safety management
Dr. Pradeep Kumar
Department of Chemical Engineering & Technology
Indian Institute of Technology
(Banaras Hindu University), Varanasi – 221005
Definitions
Safety Management is an essential and mandatory
function of industrial Management. Accidents and
unhealthy situations in industry must be prevented by
appropriate actions by management in advance. Safety
should be the way of life and work.
Several thousand lives are lost and properties are
destroyed due to accidents and fires . A casual glance at
industrial workplaces reveals the lack of essential
safety measures and casual approach to safety by
management and workers. Such happenings can be
prevented by implementing safety management
techniques at every stage.
Safety interfaces
Accidents are a leading cause of death in industrial
accidents throughout the world and in India. Several
workers are injured in industrial accidents every year
resulting in unrecoverable
personal loss. Vast sums of money are incurred annually
in medical expenses and lost income caused by
accidents.
Safety management and safety precautions are
necessary at every stage (design of plant and
equipment), manufacture of equipment and components,
testing, dispatch, site construction
work (erection/testing/commissioning), operation and
maintenance (0 & M) of industrial plants/ equipment.
Mother and parents protect the child, supervise and train the
child till it grows up safely. Same applies to management of
industrial safety.
Accident: An unpleasant, unexpected, unforeseen or
unintended happening sometimes resulting from
negligence, that results in injury, loss, damages, etc.
and is caused by a mistake or machine failure or natural
disaster, or sabotage.
Accident may cause 'Mishap, ruin, destruction, injury,
death'. Accidents must be prevented by precautions and
safety measures and safety management.
Danger: A thing or situation which may cause 'injury,
loss, accident, etc.' Such a thing or situation is
'dangerous', risky.
Hazard: To expose to 'danger, risk, chance to
accident’. Hazardous. 'Dangerous, risky , accident
prone'.
Safety: A quality or condition of being safe from
'danger, injury, damage, loss, accident'.
Safe: Free from 'injury, damage, accident, loss'.
Safety Devices: Devices which ensure safety against
injury or loss. e.g. safety belt, safety glasses, safety
earthing, safety enclosure, safety fence.
Safe Guard: Any person or thing or devices that
prevents injury, loss and ensure, safety and security.
Security: State of sense or safety protection or defense
against attack, interference, espionage, sabotage etc.
Precaution: Care or measure taken beforehand against
possible danger.
Caution: (i) A word or sign by which warning is given.
(ii) Act or practice of being cautious.
Prevent: To anticipate beforehand and stop from
happening.
Preventive: Anything that prevents.
Prevention: Act of preventing, Means of preventing.
Classification of Accidents
Accidents can be classified in various ways such as:
Classification based on the magnitude of danger of life
and property.
These can be subdivided into following four categories :
(i) Minor (ii) Moderate (iii) Major (iv) Disaster
Minor. Where there is no loss of life.
Moderate. Where there is injury but no loss of life and
property.
Major. Where there is loss of life.
Disaster. Where there is extensive loss of Property and/or
Life.
Classification based on 'principal-cause and effect'.
These can be sub-divided into several categories such as;
(i) Fires and Explosions (ii) Electrical Accidents
(iii) Chemical Accidents and Explosions
(iv) Accidents with Machines, Plant, Tools
(v) Falling of Objects on body
(vi) Falling of persons in pits or from height
(vii) Accidents from Civil Works (Buildings, Bridges,
Construction Works) (viii) Human-made Accidents
(ix) Natural Disasters
Unsafe Conditions and Unsafe Actions
Safety management should be alert to identify unsafe
conditions in which probability of accidents/ disasters is high.
The unsafe conditions may be physical or human.
The unsafe condition may be internal or external to the plant.
The management is responsible to identify, remove or
minimize unsafe conditions by appropriate actions.
Management's Responsibility
Identify unsafe condition
Identify unsafe condition
Analyze unsafe conditions, cause and effect
Decide method of attack
Remove unsafe condition
Be alert
Educate and train personnel
Individual is responsible for his safe behaviour, actions,
alertness. Human Error can cause accidents. These may be
due to lack to awareness, lack of training, lack of alertness.
Individual's Responsibility
Be alert
Know and learn the safety requirements
Operate the plant and equipment/machine as per safety
rules
Help management and fellow workers towards safety
Management ~ Individuals
Safety management is an art and science of setting safety
objectives of the Industrial Company and related activities
of planning, organizing, directing, executing, supervision,
monitoring, administration, improving various functions to
achieve the safety objectives.
Safety management aims at creating organization to
achieve total safety (freedom from accidents) and to
provide good working conditions for better health, higher
efficiency, higher productivity, morale of workers and
better working conditions.
Additional objectives of safety management level is to
promote good environment and good health of workers and
other employees.
Management, Organization
& Administration
Management, organization and administration, all the three
are the principal building blocks of an organization and
have common objectives and overlapping responsibilities.
Discord
between the three gives lop-sided results.
Management is at the higher level and decides the
organization structure suitable for achieving set
objectives and within the practical framework of
resource.
Organization denotes the total structure of
management, supervisors, workers and supporting staff
and their line of authority, functional responsibilities,
interrelationship, etc.
These are defined by the top management and are presented
in the form of organization chart.
Administration is the part of the organization which
implements the routine administrative functions.
Administration has several functional sub-divisions
such as;
(i) Finance
(ii) Marketing
(iii) Safety and Environment
(iv) Sales
(v) Transport
(vi) Health
(vii) Material Management
(viii) Personnel
(ix) Security
Objectives of
Safety Management
The objectives are to prevent accidents, personal injuries
and deaths, to minimize unsafe situations and unsafe acts
by personnel by applying management techniques. Other
objectives include:
Humanitarian
Accidents cannot be eliminated completely. However they
can be minimized and prevented to a great extent. Prime
humanitarian objective is concern for personal safety of
workers and staff. By effective safety management, the
sufferings of workers and their families are eliminated or
minimized.
The objectives include:
(i) Taking care of workers and staff in the event of an
accident by providing fast medical treatment and financial
assistance and compensation.
(ii) Providing heath full environment and surrounding.
(iii) Welfare.
(iv) Continuous vigil and improvements.
Morale
The reduction of injuries and deaths, concern about wellbeing of workers boosts up the moral of workers and
organization.
Legal
The objective of management is to implement the
stipulation of Acts and Rules formulated by Legal,
Government Standards, Industrial, Statutory bodies.
Mandatory Safety Functions Activities
Factory Acts stipulate safety provisions (Factory Act 1948,
Sec 21 to 41). These provisions must be followed by every
factory covered by this act. They are obligatory and
absolute and are in no way dependent upon previous notice
or warning from the Inspector of Factories.
The provisions dealing with the safety of workers in
different states are supplemented by rules framed by each
state government. So in relation to a factory in a particular
state, the rules of that state government must be referred to.
Organizational
To reduce down time, expenditure on workers
compensation, legal expenditure and improve productivity
and profits. Sometimes Safety is a question of Survival of
the company. Some accidents (disasters)result in closure of
the company.
Commercial
To enhance company's image and prestige. Improve public
relations, there by improving commercial competitiveness.
Social
To help society by improving environment, minimizing
miseries of people thus leading to happy human life.
Safety And Governments Role
The government has set up factory advice service and
labour institute Bombay, which functions as an integral
body to advise government, industry and other interests
concerned with matters relating to safety, health and
welfare of factory workers. It undertakes the enforcement
of the laws on safety and health of workers.
The government has drawn up a "National program for
coordinated action plan" for control of hazards, and
protection of occupational health and safety of workers in
dangerous manufacturing processes. The action plan lists
out the responsibilities of the government, managements
and workers organizations in the field of safety and health
in work environment, and includes 'model scheme for
setting up full safety control system cell' in hazardous
industries and 'Safety and Health accidents reduction action
plan' in all industries.
Approaches to Prevent Accidents
Hazards involve risk and chance, with element of unknown.
Accidents occur suddenly and unexpectedly. There can be
one or more approaches to prevent accidents and ensure
safety.
Enforcement of Safety Rules and Acts
In this approach, the rules are made mandatory. DOs and
DONTs are specified and enforced. Persons should be made
accountable for acts.
Unsafe acts must not be permitted. Punish persons for
unsafe acts. Reward for safe acts.
Persons for
- DOs are Always.
- DONTs are Never.
Mandatory Rules and Laws regarding electrical safety are
enforced on Manufacturers, Contractors, Power Supply
Company and users.
Human Resource Development Approach
In this approach emphasis is on training of every person for
following Safety principles, Special training courses are
organized periodically by HRD Centre's. Persons are given
on the job training in Safety under Senior experienced
persons who follow safety methods.
Psychological Approach
The safety awareness is created in the work-place by
placinglarge sign boards, display of drawing, displaying
DOs and DONTs, conducting safety demonstrations,
providing safety facilities, distributing safety awards etc.
Safety Management Approach
Management is committed to Safety and Accident
Prevention. The Safety Manager is appointed and Safety
Systems are established. Persons are made 'Accountable'
for their unsafe acts.
Engineering Analytic Approach
This approach gives emphasis on cause and effect
relationship, multiclause analysis and determines the
various methods to eliminate the possible causes at the root.
For example, accidents due to Short-Circuit can be
prevented by automatic protection system, accidents due to
contact with charged conductor can be prevented by
isolating and earthing the conductor. Engineering approach
is essential in electrical safety.
Total Quality Management Approach (TQM) for
Ultimate Safety
Safety is ensured by Quality Assurance and Quality Control
at various stages including: Specifications, Systems design,
Product design, Manufacture, Testing, Dispatch, Receiving,
Storage, Civil Works, Installation, Testing/Commissioning,
Operation, Maintenance, HRD and Safety Management.
Objectives Of Safety
And Security Measures
To establish Safety Management System, Safety Audit
System.
To achieve 100% safety and 100% security of
installations Equipment, Human Life and Animal Life.
To bring awareness about safety hazards and safety rules.
To educate personnel.
To understand Cause Effect relationship in accidents and
scientific phenomena associated with electricity.
To control the situation and prevent accidents, injury and
loss to human life, installations and property.
To minimize loss in case of accident
To ensure prompt first aid and emergency help in case of
accident
Study of Unsafe acts and unsafe conditions leading to
accidents. To take corrective measures to eliminate them.
Management
Management is an art and science of setting objectives,
planning, organizing, directing, executing, supervision,
monitoring, improving various functions to achieve the
objectives.
Total Safety Management is a part of Construction
Management and Operation Maintenance Management.
Principles Of Safety Management
Safety Management aims at eliminating unsafe acts and
unsafe conditions by applying management techniques.
Principle 1. Safety is an important management
function of every organization (like production,
marketing, finance, and planning).
The company must have a written safety policy.
Management must take up the responsibility of
implementing the safety policy. Management is responsible
for creating Safety Organization, set safety objectives, plan,
monitor and achieve desired results towards total safety.
Principle 2. Accidents are caused by unsafe acts and
unsafe conditions.
Safety Management is responsible for both.The unsafe acts
and unsafe conditions are due to some lapse in safety
management.
Principle 3. Behind one accident there are several
chance misses.
The accident is a culminating effect of multiple causes : one
root cause and several supplementary causes. For example,
electrical flashover was caused by a person entering in a
clearance zone while circuit was live. Principle cause was
unsafe act of entering in the clearance zone.
Supplementary causes were lapse of management in
electrical safety. Following questions were asked:
(i) Why the person was allowed to enter the clearance zone?
(ii) Why safety-fencing was not provided ?
(iii) Why person was not aware about and risk ?
( iv) Why was he not trained ?
(v) Who gave work permit?
(vi) Why work permit was given without making the circuit
dead earthed?
In conclusion: The accident was caused by lapse in safety
system.
Principle 4. Unsafe acts and unsafe conditions can be
identified in advance and eliminated at the root.
For example a bare live conductor can be replaced by
insulated cable.
Principle 5. For achieving ultimate safety, each link in
the safety chain must be healthful.
A single weak link makes the whole safety chain weak.
Safety Links
1. Plant Design
2. Equipment Design
3. Storage
1
2
Safety Chain
3
4. Civil Works
5. Erection
6. Testing/Commissioning
5
6
7
8
9
7. Operation
8. Maintenance
9. Safety Management
Concept of Safety Chain and Safety Link in Electrical Plant
“Each safety link should be strong to make the safety chain safe."
Principle 6. Safety Management systems and Human
Resource Development (HRD) in safety are the tools of
every organization for ensuring safety.
For ensuring safety the company must have safety
management systems. The employees and contractor's
persons must be trained to follow the safety management
systems.
Principle 7. Safety is a Line Function as well as Matrix
Function.
The Line Function means along the hierarchical line of
authority in the organization. viz., Manager ~ Supervisor
~Worker, each is responsible for safety in his work and the
area and follow safety down the line.
Matrix means as a network of authority with interaction
between departments on horizontal and cross basis. e.g.,
Engineering, Quality, Manufacturing, Maintenance interact
in safety network.
While line authority is followed for administrative functions,
safety is ensured by joint matrix efforts.
Safety organization charts.
Safety is Line Function as well as Matrix Function
Principle 8. Bad work harms others.
Harmful result of unsafe acts or unsafe work has
consequences which are experienced by subsequent users
down the line. The culprit may not even be aware of his
mistakes leading to the accident in future. For example : If
civil design is faulty, the persons working in the factory may
be constantly under unsafe conditions. If material used is
not fire resistant, a small spark may cause a large fire,
destruction of life and property.
Principle 9. Unsafe Acts or Unsafe Work today may
result in a disaster after a lapse of time.
The defects in civil construction work may result in larger
destruction during fire in some corner of the building during
life entire span of the building.
"A Stitch in-time ~ Saves Nine"
Safety Organization
An organization is the way in which authority is distributed
to carry the work, the organization is represented by simple
organization charts. Organization is not the end in itself; it
is the means to achieve the objective. The organization
structure is built by considering the following :
1. Listing the essential activities.
2. Grouping and assigning activities to the group.
3. Deciding line of authority delegation.
4. Co-ordination of the activities.
The safety organization will depend on the size and
complexity of the plant. For a large plant Safety Manager is
usually appointed and he reports to the Plant Manager.
The safety manager's responsibilities are listed in the safety
policy. The total plant has a line organization.
The safety manager co-ordinates the safety activities in
association with other line managers. During construction
phase of the project the safety manager interacts with
civil/erection/ testing and commissioning/store managers
and follows up safety requirements at various stages of the
project. A typical organization chart may look like
Organization chart for construction phase of project
During operation and maintenance phase of the electrical
plant safety manager may report to plant manager and may
interact with various line managers as shown in Figure
Organization chart for operation and maintenance phase of the plant.
The safety department may be combined with field
engineering and field quality department. The
responsibilities of safety manager may include conducting
safety audits, getting safety documents prepared,
establishing safety procedures, eliminating unsafe
conditions monitoring safety etc. Organization of safety
department may be as shown in Figure
Organization chart for. safety department.
(Safety is a line function, safety has interface with others.)
Supervisor/Foreman is the most important person in the line
organization. He monitors the functional line activities. He
gives orders to workers. He checks the safety requirements.
The safety department interacts with line managers and line
supervisors.
Required Personal Characteristics of Safety Manager
The Line Function
Good Manager Planning, Directing, Acting, Monitoring,
Motivation Abilities. Leadership Qualities.
Ability to get along with People.
Enthusiasm, Drive Perseverance.
Readiness for New Ideas and Approaches.
Ability to Get others to do their work.
Clear Understanding of Safely Mission and Sincere
Concern about Workers Safety.
Firmness and Authority regarding Essentials, flexibility
regarding Trifles.
Definitions Related
With Management
Management
The art and science of setting objectives, adopting techniques,
planning, organizing, executing, supervising, removing
hurdles, monitoring etc., to achieve desired objectives.
Administration
The act of management of institutional affairs, office work
and personnel affairs.
Function
Natural or characteristic action of a professional person/group
or an equipment. Management functions include :
Setting targets, planning, organizing, staffing, co-ordination,
controlling, monitoring, improving and achieving. These
functions are applicable to the safety management.
Management Techniques
The way in which managers carry out their functions. In
case of safety management the techniques are important.
Managers should be familiar with the techniques and skilled
personnel to be deployed for particular job/function.
Managers need not have all the technical skills, but they
must be able to organize skilled personnel and use their
skills fully.
Authority
The right to command and act. For performing certain
action the person must have necessary authority.
(i) Centralized Authority: Superior does not delegate
authority to their subordinates. The effectiveness of
subordinates is limited.
(ii) Shared Authority: Responsibility is shared by Managers
though final decision is retained by the superior.
(iii) Split Authority: The authority is pooled and decisions
are made simultaneously by two or more managers.
Management's Safety Policy
The company must have a written Safety Policy.
The policy refers to the principle and directive for course of
actions to be adopted and followed by the company. Policy
is above the rules and practices. Rules and practices are
made on the basis of company's policy. Policy should have
following features:
The policy should spell out long range objective of the
company.
All the management level personnel must believe in the
policy.
The policy is accepted and committed at all the levels
in the company for purpose of daily actions.
The policy should indicate the scope for decisions and
descriptions at lower management levels. ·
Safety Policy should be a part of company's
management policy.
(iv) Functional Authority. Authority
manager/supervisor/worker to carry
function/process/action/activity
given to the
out assigned
Discipline
Orderly conduct in controlled and acceptable manner as per
specified rules. Discipline requires practice, self-control and
faith. Discipline is brought about by leadership, training
positive factors.
Accountability
Obligation to account for one's acts
Responsible
Accountable, answerable.
Management must have a written safety policy and direct
the efforts for safety of personnel and plant during
construction, operation and maintenance by setting goals,
planning, organizing and monitoring to achieve the goals.
Many companies may not have written safety policy. This
shows the management's apathy (lack of interest) in setting
safety goals.
Safety policy should include the following:
Management's intent and desire to achieve safety of
personnel and plant. Management's active concern
regarding safety.
Scope of safety activities to be covered. Activities that
are not covered in the particular safety policy document.
Organization and responsibilities and accountability.
Safety Authority.
Safety Documentation
Rules, acts and Standards.
Safety Audit Team and interval of Safety Audits.
Steps in Organizing Safety Department
Safety is planned by Top Management and Safety
management of the Company well in advance, before
starting project work and while planning the project.
When there is no full time safety specialist, the safety
functions may be carried out by a person who is either a part
of the line organization, such as the Chief Engineer,
Administrator, Supervisor or a Staff Member such as the
Personnel Manager.
The following steps can be underlined for general guidance:
Management's Involvement. Obtaining Management's
Commitment and active support is the first essential.
Organize for Success. The Safety Chief is expected to
marshal facts and resources (including personnel),
forming a coordinated effort for achieving success in
safety targets.
Work out the Detail Operating Plan and Communicate
to all Executives and Supervisors and Workers the
company's safety objective, policies, rules and
regulations, and the method chosen for their
implementation.
Plan, Check, Inspect the Safety Activities.
Provide Safety Education and Training rather than
blaming for past accidents later. Awareness and
motivational development are necessary ingredients in
the remedy for controllable injuries and illness.
Consider engineering revisions as required by the Safety
Considerations. For example, Modify the civil Works,
Provide Safety Wall, Provide Safety Rail, Provide
Safety Enclosure, Hang Sign Boards, Introduce Permit
to Work
System, Conduct Mock-up Fire Fighting Exercise.
Guards and Protective devices as a last resort if
engineering revisions are not possible, or do not prevent
accidents.
Size of Safety Department
The number of personnel engaged full time in
promoting safety may vary with the size of the company
and the nature of its activities. *One Safety Person per 2000 Employees.
Nature of Work
No. of Workers in
Plant
Size of Safety Department
Small Plant
100
Chief Executive and
Maintenance manager
Manufacturing
Plant
1500
Full time 'specialist,
Assistants, Clerk
Large Plant
20,000
to
35,000
Safety Manager,
6 to 10 Safety Inspectors* and
Four clerical assistants ;
Computer Networking
Qualifications And Characteristics
Of Safety Manager
Safety manager should have the following knowledge-cumexperience:
Specific knowledge and experience regarding safety
aspects cause and effect of serious and general
conditions.
Knowledge of hazards, safety principles, and techniques.
Knowledge of safety engineering. .
Knowledge
of
safety
management,
business
administration, safety documentation.
Knowledge of Safety Act, Factory Act.
Knowledge of safety provisions.
Knowledge of applications of computers in safety
management, safety data.
Management and networking with other departments.
Safety Organization
The safety audit is the process that identifies unsafe
conditions and unsafe acts in the plant and recommends
safety improvement. Safety auditing is a very effective tool
with safety management for identifying weak spots and
planning corrective actions.
There can be three types of safety audits:
Walk-through safety audit
Intermediate safety audit
Comprehensive safety audit.
These audits are different, but they do not have rigid
boundaries. They may have some overlap.
Walk through Safety Audit. It is the least expensive safety
audit. It evaluates the unsafe conditions noticeable to naked
eye during walk through the plant with keen observation
from safety view.
During the walk through, many unsafe conditions may
be noticed. These are listed, discussed and commitments
for their dissolving are taken from line
manager/supervisors.
During construction phase walk through safety audits
may be carried out for stores, civil works, and erection
works, documentation, commissioning work. Security
requirements are also audited.
During operation and maintenance, safety auditors
observe the processes, unsafe acts and unsafe
conditions.
The safety auditors discuss their observation with safety
managers, line managers and line supervisors.
Audit report and recommendations are submitted to the
plant manager and safety manager for taking corrective
actions to eliminate unsafe conditions and prevent
unsafe acts.
The team for walk through safety audit includes :
Safety manager
Insurance Inspector
Safety consultant
Electrical Inspector
Manager-Civil/Erection/Commissioning/Operationmaintenance.
The entire plant and its stores, documents, procedures are
reviewed, interviews are conducted. observations are noted,
report is submitted. The report gives recommendations.
Intermediate Safety Audit
The intermediate safety audit involves more detailed study
and review of plant design and plant operation than a walk
through audit. Detailed measurements of high-risk zones are
conducted. These measurements are related with factor of
safety. Tests may be conducted on unsafe conditions/
equipment
Intermediate audit identifies weakness in plant design,
equipment and subsystems and operation/maintenance
procedures and improvements are also suggested.
Comprehensive Safety Audit
The comprehensive audit is a full scale audit that evaluates
the safety factors in the plant on the basis of engineering,
analysis, testing, measurement, module analysis etc. Full
scale improvements in the plant design, renovation,
operating procedures, staffing etc. are recommended, the
comprehensive audit consist of the following.
Envelope Audit
This covers civil works, switchyard, electrical plant
auxiliaries, stores, offices, canteen, ventilation system,
security arrangements, lighting etc.
Functional Audit. This covers organizational weakness,
training requirements, clarity of responsibilities and
delegation, documentation, etc.
Safety Facility Audit
This audit reviews unsafe conditions of high risk and the exiting
safety facilities vis-a-vis recommended safety facilities for high
risk, medium risk and low risk zones.
Recommendation
The unsafe conditions and unsafe acts are listed. The corrective
actions and improvements are recommended. The unsafe
conditions and unsafe acts observed are subjected to ABC analysis
(A= High risk, B = moderate risk, .C = low risk). Attention is
focused on A and B categories.
Managements Response.
The safety audit is a powerful tool available to the management to
take actions in right direction without hesitation/confusion. As
mentioned earlier the management must be concerned about
achieving 100% safety of personnel and plant. The
recommendations for A and B category must be considered first.
The actions planned are monitored. C category suggestions are
implemented side by side.
Training And Supervision
Since safety is a line function, managers, supervisors and workers
must be trained to identify unsafe acts and unsafe conditions in
their respective working areas. They must also be given training in
emergency operations, fire protection, basis electrical engineering
etc. The principles of safety and first aid must be taught. The
dangers of negligence and ignorance must be emphasized. The
attitudes of persons must be tuned to achieve safety.
The company must have training programs for safety starting from
plant manager downwards up to technicians and storekeepers.
Economic Aspects
The safety management requires certain investment and
recurring expenditures as under Fixed Expenditures
Safety facilities
First Aid facilities
Security facilities
Fire fighting facilities
Secured lighting
Rooms for security office and safety offices
Computer facilities and documentation facilities
HRD facilities, safety awareness boards.
Recurring Expenditure:
Salary to safety staff and security staff.
Royalties to consultants and inspectors.
Safety audit expenses.
Communication expenses.
Documentation expenses.
Miscellaneous expenses.
Most of these expenses are essential and justified. For
convincing and motivating the management, the economics
of safety must be worked-out and budget must be prepared.
Although the above-mentioned savings are convincing, it is
difficult to estimate them.
Economic Benefits:
Safety managements results in the following :
Reduced accidents.
Reduced down time of plant and equipment (which
would otherwise occur due to accidents).
Reduced compensation to victims of accidents.
Improved personnel relations between management and
workers. Reduced strikes.
More than above, the lives of people are saved and the
property is saved against destruction, which would occur is
case of accidents and fires
Annual Reports
The safety managers should give annual report to
management. The annual report may cover the following :
Summary of safety activities during the previous year.
The list of accidents during previous year and causes
and corrective action.
Improvement in safety systems during previous year
and their benefits.
Budget estimates for next year as against expenditure in
previous year.
Important aspects about high risk zones and essential
precautions to be taken.
Motivation To Managers
and Supervisors
Motivating supervisors, workers and users is a part of safety
manager's function. For motivating supervisors towards safety
objectives, the strong motivators could be the following:
Recognition
Chance of advancement
Increased pay
Freedom to achieve
Additional responsibility
Importance to his safety role
Specialized training.
Function
Motivator
1. Making safety performance an integral and important part of a
supervisor's performance.
2. Giving the supervisor a free hand in how he controls accidents
and retaining accountability for results.
3. Assigning the supervisor special projects in safety
Advancement and
responsibility.
Responsibility and career
growth.
Growth and responsibility.
Motivation To Employees
The employees should be motivated for achieving safety
objective. The motivation to employees could be given to
both individuals and as groups. The following are the
motivators :
Bringing awareness in essential safety aspects.
Communication regarding safety policy and its
significance.
Training in safety.
Reward for safety achievements.
Suggestion schemes for safety and rewards.
Rewards for discipline.
Competitive tests on safety and rewards.
Documentary films and demonstrations on safety.
Gifts of safety booklets and safety facilities.
Counselling.
Bringing awareness and understanding about risk zones
and unsafe acts.
Giving special incentive for following safe practices and
giving punishment for unsafe acts.
Insurance Coverage of Industrial
Plant And Personnel
Risks of loss due to accidents, fires, thefts exist during
construction and routine operation maintenance phases of the
industrial
plant substation/electrical plant and equipment.
The financial risk is covered by taking appropriate insurance
policy.
If equipment gets damaged or stolen, insurance company
provides the financial compensation against settled insurance
claims. New equipment can be purchased and installed to
resume the operation of plant.
Insurance policies for personnel; equipment and plant are
taken by project management group or contract group from
headquarters for various types of risks and during various
stages of the project in consultation with the insurance
companies.
Premiums for high risk stages of project (commissioning)
are higher. Premiums for high risk plants are also higher.
For Industrial projects and plants the following stages of
project may be covered in a single policy or a series of policies
as under :
Civil Works Policy to cover only civil works, buildings,
bridges.
Transit insurance policy.
Storage policy for entire construction period : Such a
policy may covers civil works, stores, equipment during
Storage; Erection; Testing;Commissioning.
Plant and equipment operation policy during regular
operation and maintenance.
The choice of policies and duration should be decided on
the basis of economic evaluation of premiums vis-a-vis
desired risk coverage.
Group insurance policies for employees.
Employees State Insurance and Workmen Compensation.
Transit Policy
Covers equipment dispatch to receiving store, Coverage
: Loss during transit including theft, accidents
damage, fire damage.
Civil Works Policy
Covers cost of buildings and other civil works including
cost of articles kept in the building and declared
in the policy. Risks covered : theft, fire, accidental collapse.
Storage and Erection All Covers civil works, storage, stored equipment, erection
Risk Policy
erected equipment testing, commissioning of plant and
equipment.
Risk covered : theft, fire, accidental collapse, Damage
during handling/storage/erection/testing/commissioning.
Policy ends after commissioning and handing over for
commercial operation.
Operation and
Covers civil works, storage, stored spares, erected
Maintenance Risk Policy equipment under operation and all maintenance risks
covered: theft, fire, accidental collapse, damage during
operation, maintenance.
Policy ends after date of expiry.
Personal Accident
Policy, Group Insurance
Policy
Covers persons in the plant against accidental injury/
death.
Civilizations And
Safety Requirements
Safety has begun with the birth of human civilization.
During agricultural age, man used low-risk, simple
manually operated devices, muscle power and animal
power. The risks were comparatively low.
The machines convert energy from one form to other and
have natural risk of failure and accidents. Machines using
fuels, electricity and flammable materials, high pressure
fluids etc. have higher risk factor.
Industrial civilization uses machines of various ratings from a
few watts to several Megawatt. Primary energy in form of
fuels and electricity is used for operating the machines and
transport vehicles.
Plants have some hazardous zone such as fuel systems,
chemical systems, high voltage systems with advances in
technology, the safety received higher attention.
New on-line safety techniques have been introduced and the
operator has been relieved of various on-line tasks. On-line
computer controls take care of safety aspects.
Civilization
Remarks regarding Use of Machines and Technologies
and Safety Concerns
Cave Man
(< 10,00,000
years)
Personal safety from hostile animals and natural hazards
Hunting Man
Personal safety from hostile animals and natural hazards
(<1,00,000 years)
Agriculture Man
(<5,000 BC)
Only simple manually operated or animal operated tools,
windmills, water wheels, bullock carts. Ships with sails
Industrial Man
(20th Century)
Steam Engine, IC Engines, Electrical generators/motors
Petroleum extraction and conversion, refining supply
automobiles, rail, aircraft's, marine vessels, gas turbines.
Electric power systems, substations, lines, cables, domestic
appliances
Technologically - Computers, Information Technology, Automatic Products
Advanced Man - and Systems, High per capital energy consumption, Large
(21st Century)
plants, High speed transport. Space travel, Automation.
Civilizations and Safety Aspects
Stages In Plant Life And
Unsafe-condition Factor
Let us review how the safety factor changes during the life
cycle of a plant/equipment/ machine. An industrial
factory/plant/equipment has a typically life cycle of
following stages :
Stage I : Construction Stage
Stage II : Installation and Commissioning Stage
Stage III : Operation and Maintenance Stage
Stage IV : Replacement and Phasing Out Stage
The plants and equipment are installed, tested at the project
site and Commissioned at the site, then handed over to
operation and maintenance group. The safety aspects involved
during project construction phase are different from those
during regular operation and maintenance phase.
During various stages of project construction, different hazards
assume significance.
For example, during Civil works : Pit-falls, falling of objects,
collapse of objects, collapse of structures are not unlikely.
During Erection work: falling of persons from heights, failure of
cranes/slings, falling of equipment, fires caused during welding etc.
are possible. During Testing/ commissioning : electrically caused
shocks/fires/explosions are quite possible. The accidents at site may
occur at any stage due to one or more of the following reasons:
 Human error or negligence or ignorance
 Lapse in management
 Failure of plant/machine component or subsystem
 Unavoidable natural causes (floods/storms/lightning)
 The safety management aims at zero accident and 100% safety
during each stage.
Stages in plant life for safety conditions
Unsafe Conditions and Acts
During and After Project
Construction
Construction Period
Receivi
ng and
Storage
Civil
work
Instal
lation
Accidents due to pit-falls in trench,
excavations
**
*
Fall of persons from heights
**
**
*
**
Accidents due to failure of cranes,
slings, ropes, D-Shackles
**
**
Fires
**
*
*
*
*
*
Collapse of structures, walls and slabs
**
*
Electric Shocks
*
*
Falling of objects on human body
Road Accidents, Rail Accidents
**
Testing
and
Commiss
ioning
Operation and
Maintenance
Transport
Operati
on
*
**
*
*
*
**
**
Explosions/Fires
**
**
Equipment failures
**
**
Lightning strokes
Flash overs
Unsafe equipment
*
Mainte
nance
*
*
**
**
*
**
Maintenance And Safety
Unsafe conditions exist during the entire life span of the
plant or factory. However unsafe condition factor is high
during (1) Construction period (2) Energizing (3) After
expiry of working life of 15/20/25 years of operation.
During construction period the unsafe condition factor in
high due to following reasons:
Several activities are in progress simultaneously.
Number of untrained persons working at site is high.
High risk activities are in progress.
During commissioning and energization, the unsafe
condition factor is high as high energy can flow through
the defective part, if any, resulting in fire, explosion,
disaster.
During normal working of the plant the risk factor is
lowest. Risk factor and maintenance cost increase after
some years of service (During phase IV). After prolonged
usage and aging of the plant the risk factor starts rising
sharply. Plant and machines need to be phased out.
Unsafe condition curve for plant and Industrial works.
Safety Slogan
ZZZ
Z = Zero Defect
Z = Zero Breakdown
Z = Zero Accident
ABC
A = Always
B = Be
C = Careful
CGT
C = Clean
G = Grease
T = Tight
CCC
C = Communication
C = Co-operation
C = Co-ordination
AAAA
A = Attitude
A = Awareness
A = Action
A = Accountability
Summary
Safety is freedom from harm or the danger of harm. The
word safety also refers to the precautions people take to
prevent accidents, harm, danger, damage, loss and
air/water/environmental pollution.
Safety also deals with improvements in working conditions
for better health. Safety is important to everyone and at
every stage of activities and at all times Safety First !
Principal categories of accidents include : Mechanical,
Electrical, Chemical, Transportation, Civil Works, Natural
Disasters, Sabotage. Safety Management, Organization and
Administration are three corner stones of industrial Safety.
Safety Principles include :
Safety is an important management function of every
organization.
Accidents are caused by unsafe acts and unsafe
conditions. Safety management is responsible for both.
Behind one accident there are several chance misses.
Unsafe acts and unsafe conditions can be identified in
advance and eliminated at the root.
For achieving ultimate safety each link in safety chain
must be healthful.
Safety Management Systems and Human Resource
Development (HRD) together ensure Safety.
Safety is a line function in the organization.
The management must have a written safety policy and
safety strategy. Safety organization is established before
(A) Start of project construction.
(B) Start of the regular operation and maintenance of the
plant.