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Safety & Health aspects in Hazardous Process Industry

- K. A. Thariq Muhamed Salim

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Hazardous Process : section 2 (c b) - Any process or activity in relation

to an industry specified in the First Schedule where unless special care is taken , the raw materials used therein or the intermediate / finished products, bye-products, wastes or effluents thereof, would –

cause material impairment to the health of the persons engaged in, or

result in the pollution of general environment.

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The First Schedule List of industries involving hazardous processes1. Ferrous metallurgical industries2. Non-ferrous metallurgical industries3. Foundries (ferrous & non-ferrous)4. Coal (including coke) industries5. Power generating industries6. Pulp and paper (including paper products) industries7. Fertilizer industries8. Cement industries9. Petroleum industries10. Petrochemical industries11. Drugs and pharmaceutical industries12. Fermentation industries (Distilleries & Breweries) ------contd.

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13.Rubber (synthetic) industries14. Paints & pigments industries15. Leather tanning industries16.Electro plating industries17.Chemical industries -coke oven by-products 7 coal tar distillation products -industrial gases -industrial carbon -alkalis & acids -chromates & di chromates -lead & its compounds -electro chemicals (metallic sodium, potassium & magnesium,

chlorates, per chlorates & peroxides) -electro thermal produces (artificial abrasive, calcium carbide) -------

contd.

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-nitrogenous compounds (cyanides, cyanamides etc.,) -phosphorous & its compounds -Halogens & halogenated compounds18.Insecticides, Fungicides, Herbicides & pesticides industries19.Synthetic resins & plastics20.Man-made fibre ( cellulosic & non-cellulosic) industry21.Manufacture & repair of electric accumulators22. Glass & ceramics23. Grinding or glazing of metals24.Manufacture, handling & processing of asbestos & its

products25.Extraction of oils & fats from vegetable & animal sources26.Manufacture & operations involving Carbon di sulfide28. Dyes & dyestuff including their intermediates29. Highly flammable liquids and gases.

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Section 7A. General duties of the occupier :-(1) Every occupier shall ensure, so far as is reasonably

practicable, the health, safety and welfare of all workers while they are at work in the factory.

(2) Without prejudice to the generality of the provisions of sub-section (1), the matters to which such duty extends, shall include-

(a) the provision and maintenance of plant and systems of work in the factory that are safe and without risks to health;

(b) the arrangement in the factory for ensuring safety and absence of risks to health in connection with the use, handling, storage and transport of articles and substances;

(c) the provision of such information, instruction, training and supervisions as are necessary to ensure

health & safety of all workers at work;

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(d) the maintenance of all work places in the factory in a condition that is safe & without risks to health and the provision and maintenance of such means of access to, and egress from such place as are safe and without such risks;

(e) the provision, maintenance or monitoring of such working environment in the factory for the workers that is safe, without risks to health and adequate as regards facilities and arrangements for their welfare at work.

(3) Except in such cases as may be prescribed, every occupier shall prepare, and, as often as may be appropriate, revise, a written statement of his general policy with respect to the health and safety of the workers at work and the organization and arrangements for the time being in force for carrying out that policy, and to bring the statement and any revision thereof to the notice of all the workers in such manner as may be prescribed.

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Section 104A. Onus of proving limits of what is practicable, etc : -

In any proceeding for an offence for the contravention of any provision of this Act or rules made there under consisting of a failure to comply with a duty or requirement to do something, it shall be for the person who is alleged to have failed to comply with such duty or requirement, to prove that it was not reasonably practicable or as the case may be, all practicable measures were taken to satisfy the duty or requirement.

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Safety Policy : Section 7A(3) & section 41-B(2) require preparation of a written statement of Policy in respect of Health and Safety of Workers at work, by the management of factories meeting the following criteria:

1. factories covered under section 2(m)(i) of the Factories Act & employing above 50

workers, 2. factories covered under section 2(m)(ii) &

employing more than 100 workers, 3. factories covered under section 87, 4. factories covered under section 2(c b)

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Section 16. Overcrowding:-(1) No room in any factory shall be overcrowded to an

extent injurious to the health of the workers employed therein.

(2) In every workroom of a factory in existence on the date of commencement of this Act at least 9.9 cubic metre of space for every worker shall be provided;

and of a factory built after the commencement of this Act at least 14.2 cubic metre of space for every worker shall be provided;

no account shall be taken of any space which is more than 4.2 metre above the level of the floor of the room.

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Ventilation :-

Ventilation opening in a workroom below the eaves, shall be of an aggregate area of not less than 15% of the floor area.

Amount of fresh air supplied in a workroom by mechanical means of ventilation in an hour shall be at least 6 times the cubic capacity of the workroom. It shall be evenly distributed throughout the workroom without dead air pockets.

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Precautions against dangerous fumes, gases etc. : (Section 36)

No person shall be required/ allowed to enter any chamber, tank, vat, pit or other confined space in which any dangerous gas, fume or vapour is likely to be present;

He can be permitted to enter such confined space, only after

(i) removing such gas, fume or vapour and (ii) obtaining a certificate from a competent person that the space is free of such fume, gas or vapour based on a test;

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Or else, such person shall wear suitable breathing apparatus and a safety belt which shall be securely attached to a rope, the free end of which is held by another person outside the confined space.

Precautions in the use of portable electric light : (section 36A)

No portable electric light or any other electric appliance of voltage exceeding 24 volts, shall be permitted for use inside any confined space unless adequate safety devices are provided;

If any flammable gas, fume or dust is likely to be present inside such confined space, no lamp or light other than that of flame-proof construction shall be permitted to be used therein.

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Electrical lamps shall be flame-proof conforming to IS: 2206

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FLP motors & electrical fitting are hermetically sealed to prevent spark if any , from coming in contact with external flammable /explosive surrounding. Use FLP motors &electrical fittings in places where highly flammable liquids/ gases are handled /stored.

21Flame proof tube lights

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Electrical lamps shall be flame-proof conforming to IS: 2206

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Division 2 or Zone 2 area: In this zone, explosive gas atmosphere would only be present under abnormal conditions (most often due to explosive gas leaks under abnormal conditions). As a general guide of quantifying the explosive gas atmosphere, it should only be present under 10 hours/year.

Division 1 or Zone 1 area : Gas, vapor or mist (explosive gas atmosphere) will be present/ expected to be present for long time under normal running. As a guide, this can be defined as 10–1000 hours/year.

Zone 0 area : Gas or vapor (explosive gas atmosphere) is present all the time; e. g., vapor space above the liquid in the top of a tank or drum. The ANSI/NEC classification method considers this environment a Division 1 area. As a guide, this can be quantified as over 1000 hours/year.

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Indian Standard IS 5572 Hazardous area is an area in which an explosive

gas atmosphere is present or likely to be present, in quantities such as to require special precautions for the construction, installation and use of electrical apparatus.

Rule 106 of Petroleum Rules specifies about fixed electrical apparatus.

i) No electrical apparatus shall be allowed in a Division “0” area; however, the use of an ‘intrinsically safe’ apparatus is permitted.

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ii) All electrical apparatus installed or used in a Division 1 area shall be a flame-proof or intrinsically safe apparatus,

iii) All electrical apparatus installed or used in a Division 2 area shall be either a ‘non-sparking’ apparatus or an apparatus permitted for the Division 1 area.

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Selection of electrical equipment in hazardous areas Type Ex Code Description of equipment Location Use

Flame-proof

‘d’ Equipment can stand explosion from within, without transmitting flame to outside, has flameproof gap(max 0.006" propane /ethylene, 0.004" acetylene /hydrogen).

Zone 1 if gas group & temp. class correct

Motors, lighting, junction boxes,

Increased Safety

‘e’ Equipment is very robust and components are made to a high quality.

Zone 2 or Zone 1

Motors, lighting, junction boxes,

Intrinsically safe

‘I’Any arc or spark in this equipment has insufficient energy (heat) to ignite a vapour.

'ia': Zone 0 &'ib': Zone 1'ic: zone 2

Instrumentn., measure-ment, control

Oil Filled ‘o’ Equipment components are completely covered with a layer of oil.

Zone 2 or Zone 1

Heavy current equipment

Pressurized /purged

‘p’ Equipment is pressurized with a positive pressure - gas can not get in or equipment is purged with a diluting gas such as air - if air is used, it is ducted in from outside the hazardous area.

Zone 1 (px or py) or zone 2 (pz)

Analyzers, motors, control boxes, computers

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Equipment Code Description Suitable for Zones...

Ex ‘ia’ Intrinsic safety 'ia' 0, 1, 2

Ex ‘ib’ Intrinsic safety 'ib' 1,2

Ex ‘ic’ Intrinsic Safety 'ic' 2

Ex ‘d’ Flame-proof protection 1,2

Ex ‘p’ Purge/pressurized protection 1,2

Ex ‘px’ Purge/pressurized protection 'px' 1,2

Ex ‘py’ Purge/pressurized protection 'py' 1,2

Ex ‘pz’ Purge/pressurized protection 'pz' 2

Ex ‘e’ Increased safety 1,2

Ex ‘m’ Encapsulation 1,2

Ex ‘ma’ Encapsulation 0,1,2

Ex ‘mb’ Encapsulation 1.2

Ex ‘o’ Oil immersion 1,2

Ex ‘q’ Sand / powder (quartz) filling 1,2

Ex ‘n’ Type – ‘n’ protection 2

Ex ‘s’ Special protection Normally 1 and 2

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Section 41B. Compulsory disclosure of information by Occupier.-(1) Occupier of a hazardous process factory shall

disclose all information on *Safety & Health hazards due to exposure to or

handling of materials or substances in the manufacture, transportation, storage and other processes and

**the measures taken to overcome such hazards, to the workers employed in the factory, the Chief Inspector, the local authority within whose jurisdiction the factory is situated and the general public in the vicinity.

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(2) Occupier shall, during registration of hazardous process factory,

*lay down a detailed Policy on Health & Safety of the workers employed therein and

**intimate such policy to Chief Inspector and Local Authority and, thereafter, at such intervals as may be prescribed, inform Chief Inspector and Local Authority of any change made in the said Policy.

(3) Information furnished under sub-section (1) shall include accurate information as to the quantity, specifications and other characteristics of wastes and the manner of their disposal.

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(4) Occupier shall, with the approval of Chief Inspector, *draw up an on-site emergency plan and detailed

disaster control measures for his factory and **make known to the workers employed therein and

to the general public living in the vicinity of the factory, the safety measures required to be taken in the event of an accident taking place.

(5) Occupier shall,- if proposes to engage in a hazardous process,

within 30 days before commencement of such process,

inform Chief Inspector of the nature and details of the process in such form and in such manner as

may be prescribed.

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(6) For contravention of sub-section (5), the license issued under section 6 to such factory

shall, notwithstanding any penalty to which the occupier shall be subjected to under the provisions of this Act, be liable for cancellation.

(7) Occupier of hazardous process factory shall, with the previous approval of Chief Inspector,

*lay down measures for handling, usage, transportation and storage of hazardous substances inside factory premises and the disposal of such substances outside factory premises and

**make them known among workers and general public living in the vicinity.

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Section 41C. Specific responsibility of Occupier regarding

Hazardous Processes. Occupier shall-- (a) maintain accurate and up-to-date health

records (medical records) of the workers who are exposed to any chemical, toxic or any other harmful substances which are manufactured, stored, handled or

transported; such records shall be accessible to the

workers;

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(b) appoint persons who possess qualifications and experience in handling hazardous substances and are competent to supervise such handling within the factory and to provide at the work- place all the necessary facilities for protecting workers :

Provided that where any question arises as to

the qualifications and experience of a person so appointed, the decision of the Chief

Inspector shall be final;

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(c) provide for medical examination of every worker--

*before such worker is assigned to a job involving handling of, or working with, a hazardous substance, and

**while continuing in such job, and after

he has ceased to work in such job, at intervals not exceeding twelve months.

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Section 41F. Permissible limits of exposure of chemical and

toxic substances. (1) Maximum permissible threshold limits of

exposure of chemical and toxic substances in manufacturing processes (whether hazardous or otherwise) in any factory shall be of the value indicated in the Second Schedule.

(2) Central Government may, at any time, for giving effect to any scientific proof obtained from specialized institutions or experts in the field, by notification in the Official Gazette, make

suitable changes in the said Schedule.

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The Second Schedule(Section 41 F)

Permissible levels of certain chemical substances in work environment

Substance Acetaldehyde

Permissible limits of exposure

Time weighted average concentration(8 hrs)

Short term exposure limit(15 minutes)

ppm mg/cu m ppm mg/cu m

100 180 150 270

Acetic Acid 10 25 15 37

Acetone 750 1780 1000 2375

Acrolein 0.1 0.25 0.3 0.8

Acrylo nitrile-skin (S.C.) 2 4.5 -- --

Aldrin-skin -- 0.25 -- --

Allyl Chloride 1 3 2 6

Ammonia 25 18 35 27

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Aniline-skin 2 10 -- --

Anisidine (o,p- isomers)-skin 0.1 0.5 -- --

Arsenic & soluble compounds (as As) -- 0.2 -- --

Benzene (H.C.) 0.5 1.5 2.5 7.5

Beryllium & compounds as Be (S.C.) -- 0.002 -- --

Boron Tri fluoride - C 1 3 -- --

Bromine 0.1 0.7 0.3 2

Butane 800 1900 -- --

2-Butanone (Methyl Ethyl Ketone - MEK) 200 590 300 885

n-Butyl acetate 150 710 200 950

n-Butyl alcohol Skin - C 50 150 -- --

sec/tert. Butyl acetate 200 950 -- --

Butyl Mercaptan 0.5 1.5 -- --

Cadmium dust and salts (as Cd) -- 0.05 -- --

Calcium oxide -- 2 -- --

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Carbaryl (Sevin) -- 5 -- --

Carbofuran (Furadan) -- 0.1 -- --

Carbon disulphide –Skin 10 30 -- --

Carbon  Monoxide 50 55 400 440

Carbon Tetrachloride Skin (S.C.) 5 30 -- --

Chlordane –Skin -- 0.5 -- 2

Chlorine 1 3 3 9Chloro benzene  (Mono chloro benzene) 75 350 -- --Chloroform (S.C.) 10 50 -- --

bis (Chloro methyl) ether (H.C.) 0.001 0.005 -- --

Chromic acid and chromates (as Cr) (Water soluble) -- 0.05 -- --

Chrombus salts (as Cr) -- 0.5 -- --

Copper Fume -- 0.2 -- --

Cotton Dust, raw -- 0.2 -- --

Cresol, all isomers-Skin 5 22 -- --

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Cyanide (as CN)-Skin -- 5 -- --

Cyanogen 10 20 -- --

DDT (di chloro diphenyl trichloroethane) -- 1 -- --Demeton-Skin 0.01 0.1 -- --

Diazinon-Skin -- 0.1 -- --

Di butyl phthalate -- 5 -- --

Dichlorvos (DDVP)-Skin 0.1 1 -- --

Dieldrin-Skin 0.25 -- -- --

Dinitrobenzene (all isomers)-Skin 0.15 1 -- --Di nitro toluene-Skin -- 1.5 -- --

Di phenyl (Biphenyl) 0.2 1.5 -- --

Endo sulfan (Thio dan)-Skin -- 0.1 -- --

Endrin-Skin -- 0.1 -- --

Ethyl acetate 400 1,400 -- --

Ethyl alcohol 1,000 1,900 -- --

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Ethylamine 10 18 -- --

Fluoride (as F) -- 2.5 -- --

Fluorine 1 2 2 4

Formaldehyde (S.C.) 1.0 1.5 2 3

Formic acid 5 9 -- --

Gasoline 300 900 500 1,500

Hydrazine-skin (S.C.) 0.1 0.1 -- --

Hydrogen chloride-C 5 7 -- --

Hydrogen cyanide-Skin-C 10 10 -- --

Hydrogen fluoride(as F)-C 3 2.5 -- --

Hydrogen Sulphide 10 14 15 21

Iodine-C 0.1 1 -- --

Iron Oxide Fume (Fe2 O3 (as Fe) -- 5 -- --

Iso amyl acetate 100 525 -- --

Iso amyl Alcohol 100 360 125 450

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Isobutyl alcohol 50 150 -- --

Lead, inorg., dusts and fumes (as Pb) -- 0.15 -- --

Lindane-Skin -- 0.5 -- --

Malathion-Skin -- 10 -- --

Manganese dust and compounds (as Mn)-C -- 5 -- --

Manganese fume (as Mn) -- 1 -- 0.03

Mercury (as Hg)-skin alkyl compounds --  0.1  --  0.3 Mercury-skin All forms except alkyl  vapour -- 0.05 -- --

Mercury-skin Aryl & inorganic  compounds -- 0.1 -- --

Methyl alcohol (Methanol)- Skin 200 260 250 310

Methyl cello solve (2-Methoxyethanol)-Skin 5 16 -- --

Methyl isobutyl ketone 50 205 75 300

Methyl iso cyanate-Skin 0.02 0.05 -- --

Naphthalene 10 50 15 75

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Nickel carbonyl (as Ni) 0.05 0.35 -- --

Nitric acid 2 5 4 10

Nitric oxide 25 30 -- --

Nitrobenzene-Skin 1 5 -- --

Nitrogen dioxide 3 6 5 10

Oil mist mineral -- 5 -- 10

Ozone 0.1 0.2 0.3 0.6

Parathion-Skin -- 0.1 -- --

Phenol-Skin 5 19 -- --

Phorate (Thimet)-Skin-- -- 0.05 -- 0.2

Phosgene (Carbonyl chloride) 0.1 0.4 -- --

Phosphine 0.3 0.4 1 1

Phosphoric acid (yellow) -- 1 -- 3

Phosphorus (yellow) -- 0.1 -- --

Phosphorus penta chloride 0.1 1 -- --

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Phosphorus tri chloride 0.2 1.5 0.5 3

Picric acid-Skin -- 0.1 -- 0.3

Pyridine 5 15 -- --

Silane (Silicon tetra hydride) 5 7 -- --

Sodium hydroxide C -- 2 -- --

Styrene, monomer (Phenyl ethylene) 50 215 100 425

Sulphur dioxide 2 5 5 10

Sulphur hexafluoride 1,000 6,000 -- --

Sulphuric Acid -- 1 -- --

Tetraethyl lead (as Pb)-Skin -- 0.1 -- --

Toluene (Toluol) 100 375 150 560

O-Toluidine-Skin (S.C) 2 9 -- --

Tri butyl Phosphate 0.2 2.5 -- --

Trichloroethylene 50 270 200 1,080

Uranium, natural (as U) -- 0.2 -- 0.6

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Vinyl chloride (H.C.) 5 10 -- --

Welding fumes -- 5 -- --

Xylene (o-,m-, p-isomers ) 100 435 150 655

Zinc oxide        

(i) Fume -- 5.0 -- 10

(ii)Dust (Total dust) -- 10.00 -- --

Zirconium compounds (as Zr) -- 5 -- 10

Molecular weight mg/m3 = ---------------------------------- x ppm 24.45C : denotes “ceiling limit”.

Skin : denotes potential contribution to the overall exposure by the cutaneous route including mucous membranes and eye.

S.C. : denotes “suspected human carcinogen”.

H.C. : denotes “confirmed human carcinogen”.

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Substance Permissible time-weighted average concentration (TWA) (8 hours)-------------------------------------------------------------------------------------------------------------------------------------------------------------------

Silica, Si O2

(a) Crystalline (i) Quartz 10600 (1) In terms of dust count => ------------------------------------- mppcm (Million particles per cubic % Quartz + 10 meter of air ) 10 (2) In terms of respirable dust => ---------------------------- ---------- mg/m3

% respirable Quartz + 2 30 (3) In terms of total dust => -------------------------------------- mg/m3 % Quartz + 3 (ii) Cristobalite : Half the limits given against quartz (iii) Tridymite : Half the limits given against quartz (iv) Silica, fused : Same limits as for quartz (v) Tripoli : Same limit as in formula in item (2) given against quartz

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(b) Amorphous Silicates : -------- 10 mg/m3, Total Dust [Asbestos (H.C.) (a) Amosite ……………0.5 fibre/cc*** (b) Chrystolite ………………1.0 fibre/cc*** (c) Crocidolite ………………0.2 fibre/cc***] *** (i) For fibres greater than 5 micron in length and less

than 5 micron in breadth with length to breadth ratio equal to or greater than 3:1.

(ii) As determined by the membrane filter method at 400-450 x magnification (4mm objective) phase contrast illumination.

Portland cement : ------------10 mg/m3, Total dust containing less than 1% quartz.

Coal Dust : --------------2mg/m3, respirable dust fraction

containing less than 5% quartz. __________________________________

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Section 41H. Right of workers to warn about imminent danger. (1) Where the workers of a hazardous process

factory have reasonable apprehension that there is a likelihood of imminent danger to their lives or health due to any accident,

they may bring it to the notice of Occupier, Manager or any other person who is in charge of factory or the process concerned,

directly or through their representatives in the Safety Committee and simultaneously bring the same to the notice of the Inspector of Factories.

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(2) It shall be the duty of Occupier, Manager or the person in charge of the factory or process to take immediate remedial action if he is

satisfied about the existence of such imminent danger and send a report forthwith of the action taken to the Inspector.

(3) If the Occupier, Manager or person in charge referred to in sub-section (2) is not satisfied

about the existence of any imminent danger as apprehended by the workers, he shall,

nevertheless, refer the matter forthwith to the Inspector whose decision on the question of the existence of such imminent danger shall be final.

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Section 111A. Right of workers, etc :-Every worker shall have the right to -(i) obtain from the occupier, information relating to

worker's health and safety at work,(ii) get trained within the factory wherever possible,

or, to get himself sponsored by the occupier for getting trained at a training centre or institute, duly approved by the Chief Inspector, where training is imparted for workers' health and safety at work,

(iii) represent to the Inspector directly or through his representative in the matter of inadequate provision for protection of his health or safety in the factory.

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Section 41G. Workers' participation in safety management. (1) Occupier of a ‘hazardous process’ factory or of a factory where hazardous substances are used or handled, shall constitute a Safety Committee consisting of equal number of representatives of workers and management *to promote co-operation between workers and management in maintaining proper safety and health at work and **to review periodically the measures taken in that behalf: Provided State Government may, by order in writing and for reasons to be recorded, exempt the occupier of any factory or class of factories from setting up such Committee. (2) Composition of Safety Committee, the tenure of office of its members and their rights and duties shall be such as may be prescribed.

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SAFETY COMMITTEE : (rule 61-M of T. N. Factories Rules)A safety committee shall be constituted in every factory wherein 250 or more workers are employed, or any dangerous operation defined under Section 87 of the

Act is carried on, or hazardous process defined under Section 2(c b) is carried

on.Equal no. of management’s representatives as well as

workers’ representatives (who shall be elected by the workers) shall constitute the Safety Committee .

Tenure of office of the members shall be three years.A senior official shall be the Chairman and a Safety officer

or Factory Medical Officer shall be the secretary.Safety Committee shall meet at least once in 3 months.

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FUNCTIONS & DUTIES OF THE SAFETY COMMITTEE :- Safety Committee shall Assist and co-operate with the management in achieving the aims

and objectives of the company’s Health and Safety policy. Arrive at a practical solution to the Health, Safety and Environmental

problems. Create Safety Awareness among the workers. Discuss the reports on Safety, Environmental and Health Surveys,

Safety Audits, Emergency and Disaster Management Plans. Carry out Health and Safety Surveys and identify causes of accidents. Undertake educational, training and promotional activities. Look into any complaint made on the likelihood of an imminent

danger to the Safety and Health of the workers and suggest corrective measures.

Review the implementation of recommendations made by it.

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Appointment of Safety Officers:- Every occupier, when required by the State Government by notification in the Official Gazette issued under sub-section (1) of section 40-B of the Factories Act, 1948 shall within a period of six months from the date of publication of that notification, shall appoint the requisite number of Safety Officers, as specified in that notification.

Provided that Chief Inspector of Factories may, on an application in writing made by an occupier, extend the period further by a maximum of six months for making such appointment.

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Tamil Nadu Safety Officers(Duties, Qualifications & Conditions of Service) Rules, 2005

Qualifications and Experience:- For appointment as Safety Officer, a person shall (a) possess recognized degree in any branch of

Engineering / Technology & have experience of working in a factory as Supervisor at least for two years, or

he shall be a Member or an Associate Member of the Institution of Engineers (India) & have

experience of working in a factory as Supervisor for five years, or

he shall possess recognized degree in Physics / Chemistry & have five years work experience in a factory as supervisor, or

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he shall possess recognized diploma in Engineering or Technology & have work experience in a factory as Supervisor for 5 years;

(b) possess a degree or diploma in Industrial Safety as recognized by the State Government in this behalf; and

(c) have adequate knowledge of Tamil language. However, a person having recognized degree in

Engineering / Technology and an experience of five years in a Central or State Government department which deals with administration of the Factories Act, or the Indian Dock Labourers Act, 1934, or

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having recognized degree in Engineering / Technology and an experience of five years, full time in training, education, consultancy or research in the field of accident prevention in industry or in any institution, shall be eligible for appointment as a Safety Officer:

Provided that State Government may, subject to such conditions as they may specify, grant exemption from the requirements of sub-rule (1), excepting clause (c) of sub-rule (1) , if in their opinion that a suitable person possessing the necessary qualifications and experience is not available for such appointment.

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Provided further that the State Government may, subject to such conditions as they may specify, relax all or any of the above said qualifications excepting clause (c) of sub-rule (1), in favour of any person who has been working as a Safety Officer in any factory.

No person who is directly or indirectly interested in any factory or in any patent or machinery connected with it, shall be appointed as a Safety Officer or shall be allowed to hold such office after he becomes so interested.

Explanation.- For the purposes of this sub-rule, any person holding two percent or more of the shares of a company, owning the factory shall be deemed to be directly or indirectly interested.

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Recruitment of Safety Officer.- (1) To fill up the post of Safety Officer in a factory, the

occupier shall advertise in at least two newspapers having wide circulation in the state, out of which one newspaper shall be in Tamil and other in English;

In the case of Government establishments, Quasi-government establishments and Public undertakings, vacancies in the post of Safety Officers shall be filled up through Government Employment Exchange.

Vacancies in the said establishments shall be advertised in Newspapers, only after obtaining non-availability certificate from Employment Exchange.

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(2) Selection for appointment as Safety Officer shall be made among candidates applied, by a committee constituted by the occupier.

(3) Appointment of Safety Officer, when made, shall be notified by the occupier to Chief Inspector of Factories, giving full details about qualifications, age, pay and allowances, previous experience and other relevant particulars of the officer appointed and the terms and conditions of the service applicable to him.

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Conditions of Service:- (1) Where the number of Safety Officers to be

appointed as required by the notification under section 40- B(1) of the Factories Act , 1948, published in Official Gazette exceeds one, anyone among them shall be designated as Chief Safety Officer and shall have the status higher than that of others.

Chief Safety Officer shall be in overall charge of safety functions and other Safety Officers shall work under his control.

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(2) Chief Safety Officer or Safety Officer in the case of factories where only one Safety Officer is required to be appointed, shall be given the status of a senior executive equivalent to Head of Department; he shall work directly under the control of the Chief Executive of the factory.

All the other Safety Officers shall be given appropriate status to enable them to discharge their functions effectively.

(3) Scale of pay and allowance of Safety Officers including Chief Safety Officer and the conditions of their service shall be the same as those of the other officers of corresponding status in the factory.

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(4) In the case of dismissal or discharge, the concerned Safety Officer has the right to appeal to Chief Inspector of Factories, whose decision thereon shall be final and binding upon the occupier of the factory.

(5) The appeal shall be preferred within thirty days from the date of the receipt of the order of dismissal or discharge by the Safety Officer concerned.

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Duties of Safety Officer:- Safety Officer shall advise and assist factory

management in the fulfillment of its statutory obligations, concerning prevention of occupational injuries and maintaining a safe working environment.

His duties shall include :- (i) to advise the concerned departments in

planning and organizing measures necessary for the effective control of personal injuries;

(ii) to advise on safety aspects in all job studies and to carry out detailed job safety studies of selected jobs;

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(iii) to check and evaluate the effectiveness of action taken or proposed to be taken to prevent personal injuries;

(iv) to advise Purchasing and Stores departments in ensuring high quality as well as availability of Personal Protective Equipment; (v) to advise on matters relating to carrying out of plant safety inspections;

(vi) to conduct plant safety inspections & observe the physical conditions of work, the work practices and procedures followed by workers; he shall advise on measures to be adopted for removing unsafe physical conditions and preventing unsafe actions by workers;

(vii) to render assistance on matters relating to reporting and investigation of industrial accidents and occupational diseases;

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(viii) to investigate all accidents/near-miss incidents; (ix) to render assistance for industrial diseases contracted

and in respect of dangerous occurrences reportable under rule 96 of the Tamil Nadu Factories Rules, 1950;

(x) to assist in the maintenance of such records, relating to accidents, dangerous occurrences and industrial diseases;

(xi) to promote setting up of safety committees and act as its adviser;

(xii) to organize Safety campaigns, competitions, contests and other activities for developing and maintaining workers’ interest in establishing and maintaining safe conditions of work and procedure;

(xiii) to design and conduct suitable training and educational programs for the prevention of personal injuries and for the propagation of safety awareness.

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Facilities to be provided to Safety Officers:- Occupier shall provide each Safety Officer adequate technical and secretarial staff and other facilities, equipment and information for discharging his duties effectively.

Prohibition of performance of other duties:- No Safety Officer shall be required or permitted to do any work which is inconsistent with or detrimental to the performance of duties prescribed in rule 8.

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Section 96A. Penalty for contravention of sections 41B, 41C and 41H:-

(1) For contravention of sections 41B, 41C or 41H or the rules made there under, the management shall be punishable with imprisonment for a term which may extend to seven years and with fine which may extend to two lakh rupees;

in case the contravention continues, with additional fine which may extend to five thousand rupees for every day during which such failure or contravention continues, after the conviction for the first such failure or contravention.

(2) If the failure or contravention referred to in sub-section (1) continues beyond a period of one year after the date of conviction, the offender shall be punishable with imprisonment for a term which may extend to ten years.

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Class Combustibles Hand Appliances

A

Fires in Ordinary combustibles (Wood, Vegetable fibres, rubber, plastics, Paper)

Gas expelled Water and Antifreeze type extinguishers and Water Buckets.

BFires in flammable liquids, paints, grease, solvents and the likes.

Chemical Extinguishers of Carbon dioxide type and Dry Powder type and Sand Buckets.

CFires in Gaseous substances under pressure and liquefied gases.

Chemical Extinguishers of Carbon dioxide and Dry Powder type.

DFires in reactive chemicals, Active metals and the likes.

Special type of Dry Powder, Extinguishers and sand buckets

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For a fire involving the energized electrical equipment, the non-conductivity of the extinguishing media is very important.

Extinguishers expelling Dry Powder or Carbon dioxide (without metal horn) should only be used.

Once the electrical equipment is de-energized, the extinguishers suitable for Class A, B & C, may be used safely.

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For electrical equipment, provide fire extinguishers as under – for rooms containing electrical transformers,

switchgears, motors and/or electrical apparatus only, not less than two 2 Kg Dry Powder or Carbon dioxide type of extinguishers shall be provided within 15 m of the apparatus.

where motors and/or other electrical equipment

are installed in rooms other than those containing such equipment only, one 5 Kg Dry Powder or Carbon dioxide extinguisher shall be installed within 15 m of such equipment. ---contd.

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Also, one 9-litre water/sand bucket shall be provided for every 100 sq. m of the floor area or part thereof and one 9-litre water type extinguisher shall be provided to six buckets or part thereof with a minimum of one extinguisher and two buckets per compartment of the building.

Where Class ‘B’ fire is anticipated in the above-said rooms, Water Buckets and Water Extinguishers can not be used to put out the fire.

Hence Dry Sand Bucket/s, Carbon dioxide extinguisher or Dry Powder extinguisher as specified in the Table below, shall also be included in replacement of water buckets and water extinguishers:

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(For this purpose, the same extinguisher may be deemed to afford protection to all apparatus within 15 m thereof.)

Acceptable replacement

For 1 water bucket

For 2 water buckets

For each 9 litre water type extinguisher

Dry sand 1 bucket 3 buckets ----------

Carbon dioxide extinguisher (IS 2878)

3 kg 9 kg 9 kg

Dry Powder extinguisher (IS 2171)

2 kg 5 kg 5 kg

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Storage, handling & transportation of chemicalsStorage Layout Flammable & toxic substances are the main hazards in bulk storage. They are stored as

a) liquid at atmospheric pressure & temperature, b) liquefied Gas under pressure & atmospheric

temperature, c) liquefied Gas at atmospheric pressure & at

low temperature, d) gas under pressure.

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“What you don’t have, can’t leak; so keep storage to a minimum”.

Storage is built in open, as it’s cheaper & allows dispersion of leaks.

“Ignition of a few tens of kg. of flammable gas inside a building can destroy it; whereas, if the gas is stored out door, several tons are needed to destroy it”.Contour of the ground of storage should not

allow flammable liquid or heavy gas to collect in a depression or to flow down to an area where it may find Ignition source.

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The prevailing wind should be considered as against spread of flammables to ignition source.

Segregate the storage from the process.

A fire or explosion in the process may put at risk the very large inventory in storage.

Storage tanks are arranged in groups with common bund & fire-fighting equipment.

Storage should not be located near the entrance or affect the neighboring factory.

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Inventory of hazardous materials determines the scale of hazard; larger the inventory, greater the potential loss.

For an inventory of hazardous material to explode or to disperse as flammable or toxic vapor cloud, it needs energy.

When it is stored as a liquid above its boiling point at higher pressure and temperature, it contains large quantity of energy ; this causes larger quantity to vaporize by instantaneous flash-off and to disperse if there is a loss of containment.

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On the other hand, when it is stored as refrigerated liquid at atmospheric pressure, it has much less physical energy; hence if containment is lost, it will vaporize to a little extent only.

In this case, energy needed for vaporization has to come from ground and air which is a slow process.

If a “runaway reaction” occurs in a chemical reactor & toxic gas is produced as a by-product, the energy possessed by the gas will be high and hence there will be a severe hazard.

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Employer should ensureChemicals used at work are labeled / marked,Chemical safety data sheets are provided,Assessment of risks arising from use of chemicals at work is conducted,Appropriate safety measures including provision of Personal Protective Equipment, are made to protect workers against the risks identified by “risk assessment”,Adequate & competent supervision of work and work practices is carried out,

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Appropriate and periodic instructions and training are provided to the workers,Stored chemicals are examined periodically; chemicals with expired ‘shelf life’ & damaged/ leaky containers are safely disposed off,A “first in, first out” (fifo) system of keeping stock is adopted,Storage of dangerous chemicals is supervised by a competent, trained person,Workers do not work alone in a storage

area, containing hazardous chemicals,

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Chemical storage area is located far away from process area & other storage areas, Chemical storage area is not located in close proximity of fixed sources of ignition such as boiler house, generator house etc., Compressed gases are stored in the open only if they are adequately protected from weather and direct sunlight, Compressed gas cylinder valve is protected with the cap during transport, Compressed gas cylinder is securely fastened to a rigid structure against falling, while in use,

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Storage of flammable liquids: (rule 61 of TNFR, 1950)Quantity of flammable liquids that can be stored in

any work room, shall be the minimum needed for the process carried on in such room.

Flammable liquids shall be stored in suitable containers with close-fitting covers.

In the case of flammable liquids which have a flash point of 21 degree C or less, not more than 20 litres shall be kept in any work room.

Large quantities of flammable liquids shall be stored in storage tanks, preferably underground and at a distance away from any building as required in Petroleum Rules. -contd.

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Effective steps shall be taken to prevent leakage of flammable liquids into basements, sumps or drains and also to confine any escaping liquid within safe limit.

Cylinders containing compressed gas:Compressed gas cylinders may be stored in open

space if they are protected against excessive variation of temperature, direct sunlight or continuous dampness.

Such cylinders shall never be stored near highly flammable liquids, furnaces or hot processes.

The rooms where such cylinders are stored shall have adequate ventilation.

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Protection against lightning: Protection from lightning shall be provided for - (i) buildings in which explosive materials or highly flammable substances are manufactured, used, handled or stored, (ii) storage vessels containing oils, paints or other

flammable liquids, (iii) buildings, tall chimneys or stacks where flammable gases, fumes or dusts are likely to be present, (iv) sub-stations, outdoor transformers and switch

yards.

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Installation of pipelines:Pipelines, carrying flammable or explosive

substances shall be protected from mechanical damage.

All joints in such pipelines shall be made electrically continuous by ‘bonding’; the resistance value between each such joint shall not exceed 1 ohm.

Such pipelines shall be examined by a responsible person once a week to detect any deterioration or defect; record shall be maintained in respect of the weekly examination and the repairs made.

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Case Study (legal)A factory management filed Criminal Original

Petitions (Nos.24770 to 24775 of 2005) in Madras High Court, seeking to quash prosecution proceedings pending against him in Chief Judicial Magistrate’s Court for offences punishable under Section 92 of the Factories Act.

Factories Inspector inspected petitioner’s factory on 29.09.2000 and filed complaints against the petitioner for several violations punishable under Section 92 of the Act.

Even though complaints were filed on 20.12.2000, cognizance was taken by Chief Judicial Magistrate only in 2005.

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Offences under Section 92 of the Act are punishable, apart from fine, with imprisonment for a term which may extend to 2 years.

Though complaints were filed on 20.12.2000, as the cognizance was taken only in the year , this clearly stands barred under Section 468 of Criminal Procedure Code (Cr PC).

Petitioner’s counsel submitted that on this sole ground, proceedings before Chief Judicial Magistrate ought to be quashed.

As the alleged offences attract a maximum punishment of 2 years imprisonment, the period of limitation within which a Court could take cognizance would be 3 years as per Section 468(2)(c) of Cr PC.

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Honourable Apex Court in Krishnapillai v. T.A.Rajendran had drawn the distinction between the date of filing the complaint and the factum of taking cognizance thereof .

Constitution Bench judgment clearly indicates that filing of a complaint in court is not taking cognizance.

‘Taking cognizance’ means that the court should judicially determine whether a case is made out for issuing process, by examining the complainant on oath and examining the witnesses present, if any.

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Section 473 of Cr PC does provide that Court may take cognizance of an offence after the expiry of the period of limitation, if it is satisfied on the facts and circumstances of the case that the delay has been properly explained or that it is necessary so to do in the interests of justice.

As the Chief Judicial Magistrate had not done so, the bar to take cognizance envisaged under Section 468 Cr PC directly applies.

Madras High Court allowed the Criminal Original Petitions and quashed the criminal proceedings on the file of Chief Judicial Magistrate on 16.02.2010.

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Static Electricity is the build-up of electric charges on the surface of objects.

Static charges remain on the object until they either bleed off to ground or are quickly neutralized by a discharge.

Discharge of static electricity can cause severe fire hazards in industries, handling flammable substances where a small electric spark may ignite flammable mixtures.

Static Electricity

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Kerosene has electrical conductivity ranging from less than 1 pS/m to 20 pS/m.

(pS Pico Siemens, unit for electrical conductivity). De-ionized water has a very high electrical conductivity

in the range of 10,000,000 pS/m. Hence the electrostatic hazards in kerosene are very

high.Ability of a fluid to retain its static electricity is inversely

proportional to its electrical conductivity; higher its electrical conductivity, the lower its ability to retain static charge.

Fluids that have low electrical conductivity (less than 50 pico siemens per metre) accumulate electrostatic charges.

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In Petrochemical industry, 50 pS/m is the recommended minimum value of electrical conductivity for adequate removal of electrostatic charges from a fluid.In fluids having electrical conductivity greater than 50 pS/m, accumulation of electrostatic charges is not significant.Electrostatic charge generation increases at higher fluid velocities and larger pipe diameters, becoming quite significant in pipes of diameter 8 inches (200 mm) & above.Static charge generation are best controlled by

limiting the fluid velocity.

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Bonding and Earthing (Grounding) are the usual ways to prevent the build-up of electrostatic charges.All machinery and plant in flammable atmosphere, particularly pipelines transmitting flammable liquid, on which static charge may accumulate,

shall be effectively ‘bonded & earthed’.Mobile Tankers and Wagons, transporting

flammable liquids shall be ‘bonded & earthed’ during filling and decanting; such ‘bonding & earthing’ shall be ensured before commencing the filling or unloading operation.

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*Case Study- FIRE due to Static Electricity

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• An operator placed the fill nozzle in the fill-opening on top of the tote and suspended a steel weight on the nozzle to keep it in place as the pressure from the liquid flowing through the nozzle can cause it to dislodge.

• After opening the valve to begin the filling process, he went to do other work.

• Suddenly, he heard a popping noise and found the tote engulfed in flame and the fill nozzle laying on the floor discharging Ethyl Acetate.

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Causes for fire: Due to splash- filling of Ethyl Acetate which is

a highly flammable liquid, an ignitable vapour-air mixture formed at the tote filling opening.

A static discharge (spark) between the tote body and the metal component on the fill nozzle/hose assembly, which included the steel weight could have caused the ignition.

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Correct method of ‘Bonding & Earthing’

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** Case Study – Furnace Explosion

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A Hydro carbon was getting heated in a Furnace as shown in the picture above.

‘Low flow’ Trip & Alarm and ‘Pressure relief valve’ were fitted on the hydro carbon pipeline upstream of the Furnace.

In the course of hydro carbon heating, a choke developed on the pipeline after the furnace.

So, the Relief Valve popped off and took most of the hydro Carbon flow.

As a result, hydro carbon flow through furnace tubes fell to such a low level that the tubes got overheated and burst.

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Remedial measures :-1. As the Relief Valve was fitted after the ‘low flow

alarm & trip’ and the flow was regular up to the Relief Valve, the ‘low flow alarm’ arrangement did not trip.

2. The Pressure Relief Valve should be fitted after the Furnace, so that even when the Relief Valve pops off, it will not affect the hydro carbon tubes inside the Furnace.

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An operator was asked to maintain the temperature of a reactor at 60 deg C.The Control Panel resembled the diagram below:

3. Case Study - Lack of concentration of Faulty Design

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The “set points” are established by percentage of the temperature ranging from 0 deg C to 200 deg C.

The operator simply set the instrument to 60 which corresponded to reactor temperature of 120 deg C.

The result was a “runaway reaction”, an over-pressurized reactor, liquid release and injured workers.

Error-1: There is a confusing design of the control panel as regards the temperature and the percentage.

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Error- 2 : The operator simply did not pay attention to what he was doing; the lack of concentration could have

resulted in much more serious consequences. Error- 3 Apparently there was no temperature/ pressure safety device installed on the unit. ----------------------------

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REVERSE FLOW THROUGH PUMP

vent

tank atatm.pressure NRV

tank at 15 psig

Reverse Flow through Pump

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Reverse Flow through Pump If a pump trips or is shut down and not isolated, it can be driven

backward by the pressure in the delivery line resulting in its damage.

Non-return valves are usually fitted to prevent backflow but they sometimes fail.

In one plant, light oil was pumped at intervals from a tank which was at atmospheric pressure to another tank which was at 15 psig.

The practice was not to close the Isolation Valve but to rely on the Non-Return Valve (NRV).

One day as the NRV failed, oil flowed backward and the atmospheric tank overflowed.

Hence the safe practice is to ensure positive isolation by closing the Isolation Valve.

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A worker was asked to paint white lines down the middle of road.

The first day, he did 15 kilo metre. The 2nd day, he did 10 kilo metre. The 3rd day, he did just a few hundred metre. His Foreman became furious. “Why are you doing less and less each day?,” he

asked. “Because each day, I get further away from the tin of

paint,” the worker replied. -courtesy: Reader’s Digest

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