Industrial Safety

INDUSTRIAL HAZARDS AND SAFETY
Prof. Dr. Basavaraj K. Nanjwade

Department of Pharmaceutics KLE University College of Pharmacy BELGAUM-590010, Karnataka, India Cell No: 00919742431000 E-mail : nanjwadebk@gmail.com
24 August 2012 KLE College of Pharmacy, Nipani
M. Pharm., Ph. D
CONTENTS
Introduction Types of hazards Recommendations and Suggestions Industrial effluent testing and treatment Discussion on industrial accident case studies Questions References
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INTRODUCTION
Industrial hazards:
It can be defined as any condition produced by industries that may cause injury or death to personal or loss of product or property.
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KLE College of Pharmacy, Nipani
Physical
Pollution
Chemical
HAZARDS
Electrical
Biological
Mechanical
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Physical Hazards
Heat & Cold
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Heat and Cold
Burns Heat stroke Heat cramps
Foot sore Immersion foot Frost bite
Preventive Measures
A reasonable temp. of 20-250C must be maintained

Heat and Cold
Physical Hazards
Noise
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Noise have two type of effects

a. Auditory Non auditory effects Preventive measures At source: Source of noise can be enclosed with an insulation material or concrete wall. Proper maintenance of machinery b. By distance c. Personal protection against noise.
Equipment noise sources ,level & potential control solutions
Equipment Air coolers
Sound level in dBA at 3 feet 87-94
Possible noise control treatments Aerodynamic fun blades, revolutions/min pitch, pressure drop Install mufflers on intake,& exhaust, enclosure the machine with casing, vibration isolation & lagging of piping system Acoustically lined fun covers, enclosure 7 motor mutes
9
Compressors
90-120
Electric motors
90-110
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Equipment noise sources ,level & potential control solutions
Heater & furnaces
95-110
Acoustic plenums, intake mufflers, lined & damped ducts
Valves
<80-108
Avoid sonic velocities, limit pressure drop & mass flow, replace with special low noise valves Inline silencers, vibration isolation
Piping
9-105
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Heat & Cold
Physical hazards
Radiation Noise
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Radiation
Radiation are divided into two groups
Natural
Cosmic rays Environmental (radioactive elements e.g. uranium) Internal (potassium,) Approx 0.1 rad/yr
Man made
Medical /dental x-rays isotopes Occupational exposure Nuclear radioactive fallout Miscellaneous
Use of radio active substances by different industries

Effect of hazards
i. ii. Somatic Genetic Preventive measures Radiation source should be housed in a building that shields any surrounding area. iii. Radiation badges should be worn. iv. Periodical medical examination. v. Proper use of lead shields & lead rubber aprons.
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Heat & Cold
Fire & Explosion
Physical Hazards
Noise
Radiation
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Fire & explosion hazards

Causes Smoking in the factory Defective heating equipment, electrical equipment & wiring. Explosive gas leakage. Inadequate protection of electric motors Sparking of electric wires & equipment Protection & prevention Types of fire
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Preventive measures Prohibition of smoking in manufacturing areas. Oxygen present in the inflammable atmosphere may be by dilution with gases such as nitrogen, co2,steam or combination of these. Hazardous operation should be isolated Eliminating the ignition sources Using fire resistant material in construction Suitable emergency exits Adequate venting

Automatic sprinklers Equipment should design to meet the specifications & code of recognized authorities, such as ISA, API &ASME The design & construction of pressure vessels & storage tanks should follow API & ASME codes. Inspection
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Local
Dermatitis Eczema Ulcers Cancer
Inhalation
Gas Poisoning
Chemical Hazards
Ingestion
Living tissue may be destroyed by chemical reactions such as Dehydration Digestion Oxidation
Source, effect & precautions of chemical hazards

Type/ source of chemical contaminant Acridines, phenothiazines Effect/ organ affected Dermatitis Precautions to be taken
Cleanliness, removal of people from the areas as soon as first sign of skin reaction is observed. Handle with care
Solvents like chloroform, benzene Vegetable drugs like capsicum & podophyllum Long term use of filter without cleaning
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Dust evolves, affects eye Dust explosion
Goggles are to be worn
Regular cleaning
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Source, effect & precautions of chemical hazards

Improper use of cleaning agents Working with radio pharmaceuticals contamination Hazards due to emitted radiation Follow established cleaning procedures Wearing lead coat, maintaining pressure of working area slightly less than atmospheric pressure
Underground tanks
Difficulty in Minimal use of monitoring underground tanks interior & exterior

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PREVENTIVE MEASURES
Tolerance levels for toxic chemicals set by federal regulations have to be followed. Strict observation of operations of all safety regulations
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Biological hazards
Disease due to biological hazards Brucellosis (dairy industry) Byssinosis (textile industry) Bagassosis (sugar-cane) Loco motor disorder Preventive measures Periodic health check up Personal protection The manufacturer should also provide First aid facilities Initial examination Facility for vaccination Routine sanitation programme
Mechanical hazards
Accidents usually take place by the combination of unsafe condition & carelessness. Most of industrial accidents are due to Faulty inspection Inability of employee Poor discipline Lack of concentration Unsafe practice Mental & physical unfitness for job Faulty equipment or improper working condition Improper training regarding the safety aspects
Mechanical hazards
In order to prevent mechanical accidents factories act lay down certain requirements For cranes End buffers Indicating lamps Signals Proof loading upto20 tons 25% in excess 20 to 50 tons 5 tons in excess above 50 tons 10% in excess
Mechanical hazards
Preventive measures
Building planning
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Building planning
Floors must be of unskid/non-slippery type. Enough space for employees to work.
Passages between working places.

Proper arrangements of temperature control; like fans, A.C., heaters.
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Building planning
Building planning
Preventive measures
Safe material handling

Safe material handling

Careless handling of heavy materials and components should be avoided. Full use of mechanical material handling equipment. All material handling equipments should be repaired and maintained properly. Containers employed to transport liquids should not be defective or leaking.
Personal protective devices

Protection of head by using hard hats/helmets. Protection of ears by using earmufffs and plugs. Protection of face by using face marks, face shields.
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Electrical hazards
Shocks Sparking Fire Wiring faults
Preventive measures Proper maintenance of wiring & equipment High voltage equipment should be properly enclosed Good house keeping Water should not be used for dousing electric fire Worker should avoid working in electric circuits or equipment in wet clothing or shoes.
Pollution hazards
a. b. c. d. Types Air pollution Water pollution Thermal pollution Sound pollution
Air pollution Sources Automobiles Industries Domestic

Preventive measures
i. Those suitable for removing particulate matter a. Ventilation Exhaust ventilation Plenum ventilation b. Air purifying equipment ii. Those associated with removing gaseous pollutants Water pollution 1. Types of water pollutants Physical Chemical Physiological Biological 24 August 2012 KLE College of Pharmacy, Nipani 32
Preventive measures
2. 3. a. i. ii. iii. b. Problems of water pollution Preventive measure Control of water pollution Physical treatment Storage Filtration Chemical treatment Biological treatment Treatment of industrial waste Primary treatment Secondary treatment Tertiary treatment
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Preventive measures
c. i. ii. iii. iv. Thermal pollution Effects Damage to aquatic environment Reduction in assimilative capacity of organic waste Various off stream cooling systems Wet cooling towers Dry cooling towers Cooling ponds Spray ponds
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Recommendations & suggestions

Proper treatment & disposal methods for effluents should be adopted An awareness program Measures for increase efficiency of the water use
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Classification of signs according to use
(1) Danger signs.
The DANGER header is used when there is a hazardous situation which has a high probability of death or severe injury. It should not be considered for property damage unless personal injury risk is present.
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2) Caution signs. (i)
The CAUTION header is used to indicate a hazardous situation which may result in minor or moderate injury. However, Caution should not be used when there is a possibility of death or serious injury.
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(3) Safety instruction signs
General Safety Signs (SAFETY FIRST, BE CAREFUL, THINK) should indicate general instructions relative to safe work practices, reminders of proper safety procedures, and the location of safety equipment.
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(4) Biological hazard signs.
The biological hazard warning shall be used to signify the actual or potential presence of a biohazard and to identify equipment, containers, rooms, materials, experimental animals, or combinations thereof, which contain, or are contaminated with, viable hazardous agents.
Pictograph
Pictograph means a pictorial representation used to identify a hazardous condition or to convey a safety instruction
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Signal Word
Signal word means that portion of a tag's inscription that contains the word or words that are intended to capture the employee's immediate attention.
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Tag
Tag means a device usually made of card, paper, pasteboard, plastic or other material used to identify a hazardous condition.
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Danger Tags
Danger tags shall be used in major hazard situations where an immediate hazard presents a threat of death or serious injury to employees. Danger tags shall be used only in these situations.
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Caution Tags
Caution tags shall be used in minor hazard situations where a non-immediate or potential hazard or unsafe practice presents a lesser threat of employee injury. Caution tags shall be used only in these situations.
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Warning Tags
Warning tags may be used to represent a hazard level between "Caution" and "Danger," instead of the required "Caution" tag, provided that they have a signal word of "Warning," an appropriate major message
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Biological Hazard Tags

The symbol design for biological hazard tags shall conform to the design shown below:
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Color Coding-Danger Tag

"DANGER" -- Red, or predominantly red, with lettering or symbols in a contrasting color.
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Color Coding-Caution Tag

"CAUTION" -- Yellow, or predominantly yellow, with lettering or symbols in a contrasting color.
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Color Coding-Warning Tag

"WARNING" -- Orange, or predominantly orange, with lettering or symbols in a contrasting color.
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Biological Hazard Tag

BIOLOGICAL HAZARD -- Fluorescent orange or orange-red, or predominantly so, with lettering or symbols in a contrasting color.
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Industrial effluent testing and treatment

Effluent is an outflowing of water from a natural body of water, or from a man-made structure. Water pollution or waste water discharge from the industrial facilities. REASON OF TESTING To find out -Pollution load -Presence of toxic ingredients -Color, turbidity, odour and quality of water -pH and acidity / alkalinity -Suspended solids and dissolved solids -Phenolic compounds and oily materials
GUIDELINES FOR TESTING EFFLUENTS

Samples may be collected at specific intervals and finally can be mixed before analysis. Containers made up of glass, polythene or any suitable plastic material may be used. Samples may also be refrigerated to avoid loss of volatile matter Samples could be preserved after adjusting the pH O2, CO2, CO may be estimated
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THE RESULTS OF TESTING ARE REPORTED AS FOLLOWS:
Effluents may be expressed as mg/ltr, ppm, %/ltr, and mcg/ltr Acidity / Alkalinity / Oil / Grease / CN / Phenol / Dyes content should be reported
TESTING OF WASTE WATER (EFFLUENT)

TEST
pH
TREATMENT METHOD
Acidic
Basic
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Lime or NAOH
H2SO4

Suspended Solids Sedimentation
Oil and grease

Cyanide Chlorinated & complex with pyridine pyroxolene -Colourimetrically Phosphates -Convert to ammonium molybdatephosphates -extracted with benzene/ isobutyl alcohol mixture -organic phase treated with tin chloride (blue) Colourimetrically
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-grease taps -skimming

-alkaline chlorination -oxidation with ozone -oxidation with H2O2 -ppt with chalk or lime -coagulation with alum
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Mercury -treated with nitric acid and potassium dichromate soln- treared with tin chloride Vapour determined by spectrophotometry -Coagulation -chelation with trimercaptotriazine
Phenolic compounds
Steam distillation-acidify (pH<4)- add CuSO4 solnAdd aminoantipyrine soln- extracted with chloroform
Removal by polymeric adsorbents
calorimetrically
BIOLOGICAL OXYGEN DEMAND

It is the amounts of oxygen required by micro organisms to bio chemically oxidize carbonaceous organic matter at 20 0C in 5 days. 10 mg/litre or less Excess makes water toxic
MEASUREMENT
Special designed bottle with flared cap Incubated at 20 0C for 5 day measuring DO Microorganism added if required
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Dissol oxy in ppm (mg/ltr)
N(V) (8) (1000) V1 V = Volume of sodium thio sulphate required. N = Normality V 1= Volume of sample taken.
CHEMICAL OXYGEN DEMAND

Oxygen equivalent of organic matter present in waste water that is susceptible to oxidation Waste water sample is refluxed with a known excess of pot. dichromate in a 50% sulphuric acid solution in presence of silver sulphate and mercuric sulphate
CHEMICAL OXYGEN DEMAND

The organic matter of the sample is oxidised to water, carbon dioxide and ammonia The excess of dichromate remaining untreated in the solution is titrated against standard ferrous ammonium sulphate COD(mg/l) =
(V1-V2) x N x 8 x100
X Where, V1 = Volume of ferrous ammonium sulphate solution consumed in blank
V2 = Volume of ferrous ammonium sulphate solution consumed for test solution X= Volume of sample taken
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N= Normality of ferrous ammonium sulphate solution KLE College of Pharmacy, Nipani
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Limit for Discharge into Systems

Sr. No. 1 2 3 4 5 6 7 8 9 10
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Parameters pH Oil and grease Total suspended solid, mg/l BOD, mg/l COD, mg/l Mercury Arsenic, mg/l Cyanide, mg/l Sulphides, mg/l Phosphates, mg/l
Tolerance limits 5.5 9.0 10 100 30 50 0.01 0.20 0.10 2.00 5.00
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Waste Water Treatment

Waste Water Pretreatment Attempted to render the effluent suitable for further treatment Equalization Concentrated waste is diluted if necessary -by mechanical mixing -by aeration mixing Neutralization Removal of Grease and Oils
Primary Treatment of Waste Water

Removal of large floating or suspended particle by physical and chemical treatment Screening Large particles are removed Coarse screen of metal bars or heavy wires spaced 25-50 mm apart Finer materials are separated by screening through 0.8-6 mm meshes Grit Chambers Removal of particles by centrifugal action and friction against tank walls Diffused air used for mixing pattern
It is used To prevent any damage to equipment To avoid settling in pipe bends

Chemical Reaction
Involves agglomeration of tiny particles into large particles Flocculation -by mechanical stirring and by chemical flocculants Precipitation -Large amount of suspended solid formed Coagulation -Formation of large and quick settling flocs by a) Reduction of charges and repulsive force b) Adsorption on long chain molecular structure
Secondary Treatment of Waste Water

It is a biological process C, H, and O sources are available Nitrogen should be 5% of the BOD Phosphorus should be 20% of mass of nitrogen Environmental conditions are provided Advantages Continuous waste treatment is favored Low cost system Disadvantages Prior prediction of biological degradability is not possible Solubility limits biodegradability
Secondary Treatment of Waste Water Activated Sludge Process

Microbial Floc is suspended in tank Air is continuously supplied Biological degradation of waste into CO2 and H2O Bacterial flora grows and remains suspended in the form of floc called as activated sludge 20% of sludge is recycled 6 to 24 hours aeration is required
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Secondary Treatment of Waste Water

Advantages -Removal of soluble organic substance, colloidal matter, particulate matter, inorganic substance -Produce high quality effluent Disadvantage -Maintenance cost is high -Growth of anaerobic bacteria fungi etc
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Activated Sludge Process
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Trickling filtration process

Microorganisms are attached to fixed bed It acts as a filter Bed is maintained at height of 2.5 meter Gelatinous film is formed Effluent is sprayed over the surface Slots at the bottom for air inlet Aerobic metabolism occur on the surface Anaerobic metabolism occur at the bottom
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Trickling Filtration Process
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Trickling Filtration Process

Advantages Produce effluent of consistent quality Aerobic and anaerobic digestion are achieved More economical Sludge can be removed quickly Disadvantage Cost for ventilation duct for air supply is high Efficiency decreases in the winter
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Secondary Treatment of Waste Water Oxidation Ponds

Depth should be 1 to 2 meters. Bottom and sides are lined with polyethylene, cement. Oxygen released by algae, carbon dioxide generate from biodegradative Aerobic oxidation producing carbon dioxide and water. Advantage: Operation is simple and economical. Disadvantages: Required disinfections Use for wastes having low BOD.
Tertiary Treatment Of Waste Water

Meant for polishing the effluents. Bacteria are removed by keeping in maturation ponds. Chlorinated, if still contain bacteria. Methods are more expensive than biological treatment. Coagulation : Reaction take place upon addition of the coagulants. -Metal salts -Organic Polymers In water, form insoluble product with impurities.
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Coprecipitation : Ions in solution phase precipitate with the carrier molecule by -Adsorption Process -Inclusion Process Filtration Most common type in addition to disinfection. Practiced prior to the chlorination. Should be done after coagulation. May be made up of sand, activated charcoal.
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Adsorption Involves treatment with activated carbon. Useful for removal of pesticides
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REFRENCES
Pharmaceutical Production and Management By C. V. S. Subrahmanyam www.geocities.com www.britannica.com http://nptel:iipm.ac.in
www.waste_management_world.com
Sewage and Industrial Effluent Treatment, 2 nd edition By John Arundel The Theory & Practical of Industrial Pharmacy By Leon Lachman, Herbert A. Lieberman, Joseph Kiang, 3RD Edition Varghese Publishing House. www.osha.gov
THANK YOU
Cell No: 00919742431000 E-mail : nanjwadebk@gmail.com
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INDUSTRIAL HAZARDS AND SAFETY

Prof. Dr. Basavaraj K. Nanjwade

KLE College of Pharmacy, Nipani

KLE College of Pharmacy, Nipani

Heat & Cold

KLE College of Pharmacy, Nipani

Heat and Cold

Burns Heat stroke Heat cramps

Foot sore Immersion foot Frost bite

A reasonable temp. of 20-250C must be maintained

Heat and Cold

KLE College of Pharmacy, Nipani

Noise have two type of effects

Equipment noise sources ,level & potential control solutions

Equipment Air coolers

Sound level in dBA at 3 feet 87-94

KLE College of Pharmacy, Nipani

Equipment noise sources ,level & potential control solutions

Heater & furnaces

Acoustic plenums, intake mufflers, lined & damped ducts

KLE College of Pharmacy, Nipani

Heat & Cold

KLE College of Pharmacy, Nipani

Use of radio active substances by different industries

KLE College of Pharmacy, Nipani

Heat & Cold

Fire & Explosion

KLE College of Pharmacy, Nipani

Fire & explosion hazards

KLE College of Pharmacy, Nipani

Fire & explosion hazards

Fire & explosion hazards

KLE College of Pharmacy, Nipani

Source, effect & precautions of chemical hazards

Dust evolves, affects eye Dust explosion

Goggles are to be worn

KLE College of Pharmacy, Nipani

Source, effect & precautions of chemical hazards

Difficulty in Minimal use of monitoring underground tanks interior & exterior

KLE College of Pharmacy, Nipani

KLE College of Pharmacy, Nipani

Passages between working places.

KLE College of Pharmacy, Nipani

Safe material handling

Safe material handling

Personal protective devices

KLE College of Pharmacy, Nipani

Air pollution Sources Automobiles Industries Domestic

Recommendations & suggestions

KLE College of Pharmacy, Nipani

Classification of signs according to use

(1) Danger signs.

KLE College of Pharmacy, Nipani

2) Caution signs. (i)

KLE College of Pharmacy, Nipani

(3) Safety instruction signs

KLE College of Pharmacy, Nipani

(4) Biological hazard signs.

KLE College of Pharmacy, Nipani

KLE College of Pharmacy, Nipani

KLE College of Pharmacy, Nipani

KLE College of Pharmacy, Nipani

KLE College of Pharmacy, Nipani

KLE College of Pharmacy, Nipani