Industrial Safety Essentials: Hazards and Prevention

Posted on Nov 16, 2024 in Chemistry

Safety in Gas-Welding (Cutting)

Gas welding uses flammable gases like acetylene and oxygen. Acetylene can ignite and condense, while oxygen accelerates burning. Wear eye goggles, flameproof aprons, gloves, caps or helmets, and boots. Ensure clothing is free from oil or grease.

Environmental Safety

Ensure proper ventilation, lighting, walkways, storage, escape routes, and safety posters. Keep floors clean and dry. Fire extinguishers should be accessible, and welded jobs stored properly.

Operation and Equipment Safety

Fit flame arrestors in acetylene and oxygen cylinder lines. Oxygen should have higher pressure to prevent acetylene backflow. Do not use acetylene above 1 bar to avoid explosions.

Storage Safety

Keep cylinders away from heat and flammable materials. Do not drag cylinders. Close valves before moving.

Safety in Arc-Welding (Cutting)

Arc welding uses an electric arc to melt and join metals. Ensure proper welding machine switchboards and fuses. Avoid overloading the machine. Use electrode holder insulation. Wear a helmet with a filter glass, leather apron, gloves, leg guards, and safety boots.

Hazard and Operability Study (HAZOP)

HAZOP is a systematic assessment tool to identify potential hazards in industrial processes. It involves forming a team, identifying system elements, considering parameter variations, and identifying hazards.

HAZOP Steps:

  1. Form a team of experts.
  2. Identify system elements and potential hazards.
  3. Examine operating parameter variations.
  4. Identify hazards and failure points.

HAZOP Involves:

  1. Identifying elements and parameters using P&ID or plant models.
  2. Considering effects of parameter variations.
  3. Identifying hazards and failure points.
  4. Documenting concerns and estimating impact.
  5. Evaluating existing safeguards.

HAZOP Application: New and existing facilities.

HAZOP Goal: Identify and mitigate potential failures.

HAZOP Output: Action items for process improvement.

Ergonomic Hazards

Definition: Work conditions causing strain, discomfort, injury, and chronic health issues.

Repetitive Motion Hazards: Tasks with repeated motions leading to RSIs.

Awkward Posture Hazards: Prolonged awkward positions straining the body.

Vibration Hazards: Using vibrating tools leading to HAVS and other issues.

Temperature Extremes: Working in extreme temperatures causing muscle strain.

Poorly Designed Workstations and Tools: Leading to awkward movements and injuries.

Hazardous Properties of Chemicals

Hazardous chemicals can be toxic, explosive, flammable, self-reactive, oxidizing, or corrosive. Exposure can cause adverse health effects.

Toxic Substances: Poisonous substances causing health effects.

Explosives: Substances producing rapidly expanding gas.

Flammability: Ability to burn or ignite.

Self-Reactive Chemicals: Thermally unstable substances igniting spontaneously.

Oxidizing Chemicals: Evolving oxygen and promoting combustion.

Corrosive Chemicals: Damaging body tissues.

Ladder Setting

  • Non-Slip Feet: Prevent sliding on surfaces.
  • Locking Mechanisms: Secure sections and prevent collapse.
  • Anti-Slip Rungs: Improve foot traction.
  • Spreaders (Step Ladders): Lock ladders open for stability.
  • Stabilizers and Outriggers: Increase stability.
  • Rope and Pulley System (Extension Ladders): Ensure safe extension/retraction.
  • Top Cap with Tool Slots: Stable surface for tools.
  • Step Labels and Height Indicators: Mark maximum standing height.
  • Angle Guides and Level Indicators: Position ladder safely.
  • Weight Rating (Duty Rating): Indicate maximum weight capacity.
  • Fiberglass or Insulated Design (Electrical Work): Non-conductive for safety.
  • Rail End Caps: Improve grip and stability.

Machine Safeguard Devices

  • Presence-Sensing Devices: Detect operator presence and interrupt machine cycle.
    • Photoelectric: Stops machine if light beam is broken.
    • Electromechanical: Halts machine if probe detects obstruction.
  • Pullback Devices: Pull operator’s hands away from danger.
  • Restraint (Holdout) Devices: Keep hands in a safe area.
  • Safety Trip Controls: Prevent operation under unsafe conditions.
  • Two-Hand Control Devices: Require both hands to activate machine.
  • Two-Hand Trip Devices: Start cycle with simultaneous button press.

Fire Extinguisher

Types of Fire

  • Class A: Wood, paper, fabric, rubber, plastic. Extinguishing agents: water, foam.
  • Class B: Flammable liquids. Extinguishing agents: CO₂, dry chemical.
  • Class C: Live electrical currents. Extinguishing agents: non-conductive chemical agent.
  • Class D: Combustible metals. Extinguishing agents: dry powder agent.
  • Class K: Cooking liquids. Extinguishing agents: wet chemical agent.

Types of Fire Extinguishers

  • Water Extinguishers: Class A fires. Water mist minimizes damage.
  • Film-Forming Foam Extinguishers: Class A and B fires. Forms a barrier on liquid fires.
  • Carbon Dioxide (CO₂) Extinguishers: Class B and C fires. Leaves no residue.
  • Halogenated Agent Extinguishers: Classes A, B, and C. Non-conductive and non-corrosive.
  • Dry Chemical Extinguishers: Class A, B, and C fires. Effective on deep-seated fires.
  • Wet Chemical Extinguishers: Class K fires. Cools and forms a foam barrier.
  • Dry Powder Extinguishers: Class D fires. Requires specialized techniques.