Ehs management issues& challenges safety

1. Environment Health && SSaaffeettyy MMaannaaggeemmeenntt IIssssuueess
&& CChhaalllleennggeess:: SSaaffeettyy MMaannaaggeemmeenntt
Prof. I.D. MALL
DePArtMent of CheMICAL engg.
InDIAn InstItute of teChnoLogy, roorkee
roorkee- 247667

2. Process safety, occupational health and
environmental issues are ever increasing in
importance in response to heightening public
concerns, and the resultant tightening of regulations.
SHE management is a multidisciplinary function and
every person needs to keep vigil against potential
cause of fire & accidents and draw lessons from Past
Incidents.
Safety Involves
•Protection of personnel
•Protection of plant &property
•Production uninterrupted
•Legal requirements
•Welfare of community
•Good reputation

3. Surroundings* in which an organization
operates, including air, water, land,
natural resources, flora, fauna, humans and
their interrelation.
*Surroundings in this context extend from within an organization to the
global system

4. Negatively : Absence of illness
Functionally : Ability to cope with everyday activities
Positively : Fitness and well-being.
Survival : Health also implies good prospects for
continued survival.
Biological : In any organism, health is a form of
homeostasis. This is a state of balance,
with inputs and outputs of energy and
matter in equilibrium (allowing for
growth).

5. Occupational Health
Occupational health includes
• Industrial hygiene,
• Industrial diseases,
• Industrial work physiology,
• Industrial accidents,
• Toxicology in relation to industrial hazards,
• Occupational rehabilitation,
• Occupational psychology etc.

7.  Safety can be defined as prevention of accidents using
appropriate technologies to identify hazards and to
eliminate them before an accident occurs
 Hazard can be referred to as a condition or activity that
has the potential to cause adverse consequences on
life, property and the environment.
 Risk is the probability of the occurrence of an adverse
consequence of a specified nature and magnitude
resulting from a potential hazard.

8.  ISO 14001
 European Eco-Management and Audit
Scheme
 BS 7750 ( UK )
 EPA ( USA)
• OHSAS 18001
• ILO Guidelines

9.  Public Perception Of Unsafe And Polluting
Industry
 Accidents like Bhopal, Flixborough, Seveso
 Low Frequency But High Impact
The health and safety problem in chemical industry can
be reduced by maintaining safe working conditions,
preparation and implementation of safe operating
procedures, study of environment of safety procedure,
training of employees and periodic medical supervision
and use of personal protective equipment

10. • Defined & authorized by top management
• Appropriate to the nature, scale, Envoi. Impacts
and OH&S Risks of the activities, products,
services of the organization.
• Commitment to comply with legal requirements.
• Commitment for continual improvement in HSE
performance .
• Commitment for prevention of pollution, ill
health and injury.
• Available to Interested parties .

11. Everyone
Organizational Does It
Right
Operational Discipline
Individual
Every Time
SHE & Operation
Excellence;
Individual Safety
Fig: DuPont OD Program
Sources: Chemical News

12. Individual OD Characteristics
Knowledge: I understand how to do a task correctly & safely
Commitment: I Commit to do tasks the right way every time
Awareness: I anticipate potential problem & recognize unusual situation

13. Twentieth century has brought with it the explosion in
industrial activities. Industrialization has made human life
style much easier by making many consumer products. In
addition industrialization has attracted hazards have
increased risks and turn accidents. Without adequate
safety one’s survival is threatened. Safety has made its
shape in industries from scratch to priorities in the
changing world. The following are the major requirements
for development of safety:
•Legal
•Economical
•Social
To encourage safety in India, 4th March is celebrated as the
National Safety Day every year.

14. •To respect humanity
•To preserve the environment
•To make the workplace a place of worship
•To comply with statutory authorities

15. • Adequate protection against the hazards to which the
works will be exposed
• Maximum comfort and minimum weight compatible with
protective efficiency.
• No restriction of essential movement.
• Durability and susceptibility of maintenance on the
premise’s where it is used.
• Construction in accordance with the accepted standards
for performance and material.

16. Personal protective Equipment may be divided into two broad
groups:
•Respiratory protective equipment
•Non respiratory protective equipment
Section of equipment to protect different part of the body will
depend upon the hazardous conditions like injurious
mechanical contact etc. The former includes those which are
used for protection of respiratory system or related hazards.
These provide protection from suffocation due to presence of
harmful vapors/absence of atmospheric oxygen . The non-respiratory
PPEs safe guards the other body parts.

17. Safety tag system is also in existence. The need for this
system is that any equipment in any kind of job or activity
other than its normal use needs to be identified ,hence
tagged. This help minimizing misreading/misconception. This
tags used for isolation cordoning , restricting entry, etc.
Tags available are, “ DO NOT OPERATE “ , “DANGER” ,” NO
ENTRY” , “ROAD BLOCKED” , “BLIND” “ELECTRICALLY
ISOLATED” .
In order to maintain an international level of safe work
environment and to maintain a zero accident level SAFETY
needs the cooperation of one and all as SAFETY IS
EVERYBODY’S BUSINESS.

18. Factor IInnfflluueenncciinngg PPrroocceessss HHaazzaarrdd
Many complex processes are adopted in manufacturing
processes, which are not intrinsically safe. Some of the
factors influencing process hazard are
• Reaction types (hydrolysis, oxidation, reduction,
sulphonation, nitration, polymerization, isomerisation,
alkylation)
• Reaction parameters(stability, reactivity, heat of
reaction, pressure, temperature)
• Physical and chemical properties of substances, their
toxicity, corrosiveness
• Quantities of substances used and stored
• Storage characteristics( pressure, temperature )

19. Accidents: Accidents can be classified into
five groups:
• BLEVE (Boiling Liquid Expanding Vapour Explosion)
• Release of flammable gases, flash fire, &
UVCE (Unconfined Vapour Cloud Explosion)
• Toxic vapour release
• Pool fires
• Fragmentation

20. CCaauusseess ooff aacccciiddeennttss
Indirect Causes
(Symptoms)
Unsafe Act &
Unsafe Condition
Basic Causes
Management Safety
Policy & Decisions,
Personal Factors,
Environmental Factors
Direct causes
Unplanned
Release of
Energy and/or
Hazardous
Material
Accident
Personal Injury, Property Damage

21. Pathway : Inhalation of gases, vapours and
particulates
Food : Ingestion of meat, fish, dairy,
products, grains and produce
Surface water : Ingestion, inhalation, dermal
contact,
Ground water : Ingestion, dermal contact

22. Adverse exposure of the chemicals can be acute
exposure (acute poisoning), chronic exposure (chronic
poisoning), site of toxic effects of chemicals, local,
Systemic, cumulative, synergistic or potentiating effect.
Some of the commonly occupational exposure limits are
Threshold limit values (TLV), Permissible Exposure limit,
Maximum allowable concentrations.
Commonly three types of TLVs are prescribed: TLV-TWA(
time weighted average), STEL( short term exposure
limit), TLV-C(ceiling limit)
[ ISC,2008].

23. Safety management in an organization can be reactive or
proactive. Safety management will be reactive, if safety
measures are by implemented after an accident has occurred.
However it will be proactive if safety management implies
realization of actions ahead of accidents and incidents.
Proactive Actions to Prevent Incidents are
•Process Safety through Hazard Identification
• Develop safe operating procedure to minimize operational Risk.
• Ensure Mechanical Integrity of Process Equipment & Facilities
including Safety Instrumentations
• Minimize Human error through training of Workforce
• Develop Core competency with continuous focus on Safety
• HSE Aspects to be included in the curriculum of Engineering Institute to
minimize the Knowledge Gap of fresh engineers.

24. •Safety Policy :Specifying how safety will
be achieved
•Safety Procedures : What management wants
people to do to execute the
policy
•Safety Practices : What really happens on
the job

25. •Goals and objective of the safety programme
•Risk analysis and management
•Industrial process design and operation
•Mechanical integrity of process equipment
•Safety regulations, codes and standards
•Project safety and health review
•Personnel motivation and training
•Process and plant modification and change
•Good work practices
•Incident investigation and safety audits

27. IS18001 provides the industry a systematic, structured
and documented frame work to address OH&S issues
effectively and in an auditable manner. The element of
OH&S management systems are as follows:
•OH&S Policy
•Planning
•Implementation and operation
•Measurement and Evaluation and
•Management review

28. Benefits of OH &S Management system
Reducing the number of personnel injuries through preventive
and control of work place
•Reducing the risk of major accident
•Reducing the material loss caused by accident and in
production interruption
•Ensuring the appropriate legislation is addressed
•Meeting increasing importance of OH &S for public image
•Serving the possibility for an integrated management system
including quality, environment and OH &S

29. Hazards Activities Consequences
Chemical
Hazard
Chemical
handling/
storage
Fire, acute/chronic
toxicity, ecotoxic
Electrical
Hazard
Plant
operation
Fire, shock, burns
Mechanic
al Hazard
Plant
operation
Injury
Physical
Hazard
DG
operation
Accident

30. Main stages of risk assessment
process

31. Risk Ranking
Matrix
Helps in ranking the severity of the
identified hazards/risks.
Moderate Risk High Probability with Mild
Consequences or Low probability wit
Severe Consequences.
Low risk Low Probability with Mild
Consequences.
High Risk High Probability and Severe
Consequences.
Fault Tree
Analysis
Evaluation of probability of occurrence
Consequence
Analysis
Evaluation of Consequences
(generally by use of Risk Analysis
Software under different simulated
situations).

32. Probability
→
Severity↓
Likely Unlikely Highly
unlikely
Serious Intolerable Significan
t
Moderate
Moderate Significant Moderate Tolerable
Minor Moderate Tolerable Insignificant

33. DI
S
ASTE
R
Notify state PCB/local authorities /
hospitals the nature and extent of
disaster
Undertake measures for control and
containment of disaster situation
Assist state PCB in monitoring relevant
toxic/hazardous chemicals
Finance offsite medical aid to affected
population
Monitor relevant toxic / hazardous
chemicals
Predict likely hazard area and target
population and notify local authorities
about the same
Notify public about precautions to be
taken to protect themselves and their
property
Take measures for the protection of the
public / evacuation
Assist in control / containment of disaster
situation
Provide medical aid to affected
population
Notify state PCB/local authorities (police fire, civil
defence, collector, guard) /hospital about potential
hazards and precautions to be taken by the public
to protect themselves and their properties.
Formulate plan for control and containment of
disaster situation
Develop monitoring capacity for relevant toxic
/hazardous chemicals.
INDUSTRY
Develop monitoring capacity for relevant
toxic/hazardous chemicals
Develop capability to predict likely hazard area
and ta…rget population
STATE PCB
Local Authorities

34. Safety does not happen by itself or by external
enforcement. It has to be inbred, developed, nurtured
and encouraged by management and every member of
the organization
Five Important key organization cultures that need to
be taken into account are
•Maintain sense of vulnerability
•Establish and imperative for safety
•Perform valid/timely hazard/risk assessments
•Ensure open and frank communications
•Learn and advance the culture
Eight global dimensions of safety culture: safety
commitment and support, safety, attitude and behavior,
safety communication , and involvement, safety training
and competence, safety supervision, and audit, safety
management organization, accident investigation, and
emergency planning and reward benefit.

35. Safety commitment and support,
Safety, attitude and behavior,
Safety communication , and involvement,
Safety training and competence,
Safety supervision, and audit,
Safety management organization,
Accident investigation,
Emergency planning and
Reward benefit.

36. 1. The Factories Act, 1948 and the states Rules notified
thereunder .
2. The Dock Workers (Safety, Health & Welfare) Act, 1986
and the Regulations framed thereunder.
3. The Mines Act, 1952 and the Rules framed thereunder.
4. The Explosives Act, 1884 and the Rules framed
thereunder.
5. The Petroleum Act, 1934 and the Rules framed
thereunder.
6. The Indian Electricity Act, 1910 and the Indian Electricity
Rules, 1956.

37.  The Indian Boilers Act, 1923 and the Indian Boiler
Regulations .
 The Dangerous Machines (Regulation) Act, 1983.
 The Manufacture, Storage & Import of Hazardous
Chemical Rules1989 and the Rules framed there
under
 Building and Other Construction Workers (Regulation
of Employment and Conditions of Service) Act, 1996
and Rules framed there under
 Beedi and Cigar Workers’ (Conditions of
Employment) Act, 1966
 Employers’ Liability Act, 1938
 Public Liability Insurance Act, 1991 and Rules framed
there under

38. “Recognition, evaluation & control of
those environmental factors or
stresses arising in or from the
workplace , which may cause
sickness, impaired health and well
being or significant discomfort
among workers”

39. Recognition
Evaluation
Control

40.  Chemical Hazards
Chemicals are released in the form of dust , fumes,
gases, vapors etc in the work environment
 Physical Hazards
 Noise ,
 Heat ,
 Illumination
 Vibrations etc

41. Management of Health, Safety and Environmental issues
and requirements throughout project execution through
the issue and maintenance of a project specific Health
Safety and Environmental (HSE) plan.
The HSE Plan to address all client requirements, national
and local legislation.
HSE plan shall be the principal means by which all HSE
related issues shall be managed, including risk
management.
Components of HSE plan
Scope and Responsibilities
Health and Design Safety
Environment
Construction

42. Exposure to
Chemical & Physical
Agents
Occupational
Diseases
Degree of Hazards Depends upon:
 Nature of Chemical
 Concentration & Length of Exposure
 Method of Handling
 Individual Susceptibility

43. Details of Processes / Operations
Carried Out
Chemicals or Substances Used /
Produced as a Raw Materials,
Intermediates or By Product etc

44. Toxicity of Raw Materials, and
Products etc
Sources of Air Contaminants
New Stresses: Change on
Processesetc.
Job Activities Review
Existing Control Measures

45.  NEGATIVE ASPECTS
INJURY TO PERSONS
LOSS to organization
DAMAGE TO EQUIPMENT &
PROPERTY
LITIGATION COSTS
LOST PRODUCTIVITY

46.  Safety = freedom from accidents
 Protection of personnel
 Protection of plant &property
 Production uninterrupted
 Legal requirements
 Welfare of community
 Good reputation

47. With increasing focus on worker safety
and loss prevention by both government
and industries themselves safety is no
longer confined to just hard hats,
goggles and gloves.
For complying with the regulations and
long term benefits an effective and
optimal safety system is a must and with
results so far the plant in question seems
to have got the right balance.

48. CCoonnttiinnuuee……....
 Health, Safety and environmental aspects are
incorporated into all aspects of pre-FEED, FEED,
engineering and construction and are given the
highest priority.
 All employees contribute towards Health, Safety
and Environmental (HSE) Policy implementation to
achieve safe working environment, safety
designed and constructed plants conducting
activities to safeguard the environment.
Target objectives
 Protection from risk of injury/danger to health
 Protection from property damage or loss
 Protection of the environment

49. MUMBAI HIGH INCIDENT

50. Fire in an Oil Depot in UK