IS 104 QUALITY CONTROL IN OCCUPATIONAL HEALTH AND SAFETY SBTET AP ~ SHORT NOTES

4.1 PLANT AND EQUIPMENT SAFETY APPRAISAL AND CONTROL TECHNIQUES

4.1.1 Plant Safety Rules and Procedures

Plant Safety Rules: Established guidelines to ensure safety during operation, maintenance, and shutdown of equipment.
Purpose: To prevent accidents, ensure safe behavior, and maintain discipline at workplace.
Examples:
- No smoking or open flames in restricted areas.
- Mandatory PPE use (helmet, gloves, shoes, goggles).
- Follow lockout–tagout (LOTO) before maintenance.
- Report unsafe acts or conditions immediately.

Safe Operating System

Definition: A planned and documented method to perform a job safely.
Components:
1. Job hazard identification.
2. Risk assessment and control.
3. Written safe work procedure (SWP).
4. Training and supervision.
5. Monitoring and review.
Examples:
- Safe system for confined space entry.
- Permit-to-work system for hot jobs.

Checklist

A checklist is a written list of inspection points to ensure compliance and detect deviations.
Types:
- General plant inspection checklist.
- Equipment maintenance checklist.
- PPE and housekeeping checklist.
- Fire safety and electrical checklist.
Benefits:
- Ensures systematic inspection.
- Helps identify hazards early.
- Provides documentation for audits.

Plant Safety Inspections

Definition: Regular and systematic examination of workplace, machinery, and practices to detect unsafe acts and conditions.
Types:
1. Routine Inspection: Daily/weekly checks by supervisors.
2. Periodic Inspection: Scheduled audits by safety officers.
3. Special Inspection: Conducted after an accident or modification.
Steps:
- Plan inspection area and team.
- Use checklist.
- Record observations.
- Recommend corrective actions.
- Follow up on implementation.

Safety Sampling

A method of measuring safety performance statistically.
Process:
- Observe random work areas.
- Record safe and unsafe acts/conditions.
- Analyze percentage of safety compliance.
Use: For comparing safety performance between departments or over time.

Safety Survey

Definition: A detailed examination of a specific area or process to identify potential hazards.
Purpose: To assess effectiveness of safety programs and to recommend improvements.
Conducted by: Safety engineers or external consultants.

Job Safety Inventory System

A database that records job-related hazards, risks, and safety measures for each operation.
Helps in training, supervision, and risk management.

Product Safety

Ensures that the final product manufactured or used is safe during handling, transport, and usage.
Focus Areas:
- Material safety data sheet (MSDS).
- Packaging and labeling.
- Ergonomic design.
- Warning instructions.

Safety Tag Systems

Visual warning system using tags on equipment.
Types:
- Danger Tag: “Do Not Operate” — used during maintenance.
- Caution Tag: Indicates temporary hazards.
- Out of Service Tag: For defective tools or equipment.
Tags must be durable, dated, and signed by authorized personnel.

Total Loss Control and Prevention

A comprehensive approach to control all types of losses (people, property, production, and environment).
Elements:
- Hazard identification.
- Risk evaluation.
- Preventive maintenance.
- Training and motivation.
- Continuous monitoring.

4.2 HAZARD IDENTIFICATION TECHNIQUES

Purpose

To systematically identify hazards, assess their risk, and implement control measures before accidents occur.

Quantitative and Qualitative Risk Analysis

Type	Description	Examples
Qualitative	Uses descriptive data to categorize risks as Low, Medium, or High.	Safety checklist, HAZOP, HAZAN
Quantitative	Uses numerical or statistical data to measure likelihood and consequence.	Fault Tree Analysis, Event Tree Analysis, FMEA

Failure Mode and Effect Analysis (FMEA)

A step-by-step method for identifying potential failure points in a system.
Steps:
1. Identify possible failure modes.
2. Determine effects of each failure.
3. Assign Risk Priority Number (RPN = Severity × Occurrence × Detection).
4. Implement corrective actions.
Example: Failure of pressure valve → overpressure → explosion.

Maximum Credible Accident Analysis (MCAA)

Identifies the worst possible accident that can occur under realistic conditions.
Used for: Chemical plants, refineries, storage facilities.
Purpose: Emergency preparedness and layout design.

Fault Tree Analysis (FTA)

A top-down approach starting from an undesirable event (accident) and analyzing possible causes.
Uses logic gates (AND, OR) to trace failure combinations.
Example: Boiler explosion → overpressure + safety valve failure.

Event Tree Analysis (ETA)

A bottom-up approach starting from an initiating event and analyzing possible outcomes.
Example: Gas leak → ignition? → explosion or safe dispersion.

HAZAN (Hazard Analysis)

Identifies and evaluates potential hazards in plant operations.
Helps to prioritize safety measures.

HAZOP (Hazard and Operability Study)

A team-based systematic study to identify deviations from design intent using guide words like No, More, Less, Reverse.
Used in: Chemical and process industries.

MORT (Managerial Oversight and Risk Tree)

Focuses on management and system failures contributing to accidents.
Useful for evaluating organizational control systems.

Incident Recall Technique

Uses past incidents to predict and prevent future accidents.
Promotes learning from experience.

Critical Incident Review Technique

Detailed review of specific serious incidents to find root causes and system weaknesses.

Safety Integrity Levels (SIL)

Defines reliability levels of safety instrumented systems (SIS).
Ranges from SIL 1 (lowest) to SIL 4 (highest) depending on required risk reduction.

4.3 ACCIDENT AND INCIDENT INVESTIGATION, REPORTING AND ANALYSIS

Philosophy

Accident investigation is not to find fault, but to find facts to prevent recurrence.

Purpose

Identify immediate and root causes.
Recommend corrective and preventive measures.
Improve systems and training.
Comply with legal reporting requirements.

Types of Investigation

Preliminary: Immediate site inspection after accident.
Detailed: Thorough analysis involving technical experts.
Special: Conducted by statutory bodies (Inspectorate, DGMS, etc.).

Key Factors in Investigation

Immediate Causes: Unsafe acts and unsafe conditions.
Basic Causes: Management system failures, lack of training, poor supervision.
Contributing Factors: Environmental or behavioral elements.

Corrective Actions

Eliminate root causes.
Implement engineering or administrative controls.
Conduct retraining and awareness programs.
Review risk assessments and SOPs.

Agencies Investigating Accidents

Factory Inspectorate (under Factories Act).
Directorate General of Factory Advice Service & Labour Institutes (DGFASLI).
State Labour Department.
Insurance and legal authorities.

Accident Reporting

Legal Requirement: As per Section 88 of Factories Act, 1948, report all serious, fatal, or dangerous occurrences to the authorities.
Report Forms:
- Form 18 – Notice of Accident.
- Form 24 – Dangerous Occurrence.
Essential Elements of Report:
- Date, time, and location.
- Details of injured persons.
- Description of incident.
- Causes and preventive action.
- Signature and certification by responsible officer.

Accident and Incident Analysis

Purpose: To identify patterns and trends for prevention.
Classification of Factors:
- Human factors.
- Machine factors.
- Material factors.
- Environmental factors.
- System factors.

Methods of Collecting and Tabulating Data

Observation reports.
Safety sampling.
Interviews and witness statements.
Photographic or video evidence.
Graphs, pie charts, and trend analysis for management review.

Record Keeping

Maintain accident registers, medical records, and corrective action logs.
Use software-based systems (MIS) for long-term trend analysis.

4.4 MEASUREMENT AND EVALUATION OF PERFORMANCE

4.4.1 Definition of Accident

Accident: An unplanned and undesired event resulting in injury, damage, or loss.
Reportable Accident: Must be reported to statutory authority under the Factories Act 1948 or ESI Act.
Examples – death, fractures, burns, or loss of body part.
Fatal Accident: Results in death (immediate or within specified time).
Non-fatal Accident: Causes injury but no death.

4.4.2 Types of Accidents and Indicators

Near Miss Accident

An undesired event which could have resulted in injury or damage but did not — a warning for preventive action.

Lost Time Accident (LTA)

An injury that results in one or more days away from work after the day of the incident.

Disabling Injury

Any injury that prevents an employee from performing normal duties for ≥ 1 shift.

Reportable Accidents under Acts

Factories Act 1948:
- Section 88 – Serious or fatal accidents to be reported to Inspector within 24 hours.
- Section 88A – Dangerous occurrences to be reported even without injury.
ESI Act 1948:
- Employer must submit Form-12 for all employment-related injuries.

Performance Indicators and Formulas

Term	Formula	Meaning / Purpose
Frequency Rate (FR)	(No. of Injuries × 1,000,000) / Total man-hours worked	Measures how often accidents occur.
Severity Rate (SR)	(Total lost days × 1,000,000) / Total man-hours worked	Indicates seriousness of accidents.
Incidence Rate (IR)	(No. of injuries × 1000) / Average no. of workers exposed	Shows injuries per 1000 workers.
Frequency-Severity Index (FSI)	√(FR × SR)	Combined indicator of frequency and severity.
Safe Score	(Safe Man-hours × 100) / Total Man-hours Worked	Expresses percentage of accident-free hours.

✅ Interpretation:
Lower FR and SR = Better Safety Performance.

4.4.3 Disablement and Compensation

Type	Meaning
Temporary Disablement	Loss of work capacity for a limited period (e.g., fracture, burn).
Permanent Disablement	Lifelong reduction or loss of work capacity (e.g., loss of limb, eye).
Partial Disablement	Reduces earning capacity but does not completely disable the worker.
Total Disablement	Worker cannot work in any occupation for the rest of life.

Workmen’s Compensation Act 1923 (Schedule I)

Provides a percentage of wage as compensation based on type of injury.
Example:
- Loss of one eye → 40% loss of earning capacity.
- Loss of two limbs → 100% (total disablement).

National & International Standards

ILO Convention No. 121 – Benefits for Employment Injury.
BIS and DGMS recommend uniform criteria for reporting and recording.

4.5 MAJOR ACCIDENT HAZARDS CONTROL (MAHC)

4.5.1 Major Accident Control

Definition:
A major accident is an event resulting from uncontrolled developments in an industrial activity leading to serious danger to people, property or the environment.

Examples:

Explosion in chemical plant (Bhopal Gas Tragedy 1984)
Fire in refinery or storage tank
Toxic gas leak (ammonia, chlorine)

Major Accident Hazards (MAH)

Large storage of flammable liquids (LPG, petrol).
Explosives and pyrotechnics.
Toxic chemicals (H₂S, Cl₂, NH₃).
High pressure boilers and reactors.
Bulk transportation of hazardous materials.

Identification and Assessment of MAH Units

Done through:
- HAZOP, MCAA, Risk Analysis.
- Threshold quantity criteria as per Manufacture, Storage and Import of Hazardous Chemical Rules (1989).
MAH units must prepare on-site and off-site emergency plans.

Roles and Responsibilities

Agency	Duties
Government Authorities	Enforce safety laws and approve emergency plans (Factories Inspectorate, PCB, DM).
Management of Industry	Identify hazards, install control systems, train workers, conduct mock drills.
Local Authorities	Coordinate emergency services (Fire, Police, Hospitals).
Public	Participate in awareness programs, follow evacuation guidelines during emergencies.

✅ Goal: Prevent major accidents and reduce their impact through preparedness and co-ordination.

4.6 SAFETY AUDIT AND STANDARDS

4.6.1 Preparation and Assessment of Safety Audit

Definition:
A systematic and independent examination to determine whether safety activities and results comply with planned arrangements and are implemented effectively.

Objectives:

Assess effectiveness of safety programs.
Ensure legal and standard compliance.
Identify areas for improvement.

Steps in Safety Audit:

Planning: Define scope and objectives.
Data Collection: Review documents, records, SOPs.
Field Inspection: Observe workplace conditions and practices.
Interview: Discuss with employees and supervisors.
Evaluation: Compare against standards and legal requirements.
Report: Prepare audit findings, non-conformities, and recommendations.
Follow-up: Verify corrective actions and track implementation.

4.6.2 Report of BIS 14489 (1998)

BIS 14489 – Code of Practice on Occupational Safety and Health Audit

Key Highlights:

Lays down audit objectives, scope, frequency, and methodology.
Divides audit into 12 elements, including policy, training, inspection, emergency planning, health and environment.
Recommends audit frequency of once in 12 months.
Audit team should include qualified safety professionals.
Report must contain findings, risk rating, and action plan with responsibilities and deadlines.

Safety Report and Standards

Each MAH unit must prepare a Safety Report containing:
- Process description and layout.
- Hazard identification and risk analysis.
- Preventive and protective measures.
- Emergency plan details.
To be submitted to Chief Inspector of Factories and Pollution Control Board.

ILO Code of Practice for Major Accident Hazard Control

Provides international guidelines for:
- Design and operation of hazardous installations.
- Emergency planning and communication.
- Worker training and public information.
- Accident reporting and learning from incidents.

4.7 – MAJOR ACCIDENT CONTROL SYSTEM

4.7.1 Major Accident Control System

Definition

A Major Accident Control System (MACS) is an organized framework at local, state, national, and international levels to prevent, prepare for, respond to, and recover from major industrial accidents involving hazardous substances.

Its goal is to ensure:

Protection of life and property,
Environmental conservation, and
Effective coordination among authorities, industries, and the public.

1️⃣ LOCAL LEVEL SYSTEM

Objectives:

Immediate control and rescue during industrial emergencies.
Quick communication and coordination between plant, district administration, and emergency services.

Key Components:

On-Site Emergency Plan
- Prepared by the Occupier / Factory Management.
- Covers scenarios like gas leak, fire, explosion, chemical spillage, etc.
- Includes:
  - Alarm and communication system,
  - Safe assembly points,
  - Firefighting and medical arrangements,
  - Mutual aid with nearby industries.
Emergency Control Centre (ECC):
- Command center within the factory.
- Equipped with emergency contact list, plant layout, and first aid materials.
Emergency Team Structure:
- Site Main Controller (Factory Manager) – overall in charge.
- Incident Controller – controls operations at the scene.
- Communication Officer, Fire and Rescue Team, First Aid Team – perform specific functions.
Mock Drills:
- Conducted periodically to ensure preparedness and response efficiency.

✅ Example:
LPG bottling plant or chemical factory on-site emergency plan coordinated with local fire station and hospital.

2️⃣ STATE LEVEL SYSTEM

Objectives:

Supervise, coordinate, and monitor major accident control at district and industrial levels.
Integrate multiple agencies for emergency response.

Key Agencies:

State Factory Inspectorate / Directorate of Industrial Safety & Health (DISH)
- Approves on-site and off-site emergency plans.
- Conducts periodic audits and inspections.
- Maintains accident statistics and safety records.
State Pollution Control Board (SPCB):
- Ensures environmental protection and pollution control during and after accidents.
District Crisis Group (DCG):
- Constituted under the Chemical Accidents (Emergency Planning, Preparedness and Response) Rules, 1996.
- Headed by the District Collector.
- Prepares Off-Site Emergency Plan for MAH units.
- Coordinates evacuation, relief, and rehabilitation measures.
State Crisis Group (SCG):
- Headed by Chief Secretary of the State.
- Advises and assists DCGs.
- Reviews major accident reports and recommends corrective actions.
- Coordinates with health, fire, and police departments.

✅ Example:
In Andhra Pradesh, the Directorate of Factories and Andhra Pradesh Pollution Control Board (APPCB) play vital roles in accident prevention and control.

3️⃣ NATIONAL LEVEL SYSTEM

Objectives:

Develop national policies and codes for major accident prevention.
Coordinate among ministries, states, and industries.
Provide expertise, resources, and training for large-scale incidents.

Key Components and Agencies:

Agency / Organization	Role / Responsibility
Ministry of Environment, Forest and Climate Change (MoEFCC)	Nodal agency for the “Chemical Accidents (EPPR) Rules, 1996)” under the Environment (Protection) Act, 1986.
National Crisis Management Committee (NCMC)	Headed by the Cabinet Secretary – Coordinates response for national-level industrial disasters.
National Disaster Management Authority (NDMA)	Issues guidelines for chemical, industrial, and environmental disaster management.
Ministry of Labour & Employment (DGFASLI)	Provides technical guidance and safety research for factories and ports.
National Safety Council (NSC)	Conducts safety training, awareness, and safety audit programs.
Central Crisis Group (CCG)	Apex body for accident control under MoEFCC; prepares national-level response plans and coordinates with state and district groups.

Central Crisis Group Functions:

Review major accident reports from states.
Advise industries on preventive and mitigation measures.
Maintain national inventory of hazardous chemicals and MAH units.
Ensure coordination with international bodies like ILO, UNEP, WHO.

✅ Example:
The Central Crisis Group coordinated national response during the Visakhapatnam LG Polymers gas leak (2020).

4️⃣ INTERNATIONAL LEVEL SYSTEM

Objectives:

Promote global cooperation for prevention, preparedness, and mutual assistance in case of transboundary industrial accidents.

Major Organizations & Systems:

Organization	Functions / Contributions
ILO (International Labour Organization)	Provides international conventions and codes of practice, e.g., “Prevention of Major Industrial Accidents Convention (C174, 1993)” and “Code of Practice on Major Accident Hazards Control.”
UNEP (United Nations Environment Programme)	Developed “APELL” (Awareness and Preparedness for Emergencies at Local Level) program promoting community-based disaster preparedness.
WHO (World Health Organization)	Focuses on public health aspects during chemical and toxicological emergencies.
OECD (Organization for Economic Co-operation and Development)	Issues guidelines for chemical accident prevention, preparedness, and response.
ILO-UNEP Joint Initiatives	Promote exchange of knowledge, training, and safety information globally.

✅ Key Global Principles:

Prevention First – emphasis on hazard identification and design safety.
Preparedness and Planning – local community involvement.
Information Exchange – between countries and industries.
Mutual Assistance – during transboundary or international accidents.

Summary of Major Accident Control System

Level	Main Authority	Key Document / Plan	Purpose
Local	Factory Management	On-Site Emergency Plan	Immediate control & evacuation
District / State	DCG / SCG	Off-Site Emergency Plan	Public safety & coordination
National	CCG / NDMA / MoEFCC	National Chemical Disaster Plan	Policy, resources & national coordination
International	ILO, UNEP, WHO, OECD	Conventions & Codes	Global cooperation & best practices

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