

employed.

P RODUCTIVITY IMPROVEMENT MEANS

•

Increasing the output for the same amount of resources.

OR





• Reducing the resources for the same amount of output.

SAFETY AND P RODUCTIVITY

• Every resource has to be optimally made use of.

• There can be no two opinions that out of all the resources the human resource is the

most vital one.

• Accidents cause not only injury to the persons but also damage to the properties.

Safety assumes the greatest dimension because the losses to the human resources as well as to

the plant and machinery and the various properties assume such a huge proportion cutting a

sizeable portion of the production effort

T HE REASONS FOR THE CONTINUING EFFORT TO PREVENT ACCIDENTS ARE

• Needless destruction of life and health is a moral evil

• Failure to take necessary precautions against predictable accidents -moralresponsibility for those accidents

• Accidents severely hurt efficiency and productivity

• Accidents produce far reaching social harm

• Safety movement has already demonstrated that its techniques are effective in reducing

the accident rates and promoting the efficiency

INCREASING P RODUCTIVITY AND P ROFITABILITY THROUGH SAFETY E NVIRONMENT

Truly said, human resources are undoubtedly the most important assets of any industry and their

safety should be of prime concern. Adherence of safety codes and regulations ensures healthy

and safe working conditions of the workers, eventually increasing productivity and profitability

of the industry.





In all workplaces the health and safety of employees is closely linked with the company's

profitability. Safety and productivity are the two sides of the same coin and productivity without

safety is not possible. Human resource strategies for improving the health and safety of people

in the workplace do not necessarily cost money - in fact they usually save money.

For greater productivity, a healthy manpower is essential requisite. In order to ensure the health

care of the employee, the pre employment examination and pre placement examination are of

importance. To provide a congenial atmosphere, the work environment is to be monitored to

detect the symptoms of occupational health problems.

ACCIDENTS

An industrial accident may be defined as an event, detrimental to the health of man, suddenly

occurring and originating from external sources and which is associated with the performance

of a paid job, accompanied by an injury, followed by disability or even death. In every sphere of

human activity there is the possibility of an accident and the work place is no exception.

Industrial accidents are the end products of unsafe acts and unsafe conditions at work .

Many of the accidents have been attributed to human errors. As bought out by Heinrich

Pyramid one fatal injury arises out of 30 which in turn is the result of about 600 near missinjuries. Ample scope is therefore available to mould the employees attitude by supervision,

inspection etc, to control the unsafe acts and unsafe condition .

C AUSES OF ACCIDENTS

Accidents may be caused due to

• Technical causes or unsafe conditions• Human causes or unsafe acts

Technical causes reflects deficiencies in plant, equipment, tools, materials handling system,

general work environment etc.

Human causes by the person concerned are due to his ignorance, carelessness, day- dreaming

etc

M ECHANICAL CAUSES





• Unsafe mechanical design or construction

• Hazardous arrangement

• Improper machine guarding

• Unsafe apparel

• Defective agencies or devices

• Improper material handling

• Broken safety guards

• Protruding nails

• Leaking acid valve

• Untested boilers or pressure vessels

E NVIRONMENTAL FACTORS

Environmental factors indicate improper physical and atmospheric surrounding conditions

which directly promote the occurrence of accidents. Environmental factors include

• Too low temperature cause shivering

• Too high temperature cause head ache and shivering

P ERSONAL FACTORS

1. Age.

2. Health.

3. No: of dependents.

4. Financial position.5. Home environment.

6. Lack of knowledge and skill.

7. Improper attitude towards work.

8. Incorrect machine habits.

9. Carelessness and recklessness.

10. Day dreaming and inattentiveness.

11. Fatigue.

12. Emotional instability.

13. High anxiety level.





14. Mental worriness.

15. Unnecessary exposure to risk

16. Non use of safety devices

17. Working at unsafe speed

18. Improper use of tools

E CONOMIC COST OF ACCIDENTS

• An accident can be very costly to the injured employee as well as to the employer of the

concern

• Every accident / occupational health disorder also represents loss to the organization

through various definite cost e.g.:- direct and measurable costs and indirect i.e.

somewhat intangible but nevertheless real costs.

D IRECT COSTS

Direct costs of accidents are represented by compensation payable to the worker/worker’s

dependents; cost of insurance premium; cost of treatment of worker/injured persons; cost of

repair of equipment damaged due to the accident; fines imposed by the Court for breach of lawtogether with cost of defense for legal recourse.

INDIRECT COSTS

Indirect costs to the organization include the cost of lost time of the injured persons,

management, first aid staff and other persons involved; cost of lost production and cost of

overtime required to be paid to meet the delivery schedules; cost of investigation of the

accidents including time involvement of management, supervisory staff and witnesses, cost of

replacement of damaged personal property and incidental cost incurred by witnesses attending

the court.

INTANGIBLE LOSS

Intangible loss to the organization includes loss of reputation to the company; impact on

motivation of fellow workers; impact on labor relation as an outcome of the accident etc.

DIRECT COSTS (Eg:-FOUNDARY ACCIDENT)





Compensation paid for injury=Rs 700/-

Medical expenses=Rs 300/-

Total compensation cost=RS 1000/-

Uncompensated wage loss=Rs 200/-

Total direct cost=Rs 1200/-

INDIRECT COST

Material spoiled =Rs X/-

Labour for cleaning it up=Rs 400/-

Injured worker’s make up pay while at home=Rs 200

Fellow workmen standing and watching at time of accident=Rs 600/-

Supervisor’s time in reporting and investigating=Rs 220/-

Down time on casting=Rs 300/-

Slowed up production rate of other employee=Rs 240/-

Total indirect cost=Rs (X+1960)

Total cost of accident(Not including over head charge which may raise the total cost of accident

by as much as 50%)=Rs(3160+X)

C OST OF ACCIDENT PREVENTION

On the other hand the cost of accident prevention includes cost of protection equipment/ cost of

engineering solutions for eliminating or controlling the hazards; cost of building infrastructure

within the organization for implementation, running and monitoring of an effective safety

management system: cost of managing such infrastructure ; cost of safety training etc.





While the cost of accident prevention is pre planned allowing greater flexibility and control to

the management, the cost of accident has to be borne in a totally unplanned manner. Intangible

benefits of better worker morale, higher productivity, reduced cost of production, better labor

relation also accrue to the Company. Above all it helps in safeguarding valuable human

resource hence; adoption of measures for safety of the workers is always the better option.

ACCIDENT PREVENTION

Prevention of accidents is a true humanitarian concern, it doesn’t occur by itself ;there should

be a consistent implementation of safety measures and safety programmes emphasizing the

need for 1. Safe work place lay out and working conditions.

2. Safe material handling.

3. Personal protective devices.

4. Safety activities in the organisation.

PRODUCTION MUST SAFETY FIRST

The studies on accidents during the last five years’ have well established that around 90% of

the accidents took place because of human reasons. It has also been accepted that the journey

towards excellence in safety could be made, in a nutshell, through

(a) Well laid policy, systems & procedures.

(b) Infrastructural support.

(c) Human Competency and

(d) Human attitude.

A deep insight into the failure to achieve excellence in safety from an otherwise efficientorganization revealed that the major factors responsible for the lack of success in safety are: -

(1) Lack of visible and felt leadership across all levels.

(2) Belief that safety is the function only of a particular division.

(3) Tolerance of non-conforming habits.

(4) Concern for corrective actions rather than for preventive actions.

(5) Expenditure on safety viewed as mere outflow of funds.

(6) Feeling that importance on safety affects productivity.





The root cause behind this lack of genuine interest and commitment for Safety emanates from

the perception of dichotomy between productivity and

safety – a feeling that safety is extraneous to the core operation not having positive impact on

productivity, Balance Sheet and Profit & Loss accounts.

Therefore, there is a need to explore

(i) Whether synthesis between Safety & Productivity is possible and

(ii) Whether that is really rewarding for the organization.

DICHOTOMY – HISTORICAL PERSPECTIVE

Previously, since the days of industrial revolution, the main objectives of the

Organizations were productivity & profit making. The working conditions used to be

horrible with no concern for safety & health of the workers. However, with the

pressure from the middle class intelligentsia and enactment of laws, the concept of

safety was incorporated.

As the concept of safety did not grow naturally from within and was mostly

thrust upon from outside; it was perceived as an extraneous obligation eating

away productivity & profitability. This belief compelled the organizations to framepolicies, procedures and systems separately for safety and for productivity using

different sets of resources.

DISSOLVING THE DICHOTOMY

The dichotomy can be dissolved by proper “synthesis” of the factors

influencing both productivity & safety and through “harmony” in their

manifestation.

(A) POLICY, SYSTEMS & PROCEDURES

“Well Laid Policy” for better safety has always many common elements





meant for higher productivity. “Well framed systems & procedures” for safety also

give impetus to productivity. For example, Safety requires compliance regarding

quality maintenance, testing and certification to avoid breakdown or unwarranted performances.

This also helps in higher productivity and longer life span, thereby leading to more earning &

more saving.

Excellent infrastructural support statutorily required for safe operation directly improves

productivity through uninterrupted and quicker operations. Giving human protection through

right personal protective equipments for safety also gives confidence and courage to work

efficiently on sustainable basis, thereby having direct positive impact on profit. The variables

influencing policy, systems &procedures for safety being also contributory to productivity.

(B) HUMAN ASPECTS

(I) H UMAN C OMPETENCE

Competence, an essential precondition for productivity, is based on

education, experience and training. Analysis of the above components would

reveal that competence for productivity is a pre-requisite for gaining competence

in safety. Whereas, separate programmes are generally framed for improvingcompetence in productivity and safety, it is feasible, effective and economical to

synthesize the productivity and safety related competence developmental

programmes.

(II ) A TTITUDE

The intangible yet most dominant factor for both productivity & safety is the ATTITUDE .

Attitude development has an all-encompassing effect on organization, nation and the human

civilization as a whole.An introspection into the above behavioural pattern would reveal that they are also essential for

excellence in safety. Therefore, behavioural development through ethico-moral transformation

and creation of the organizational culture for its sustainability need not be addressed separately

for improving productivity and safety. The core values influencing both productivity and safety

being similar, the organization would reap multiple benefits through value orientation if the

apparent dichotomy between safety & productivity is ignored and be rightly integrated and

synthesized.

SOLUTION





Although all the aspects for ensuring safety are not identical to those for ensuring productivity,

they are so much similar that it is not practical and economical to treat them in disintegrated

fashion. The different components of productivity i.e. production process, maintenance, quality

control etc. having partially different domains; which were earlier treated as separate

disciplines, have long been adopted as an integrated one. The economy and the synergy thus has

been so successfully reaped, that now it is unbelievable that once some of them were

disintegrated.

Similarly, “Safety” having so many common variables with “Productivity” in the systems,

procedures, infrastructure and human components should be synthesized with “productivity” in

a holistic manner . Such integration would ensure

(i) higher productivity through safety,

(ii) eliminate separate monitoring process,

(iii) reduce overheads,

(iv) reduce expenditure and most importantly,

(v) the managers would be genuinely interested in safety while

focusing on productivity.

This will bring radical positive transformation from the “compulsive extraneous thrust” on

safety to the “inspiring empowerment coming from within” in the journey beyond excellence insafety.

9. AREA VISITED/INSPECTED/OBSERVATIONS

I am doing my project work in Heat exchanger and condenser manufacturing division

(HCM).It is situated in bay8 of block1. There are 125 employees working in the HCM

division. Out of the total employees 92 artisans are engaged in various activities like

machining, fitting, grinding, store keeping, and material handling.

Here heat exchangers of different types and sizes are manufactured and the installed capacityis 250MW high pressure heaters ,270-500MW low pressure heaters and 500MW surface





condensers.HCM has 30 small and large machine tools where components of heat exchangers

are machined. They are mainly lathes, drilling, horizontal boring and vertical boring

machines. To facilitate the movements of components from one work place to another, the

bay has EOT cranes of various capacities One is of 10 tons, another of 20 and 50 tons while

third is of 10 and 50 tons .In addition to that there are 8 jib cranes of various capacities at

different locations for local material handling requirements. The components are machined in

the machine shop and are then assembled in the assembly section.

The various functions in HCM are

1. Material handling

• Indenting

• Purchase order

• Receipt of material

• Production plan

2. Machining

• Drilling

• Turning

• Boring

• Lathe operations

3. Assembly and testing

• Baffle Assembly

• Tubing

• Shell Assembly

• Welding





• Grinding

• Painting

• Testing

Products of HCM division:-

HP Heaters

LP Heaters

Gland Steam Condenser (GSC)

Turbine Oil Coolers (TOC)

Control Fluid Coolers (CFC)

Hydro Coolers

Transformer Coolers

Flash Tanks & Misc. Tanks

FIG :- LAYOUT OF HCM DIVISION





FIG :- MULTI SPINDLE CNC MACHINE FIG :- FINISHED HP HEATERS

FIG:-VERTICAL DRILLING MACHINE FIG:- INNER COIL OF H P HEATERS





HAZARD & RISK ANALYSIS

A hazard analysis is a process used to assess risk. The results of a hazard analysis are the

identification of unacceptable risks and the selection of means of controlling or eliminatingthem. The term is used in several engineering specialties, including avionics , chemical process

safety, safety engineering and food safety to identification, studies and monitoring of any

hazard to determine its potential, origin, characteristics and behaviour.

Risk analysis should be performed as part of the risk management process for each project . The

data of which would be based on risk discussion workshops to identify potential issues and risks

ahead of time before these were to pose cost and/ or schedule negative impacts.

The risk workshops should be chaired by a large group ideally between 6 to 10 individuals from

the various departmental functions (e.g. project manager, construction manager, site

superintendent, and representatives from operations, procurement, [project] controls, etc.) so as

to cover every risk element from different perspectives.

The outcome of the risk analysis would be the creation or review of the risk register to identify

and quantify risk elements to the project and their potential impact.

Given that risk management is a continuous and iterative process, the risk workshop members

would regroup on at regular intervals and project milestones to review the risk register

mitigation plans, make changes to it as appropriate and following those changes re-run the risk

model. By constantly monitoring risks these can be successfully mitigated resulting in a cost

and schedule savings with a positive impact on the project.

HAZARD IDENTIFICATION RISK ASSESSMENT AND DETERMINING CONTROL

(HIRA DC)

HAZARD

Source or situation with potential for harm in terms of injury or ill health, damage to property,

damage to workplace environment, or combination of these.

(i) Safety Hazards (Injury, fatal accidents)

(ii) Health Hazards (illness, chronic diseases )


http://en.wikipedia.org/wiki/Risk

http://en.wikipedia.org/wiki/Avionics

http://en.wikipedia.org/wiki/Process_engineering


http://en.wikipedia.org/wiki/Safety_engineering

http://en.wikipedia.org/wiki/Food_safety

http://en.wikipedia.org/wiki/Risk_management

http://en.wikipedia.org/wiki/Project


http://en.wikipedia.org/wiki/Construction

http://en.wikipedia.org/wiki/Risk_analysis



http://en.wikipedia.org/wiki/Avionics



http://en.wikipedia.org/wiki/Safety_engineering

http://en.wikipedia.org/wiki/Food_safety

http://en.wikipedia.org/wiki/Risk_management



http://en.wikipedia.org/wiki/Construction

http://en.wikipedia.org/wiki/Risk_analysis





HAZARD IDENTIFICATION

Process of recognizing that a hazard exists and defining its characteristics.

RISK

Combination of the likelihood and the consequences of a specified hazardous event occurring.

RISK ASSESSMENT

Overall process of estimating the magnitude of the risk and deciding whether or not the risk is

tolerated.

DETERMINING CONTROL

Providing control measures to reduce the risk to acceptable level.

RANKING HAZARDS BY RISK.

Hazards may be categorized in several different ways. The actual method used will depend on

the safety management teams approach to the problem, what is important is that hazards are

properly and realistically assessed and priorities established. Techniques for producing a

ranking vary from very simple to complex. Here we have taken the severity of consequence,

extent of exposure to hazard and the probability of the event occurring as the measuring system.

The risk is assessed by introducing a new factor called Risk Assessing Factor

SEVERITY R ATING (SR): An assessment of the worst potential consequence, defined

by the degree potential injury, illness or property damage which ultimately occur.

F REQUENCY R ATING (FR): An assessment of the probability that any particular hazard will resultin an injury, an occupational illness or property damage.

The assessment is based on such factors as location and extent of exposure (ER) to the hazard in

terms of cycle or hours of operation. It also helps to calculate the immunity power of a worker

involved in a work, with particular occupational health hazard.

R ISK ASSESSING F ACTOR (RAF): Products of hazard rating. It helps to access the risk.

RAF=SR× FR





R ESIDUAL R ISK (Rr ): It is the risk level after recommendations.

Rr= RAF (Acceptable or Low)





CALCULATION SHEET FOR HAZARDS AND

ASSOCIATED RISKS

SEVERITY & PROBABILITY MATRIX

Rank

Injury

ChronicEffect

Probability(Frequency)

Rank

5 DisasterinvolvingMultiplefatalities

May result inIncurablediseases likeCancer, kidneyFailure

Repeatedly during lifecycle of system/ at least onceper year.

5

4 Singlefatality

Serious illnessresulting inhospitalization

Several timeduring lifecycle of system/ at least Oncein 3 years.

4

3 DisablingInjury

Permanent losses( Hearing,vision,limb/finger/toeetc but not lifethreatening)

Once in lifecycle of system/ once in 8years.

3

2 Medical AidInjury

Reversible effectsbut requiremedicalmonitoring

Unlikely to occurduring lifecycle of system / oncein 6-16 years.

2

1 Minor injuryillness

(first aid)

Temporary/reversibleeffects due to

release of gasetc

Unlikelyto occur in 15years .

1





LEG

END

4

EXTREME RISK : CANNOT BE ACCEPTED, MUSTBE CONTROLLED TO ACCEPTABLE LEVEL

3

HIGH RISK : MUST IMPLEMENT EXTENSIVECONTROLS

2

MODERATE RISK : TO BE ANANLYSED FOR

ADEQUATE CONTROLS

1LOW RISK : TOLERABLE, CAN BE

ADDRESSED BY LOWER HIERARCHY OF CONTROLS





S No LEGISLATION





HAZARD IDENTIFICATION RISK ASSESSMENT AND DETERMINING CONTROLS

AREA: BLOCK 1 BAY 8(HCM)

ITEM/

ACTIVITY

CONCERN

(HAZARD)

IMPACT HAZARD

(IDENTIFICATION)

RANKING HAZARD BY

RISK

RISK CONTROL MEARURE RESIDUAL

RISK (Rr)

SF FF RAF=

SF*FF

Machining Moving Parts. Entanglement 2 3 6 Provide interlocking guards,

avoid wearing rings, metallic

watches etc

Low

Flying Chips. Injury to Eyes, may fall

in to gangways3 3 9

Electric shock. Burn

1 2 2

Grinding Dust Adverse Effect on

respiratory system

3 2 6 Use ear plug, mask, goggles etc,

proper wheel dressing and

Acceptable





truing, the gap between the

wheel and tool rest should be

3mm

Noise Damages ear and creates

psychological problems2 2 4

Striking of tools to

the worker or

nearby persons

Injury

2 3 6

Maintenance Spillage of oil Accident due to Slippage 2 3 6 Pour dust powder Low

Storage &

handling of

hazardous

substances

Inflammable

material

Fire & explosion, 1 4 4 Good house keeping Acceptable

Work

through

contract

Labourers

Lack of skill Creates accidents 2 3 6 Appointment of skilled labourer, Low

Crane

Operation

Fall of Job during

unloading

Fatal 1 3 3 Provide lock pins, inspection of

cranes.

Low

Tube Bundle

insertion

Sling Failure,

Failure of weld

joint

Causes harm to the

worker and damages the

casing

3 3 9 Periodic inspection of slings, use

good quality of welds

Acceptable

Material

Storage

Congested space Obstruct the gang ways,

lack of required

3 3 9 Provide required work space, Low





ventilation install exhaust fans

Welding

Operation

Electric Arc Damages eyes due to

harmful radiation

2 2 4 Provide a separate space for

welding, use welding screens ,

gloves etc, earth cable should be

properly earthed, use skilled and

experienced operators

Low





Severity Rating of Hazard(SR)

Severity Rating of Hazard Value

Catastrophic – imminent danger exists, hazard capable of causing

death or loss of facilities.1

Critical – hazard can result in serious occupational illness, severe

injury or minor property and equipment danger.2

Marginal – hazard can cause minor illness, injury or equipment

damage, but not serious.3

Negligible – Probably would not cause injury or occupational

illness, remote possibility of damage beyond minor first aid case.

4


Fumes Adverse Effect on

Health because of

inhalation affects

eyes

2 2 4

Heat Burn 2 3 6

Electric shock Injury 1 3 3




P ROBABILITY R ATING OF H AZARD (PR)

Probability Rating of Hazard Value

Probable - Probably likely to occur immediately or shortly. 1

Reasonable Probable – Probably will occur in time. 2

Remote – may occur in time. 3

Extremely Remote – Unlikely to occur. 4

E XPOSURE RATING OF HAZARD (ER)

Extent of Exposure to Hazard Value





HIGH-Exposure limit 8Hrs H

MEDIUM-Exposure limit 4Hrs M

LIGHT-Exposure limit 2Hrs L

NEGLIGIBLE-exposure limit ≤1Hrs N

R ISK ASSESSING F ACTOR (RAF)


Score 1(ER)≤RAF≤4(ER) 6(ER)≤RAF≤8(ER) 9(ER)≤RAF≤12(ER) 12(ER)<RAF≤16(ER)

Level of

Risk

UNACCEPTABLE MODERATE ACCEPTABLE LOW




10. PRESENT SCENARIO

The turnover has doubled in last 4 years i.e. from 73 crores during year 2005-06 to Rs. 145

crores in 2009-10.

It was revealed that single bay area for carrying out activities such as material handling,

machining, hydraulic testing, painting, dispatch etc. of wide range of products was not sufficient

and hampering the productivity very badly and almost reached up to saturation level.

The turnover of Hydro coolers, Transformer and Generator coolers are also increasing at a

faster rate because of ambitious plan of expansion of Hydro turbines and Transformers. During

last 4-5 years 250 MW HP Heater and 500 MW Surface condensers have been added as a

regular product which are very large in size and numbers and are not getting accommodated in

present area and are creating serious safety hazards.





11. SITUATION OF SAFETY MANAGEMENT

SAFETY MANAGEMENT IN BHEL, BHOPAL

Concern for and action to control a safety, health and environmental for the action to controlsafety, health and environmental risk to the world’s population are rapidly accelerating.

Industries have responded to the need for reliable control of these risks with a broad range of

system employing physical, operational and management control. Each system is designed to

reflect the inherent risk of operations, the structure and culture of the organisation.

Employees are assets of any industrial complex and it will remain healthy if its workmen are

healthy. The health of the workmen gets affected because of constant exposure to toxic





substances in the work environment. It has become mandatory on the part of management to

keep the work environment safe and healthy safe working conditions depend on safe plant

operation. Right from project, site and technology selection to the plant commissioning and

regular operation .Training and preparedness play an important role in maintaining safe work

environment. Above all co-operation between workers and management is required to safe-

guard the occupational safety and health of the workmen.

In BHEL, BHOPAL safety management and implementation of statutory needs are being

carried out by and independent safety engineering department with the assistant of occupational

health centre, fire fighting department and welfare department. This is established in close

liaison with directorate of industrial health and safety, Govt of M.P. Some of the salient

activities is as follows.

OCCUPATIONAL HEALTH





The statutory requirements such as cleanliness, disposal of wastes and effluents, ventilation and

temperature, dust and fumes, artificial humidification, overcrowding, lighting, drinking water,

latrines and urinals, maintained and are regularly inspected by safety representatives.

Besides, the above statutory provisions, BHEL has provided following additional health care

facilities.

OCCUPATIONAL HEALTH SERVICES, PERIPHERAL DISPENSARIES AND

HOSPITAL

• First aid & emergency services.

• Man maintenance programme.

• Preventive health care programme.

• Pathology and Bio-chemistry Analysis.

• Psychological guidance and counselling.

• Industrial Hygiene & toxicology lab.

• Audiology monitoring.

• Health Education Programme.

• Ergonomics.

Safety activities as per statutory requirements are regularly inspected and records are kept ready

for verification by the directorate of industrial Health &Safety, Govt of M.P.

Provision of latest electronic machine guards, radio remote control cranes, exhaust systems for

dust/gas collections, automatic fire-fighting systems have been installed at accident and health

prone areas.





SAFETY PROMOTIONAL ACTIVITIES

TRAINING

1. Industrial employees are exposed to industrial safety training.

2. Employees are also nominated to attend external training/seminars arranged by

NSC/RLI/CLI/LPA/DMI and other organisations to have latest knowledge about the safety

developments.

3. All the daily rated workers/contracted labours are given one day safety awareness safety

training which has resulted in reduction of accidents.

4. With the faculty member of RLI Kanpur all the lady employees and lady workers of BHEL

were given safety awareness training.

5. Every department has got trained persons for first-aid and for fire extinguisher operation.

SAFETY AWARD SCHEME

Awards are given on the following grounds:

Departments of Zero-Accident

Department of Best- Housekeeping

Best safety Steward

SAFETY COMPETITIONS

SUGGESTION SCHEME

Safety suggestions are invited from the employees and after due consideration by

suggestion committee the good suggestions are implemented and suggestees are

awarded with cash as well as certificates.

SAFETY COMMITTEES

Central Safety Committee meets once in three months.





Central Safety Sub-Committee.

Stewards Safety Committee once sin a month.

Departmental Safety Committee meets once in a month and implement the safety suggestions.

DAILY SAFETY INSPECTION OF SHOP FLOORS

The safety representative visit daily to shop floor and with the help of safety stewards, brings in

notice the unsafe acts and unsafe conditions prevailing and suggests remedial action to the shop

in charges. A sample checklist used for the departmental safety inspection card is given below.

BHARAT HEAVY ELECTRICALS LIMITED. Bhopal

SAFETY & ENVIRONMENT ENGINEERING DEPARTMENT

Block Safety Inspection Report





Card Ref No: Date: Dept:

Block No: HOD: HSE Officer :

SlNo Bay Section Position/Machine

Safety Problem Noticed Recommendations

IMPLEMENTATION OF OHSAS 18001

As a part of implementing OHSAS guidelines in an organization, BHEL have to create health

and safety systems manual in which all the guidelines of the OHSAS requirements applicable to

the particular organization will be covered and it will be communicated all the agencies of the

company according to which they have to comply with.

While developing the systems manual, BHEL have to describe about the company’s profile

which includes what are all the products of the company, manufacturing facilities that are

available in the company and the various initiatives they have taken towards environmental

friendly activities.

Firstly, evaluate the Health and Safety needs of the staff and visitors in the industry. Then

identify the boundaries of the Health and Safety system and document the procedures for

meeting the requirements of OHSAS 18001. Ensure these procedures are fully implemented,then audit and review them.

Once developed, internal audits are needed to ensure the system continues to be effective.

Always bear in mind the need to conform to legislative requirements.

Having chosen a third party certification body for the audit, it will review your documentation

to ascertain that it meets all the requirements of OHSAS 18001. This is followed at a later date





by an audit to check that records are being kept and documented working practices are being

followed.

After a successful audit, a certificate of registration to OHSAS 18001 will be issued. There willthen be continual surveillance visits (usually once a year) to ensure that the system is

maintained and continues to be effective

IMPLEMENTATION OF ISO 14001

ISO (the International Organization for Standardization) is a worldwide federation of national

standards bodies (ISO) member bodies. The work of preparing International Standards is

normally carried out through ISO technical committees. Each member body interested in a

subject for whom a technical committee has been established has the right to be represented on

that committee. International organizations, governmental and non-governmental, in liaison

with ISO, also take part in the work. ISO collaborates closely with the International Electro

technical Commission (IEC) on all matters of electro technical standardization.

As a part of implementing the ISO standards a MR (Management Representative) (HSE) will be

appointed and he will be given full authority and organizational freedom to approve, revise,

manage and implement this manual consistent with Company’s policies and objectives relatedto HSE.

All the other concerned departments are responsible for complying with this manual. Each

section head identified in this manual is responsible for implementing the requirement and

resolves any non-conformity within his department/section.

The organisation shall ensure that interning audit of the ems are conducted period of intervals to

1. Comfier med to planned arrangements for environment management systemincluding the requirements this international standard

2. Hs been properly implemented and is maintained

a. Provide information on the results of audit to management

After a successful audit, a certificate of registration to ISO 14001 will be issued. There

will then be continual surveillance visits (usually once a year) to ensure that the system

is maintained and continues to be effective





Environmental Aspects Feasibility Analysis

Sl

No

Activity/

Product/Services

Significant

Aspect

Associat

edImpact

Eliminatio

n/Reduction/ Control

1 Machiningof variousComponent

Disposalof coolant

WaterPollution

Control of coolant

2 Preparation of Coolant/water

OverConsumption of Oil

Depletion of Naturalresources

Control

3 Generationof NonSaleable

SolidWaste

Disposalof NonSalable

SolidWaste

LandNuisance

Control

4 Use of Coolant/Lubricant

Disposalof Drums

LandNuisance

Control

5 Generationof Non

SaleableSolid Scrap

Disposalof Solid

Scrap

LandNuisanc

e

Control

CELEBERATION OF NATIONAL EVENTS

1. Road Safety Week - 1st week of January

2. National Safety Day - 4th March





3. Fire Fighting Day - 14 th April

4. World Environment Day - 5 th June

5. Industrial Safety Day - 3 rd December

NATIONAL SAFETY COUNCIL, M.P. CHAPTER

BHEL, Bhopal is Head Quarter of National Safety Council, M.P. Chapter and takes leading role

in propagating safety awareness programme in the whole of Madhya Pradesh through five

action-centres situated at Vijaipur, Jabalpur, Korba, Bhilai and Indore. The chapter arranges

safety audit programmes, safety seminars and helps in celebration of national events and also

publishes quarterly “Suraksha Pradeepika” in Hindi highlighting the safety needs andachievements.

SAFETY DISPLAY ROOM

Safety has been equipped with:-

Overhead projector with the screen

Sitting arrangement for 50 persons

Display of latest magazines

Display of safety appliances

Display of fire-fighting equipments

Display of safety awards and safety certifications received

ACCIDENTS

With implementation of statutory as well as mandatory regulations the accidents in BHEL are

substantially reduced and management is aiming to achieve Zero-accident

ENVIRONMENT





Massive plantation in BHEL and in Township.Water and air quality regularly monitored by

industrial hygienist, Technical Services department of BHEL and by the scientist of Pollution

Control Board of Govt. of (M.P.)

1. Workplace monitoring regularly carried out to keep the water, air and airborne dust particles

within the Threshold Limit Value.

2. Noise level, lighting, vibration, heat stress are regularly monitored and corrective actions are

taken, if needed.

3. At Berkhera Sewage Treatment Plant bio-gas is generated for making chapattis, and for

hospital use, water treated and used for orchards and solid waste is converted into manure.

4. All the solid and liquid wastes generated are fully neutralised before their disposal.

5. All the water used in BHEL is re-cycled and used and not allowed to go outside for general

public or for public cultivation.

FIRE FIGHTING SERVICES

BHEL, Bhopal has its own fully fledged fire fighting services department to control the fire

hazards. Complete BHEL factory is connected by fire hydrant system and hazardous areas are

installed with automatic fire control systems.





12. STRENGTH, WEAKNESS, OPPURTUNITIES & THREATS

STRENGTH

Sound engineering base and ability to assimilate

Relatively stable industrial relationship

Access to contemporary technologies with the support from renowned

Collaborators.

Ability to manufacture or procure to supply spares.

Largest source of domestic business leading to major presence and influence in the

market.

Low labour cost.

WEAKNESS

Larger delivery cycles in comparison with international suppliers of similar equipment.

Inability to provide supplier’s credit, soft loans and financing of projects.

Due to poor financial position of state electricity boards, which are the major customers

of BHEL in India, liquidity position of BHEL is not satisfactory.

Being a public sector company BHEL is suffering from sub optimality of control due to:





Displacement of social objectives by political objectives, which may lead to

redundant costs and also rising costs

Direct political intervention in managerial decision over an arm length relationship thatwould restrict government’s task of setting appropriate managerial incentive structure.

Internal inefficiencies in bureaucratic activity.

OPPORTUNITIES

Demand for power and hence plant equipment is expected to grow.

Private sector power plants to offer expanded market as utilities suffers resource crunch.

Ageing power plants would give rise to more spares and services

business.

Life expansion program for old power stations.

Easy processing of joint ventures/ collaboration/import/ acquisition of

new technology.

Financial and operational autonomy for profit making public sector enterprises. To make

the public sector more efficient government has decided to grant enhanced autonomy

and delegation of powers to the profit making public sector enterprises

THREATS

Increased competition both national and international

Multilateral agencies reluctant to lend to power sector because of poor financial

management of S.E.Bs

More concessions to private sector and not to government owned utilities like NTPC or

S.E.Bs, so future power projects would be opened up in private sector





Level playing ground not available, foreign companies spending much more on business

promotion tactics.

13. TANGIBLE AND INTANGIBLE BENEFITS

T ANGIBLE BENEFITS

1. Increased productivity and profitability.

2. Accident prevention.

3. Hygienic work area.

4. Less material loss.

6. Involvement of everyone in safety.

7. Make a safe working environment.

INTANGIBLE BENEFITS

1. Certification of ISO-9001, ISO-14001, OHSAS-18001.

2. Improvement of employee morale.

3. Employee welfare programmes

4. Helps to maintain continual improvement.

5. Bonus and incentives.





6. Enhancement of employee/employer relations.

14. RECOMMENDATIONS

1. Only items required for recent production requirement be available on the shop floor, no

unnecessary items, materials, components etc.

2. Gangways must free from obstrucles.

3. Clear identification of machines as critical.

4. The noise zone should be categorized.

5. Sign boards are to be provided inside the site. The speed limit should be 15-20kmph

inside the factory and in the plant it should be 2-5kmph.

6. The damaged welding cables should not be used for long time and it should be replaced

frequently and earth cable should be properly clamped to the work piece and near to the

welding spot.7. Additional responsibilities of safety officer should be removed.

8. Wire rope shall be taken out of services when in any length of 8 times the diameter; the

total number of visible broken wires exceeds 10% of the total wire construction of the wire

rope. (A 6x7 constructed 1 inch diameter rope has 42 wires. 10% of 42 = 4 wires. 1 inch

diameter X 8 = 8 inches. Thus if the wire rope has 4 visible wire broken in any 8 inch

section, it must be replaced.)

9. Regularly lubricate the Wire ropes.





10. All openings in floors and other similar areas are to be covered in a manner that prevent

falls. .

11. Safe access to reach platform must be provided.

12. Provide a separate area for welding.

13. Fire extinguishers availability near welding and cutting operations.

14. Flame arrestors provided on gas cylinders

15. Acetylene and Oxygen hoses non-inter changeable, easily identified and inspected daily.

16. Cylinders must be kept erect during gas cutting operation.

17. Proper eye protection and protective apparel must be worn during all welding/gas cutting

operations.

18. Provide inter-locking guard for ARBOG CNC machine.

15. CONCLUSION

The need to improve working conditions is a collective concern, prompted by both

humanitarian and economic considerations. Creating more jobs and of better quality is one

of the main objectives of the social policy which in turn creates chances for industrial

accidents affecting the productivity and profitability of an organization. A safe and healthy

working environment is thus an essential element for accident prevention. Accident

prevention can only be attained through safety. It represents control of man performance,

machine performance and physical environment. Organisations must strive at to

institutionalize accident prevention programs in their respective units on a scientific

footing ,keeping liaison between their business interest and employees safety and welfare

thus we can conclude that safety plays a vital role in the productivity of the company which

in turn the profitability.





16. BIBLIOGRAPHY

• Safety management in industries by Dr. S. A. Pillai.

• www.bhel.com .

• Journals of National Safety Council.

• Industrial Engineering and Management by O.P. Khanna.• Indian Factories Act 1948.


http://www.bhel.com/

http://www.bhel.com/

jithu thampi

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