Ibrahim Fibres limited Training & Safety Department SAFETY TRAINING COURSE Contents 1. Concept of safety &its Importance. 2. General Safety Rules 3. Accident Prevention. 4. Accident Reporting & Investigation 5. Work permit system 6. Compressed air safely 7. Using nitrogen safely 8. Fire safety 8.1 Components of Fire 8.2 Reactions & Definitions 8.3 Fire Classification 8.4 Fire Extinguishing methods 8.5 Fire Extinguishers; Type & their Use. 8.6 Fire Fighting with water 8.7 Fire Fighting drill Ibrahim Fibres Limited Training & Safety Department PERSONNEL SAFETY AND PLANT PROTECTION Concept of safety and its Importance Basic objectives of any industrial organization are Smooth and safe production Efficient and cost effective maintenance Quality - not only in product but also in every aspect of Plant actives. But All activities carried out at Plant must be done keeping in view. - Personnel Protection Process Protection Equipment Protection Environment Protection As Apart from benefits, every activity, process and task executed at Plant may have some - Injury Potential Accident hazard Some sort of risk And safety Identifies all hazards and risk of injuries, fire and damges suggests ways and means to control and prevent these hazards. Therefore contributing towards avoidance of costs on treatment of injuries damages to process equipment and enhancement of employee moral. A job done safely is a job well done. Ibrahim Fibres Limited Training & Safety Department All chemicals (including contaminated water) should be treated as hazardous. Know the Hazardous effect and the precautions and measures to control them. You must know what to do in case of Chemicals coming in contact with your eyes Chemicals coming in contact with your skin Chemicals ingestion Chemical / vapor inhalation You must know which chemicals are Explosive Corrosive Toxic Combustible Irritating That can cause chemical burns You should know what to do in case of following emergency situation Fire Explosion Fumes Emission Spillage Injury accident Equipment Damage Power Failure Natural Disasters Ibrahim Fibres Limited Training & Safety Department GENERAL CAUSES OF ACCIDENTS Lack of knowledge Lack of skill Starting work without prior information of work hazards Poor housekeeping habits Unsafe electrical safety measure Working on chemicals without knowing their hazardous effects Ignoring instructions in-charges Taking shortcuts and displaying overconfidence Anger, worry and frustrations Use of improper tools Proper tools but used non-safely Poor communication skills and habits Bad attitude towards safety Improper/loose clothing Keeping long hair and working near rotating equipment Wearing jewelry items and working near rotating machinery Ignoring warning/caution/danger signs Lack of proper training to the staff Working on any equipment/process etc. without authorization Horseplay/practical jokes at plant BASIC ACCIDENT PREVENTIONPRINCIPLES - Identify and know the hazard associated with every activity Adopt the specified safety measures for the concerned activity Know the hazards of chemical you are handling Know the protective measures for the chemical being handled No maintenance work should be done in the operational area without work permit Maintain good standards of housekeeping Report all accidents/injuries/near-miss accidents to your Incharge immediately Only the authorised personnel to work on electrical equipment/cables etc. Obey traffic rules applicable to the plant Powered trucks operation safety rules to be followed. Use of drugs/intoxicants is to be strictly avoided Do not run at the plant except in case of emergency All stairways, aisles and exit routes must be kept unobstructed. Ensure all guards are in place on all rotating equipment except where it cannot be installed due to operational constraints Maintain a sense of co-operation and cordial atmosphere Ibrahim Fibres Limited Training & Safety Department ACCIDENT REPORTING AND INVESTIGATION All injury accidents, near miss occurrences, unsafe act, unsafe conditions, equipment/property damaging accidents and fire incidents must be reported. Why reporting of above mentioned incidents are necessary To immediate start investigations of the incidents to gather all facts and information leading to the incident to visit the scene of incident as soon as possible to know technical details involved in the particular activity to take pictures. Draw sketches if needed to interview the individual/s involved in the incident to interview the witnesses to determine the apparent and root causes of the accident to make recommendations to prevent similar recurrence in future to make an action plan for implementing the recommendations REMEMBER All accidents are preventable Behind every accident, there are definite causes Think what you can do to prevent yourself from being injured and protecting the people working around you. Safety is an attitude. If the attitude towards safety is good a person can have safe working habits. Ibrahim Fibres Limited Training & Safety Department UNSAFE COMPRESSED AIR SAFELY 1. Avoid using compressed air for any type of cleaning work unless necessary as a last resort. If it is used, the pressure of air should not be more than 30 PSIG. 2. Examine all connections before an air hose is operated. 3. Do not kink (bend) the hose to stop the air flow. Always close the air at control vale. 4. Check air hose to ensure it is in good condition. 5. Keep air hose out of aisleways. Tripping hazard will also be taken care of. 6. Never point a compressed air hose at any part of your body or at another person. 7. While using compressed air, use eye protective devices. USING NITROGEN GAS SAFELY 1. Inhalation in high concentration may cause asphyxiation. The effected person may feel loss of mobility and can become unconscious. He may not feel any asphyxuation 2. Nitrogen is sometimes called silent killer. It is used very extensively in polyester plant. 3. The effected person should be kept warm and restful. 4. In case of accidental release, evacuate the area. 5. When emergency is over, oxygen %age test will be required for re-entering the effected area. 6. Non flammable but exposure to fire may cause rupture to containers. 7. All containers should be kept below 50 0C in a well ventilated area. Ibrahim Fibres Limited Training & Safety Department BASIC FIRE PREVENTION MEASURES Following the smoking restriction rules. All hot jobs should be done using a hot work permit. Use only approved electrical accessories. Use only approved explosion proof accessories in the hazardous areas. Know which chemicals are flammable and combustible in nature. Adopt preventive measures. Do not store reactive and oxidising chemicals toghether. Do not store flammable/combustible materials near hot surfaces or near hot work operations. Lubrication schedules must be followed properly. Immediately report any chemical/gas/vapour leakage to your supervisor. All waste stationary, oily rags or wooden pieces should be put in waste bins. Check all static charge dissipation accessories to prevent fires due to static discharges particularly in hazardous areas. Use protective blankets/GI sheets during welding or cutting operations. Oxygen and Acetylene cylinders must be stored separately. Welding equipment must be inspected by qualified electrical personnel before use at agreed schedule. Read MSDS available at plant and know the flash points and other flammability data of the chemicals used at site (to know the fire potential). Hydrogen gas is highly inflammable, odourless and its flame is invisible in daylight. Know the location of all fire fighting equipment at site and how to use them. Report any defect in electrical cabling /equipment to your area Incharge. Report any sign of charring/smoke/spark/ flame etc. to your area Incharge. Keep all electrical panel doors closed unless required to be open necessarily. Ibrahim Fibres Limited Training Safety Department DEFINITIONS ACCIDENT An accident is an unplanned occurrence which causes or might have caused injury to personnel or damage to plant equipment, property, material or environment or both personnel and other described items. CATEGORIES OF ACCIDENTS FATAL ACCIDENT A case of death regardless of time between injury and death or length of illness. LOST TIME ACCIDENT A case other than fatality in which the effected employee is unable to report for duty for two consecutive days after the accident (48 hrs) or several days thereafter. NEAR MISS OCCURRENCE An incident which did not cause an injury or both the injury and the plant equipment/property damage but had a distinct potential to do so. In other words, such an incident did not result in an injury but resulted in equipment/property damage at the least, but there were chances of a minor or major injury e.g. falling of a metallic piece from a elevated position just two feet away from the working personnel, and it may have/may not have damaged some equipment/other item. MINOR ACCIDENT An injury accident requiring either a first aid treatment, or treatment by the doctor/at clinic and the injured may not report for duty for a maximum period of less than 48 hours due to the injury. ACCIDENT FREQUENCY RATE (AFR) AFR= No. of injuries times 20000 Man-hours worked in a period FLAMMABLE MATERIAL Any liquid whose flash point is less than 37.8 degrees centigrade as termed as flammable material. FLASH POINT The flash point is the lowest temperature in degree centigrade at which vapours are developed from a liquid at 1013 mbar and under established test conditions in such quantity that an inflammable mixture of the vapours with the air results. UPPER OR LOWER IGNITION LIMIT The upper or lower ignition limit (explosion limit) is the concentration of a substance in air of the values of gas/air of vapour/air mixtures which if these are less than the lower explosion limit are too lean to burn, or are the values greater than the upper inanition limit are too rich. COMBUSTIBLE MIXTURE A concentration of or vapour in air capable of ignition or explosion is designated as combustible mixture.
