ASIAN INSTITUTE OF FIRE SAFETY (AIFS)

(23113) Quality Control In Occupational Safety And Health

1. Attempt any FIVE of the following:

a) Describe LOTO system with example.

It goes without saying that industrial equipment can be dangerous when it's being used.
That's why machines are designed with safety equipment and operators wear personal
protective equipment when using them. But machinery can also present hazards when it's not
in operation. As long as energy sources such as electricity, natural gas, steam, pressurized
water, and compressed air are attached to the machine, a hazard exists. Workers who
maintain or repair the equipment, or who will be working in close proximity to it. need to be
made aware of these hazards and recognize that steps have been taken to protect them. That's
why OSHA requires a formal lockout tagout program. While it may seem that having a
formal program with multiple steps may be overkill it actually makes good sense. After all,
most companies use a variety of equipment that has very different safety practices. In
addition, any number of workers may be asked to deal with the equipment, and some will be
more familiar with it than other
b) Explain off-site emergency plan.
Off-site Emergency Plan:
1. The main objective of the plan are-
2. To save lives and injuries.
3. To prevent or reduce property losses and
4. To provide for quick resumption of normal situation or operation.
Risk Assessment: Risk assessment is most essential before preparing any off site emergency
plan. Hazardous factories and their hazard identification, other hazard prone areas, specific
risks, transportation risk, storage risks, risks by air and water pollution, catastrophic risks
such as disasters, natural calamities, acts of god, earthquake, landslide, storm, high wind,
cyclone, flood, scarcity, heavy rain, lightening, massive infection, heavy fire, heavy
explosion, volcano, heavy spill, toxic exposure, environmental deterioration etc., risks from
social disturbances, risks from the past accidents must be considered while carrying out risk
assessment for a particular area(district) from which the offsite emergency plan is to be
prepared.

c) List out the control of accident report form.

Accident report form:-
Accidents report form is essentially interrogative in character and with question "what went
wrong" Obvious something went wrong otherwise no accident would have occurred. A
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report from should be brief with simple language and practical and direct any report for can
be
broadly split into three distinct parts:
1. Introductory part
2. Body Information
3. Conclusion.
1. Introduction part gives all preliminary information which has got least being with the
Occurrences of accident like:
 Name of the injured person
 Identification Number
 Witness.
2. Body information provides data directly or indirectly relevant of actual occurrence of
accident like:
 Age and Sex of the injured person
 Date, Time and Shift of Occurrence
 Description of the accident in brief
 Part of body injured.
 Immediate causes of the accident. Unsafe act / Unsafe condition.
3. Concluding part gives the option, suggestion, recommendation or advice for corrective
actions like:
 Improvement of physical condition of work
 use of personal protective equipment
 Recommendation of doctor.
Taking into account all above points together an accident report form should be of the
following shapes.
 Name of person / Age / Sex
 Token no. / Shift
 Time & Date of occurrence
 Part of body injured
 How the person was injured,
 What he was doing at the time of accident
 How the accident occurred
 What safeguard was used to prevent accident
 Witness

d) Write down classification of accident As per IS 3786 – 1983.

CLASSIFICATION (ANALYSIS) OF ACCIDENT (AS PER IS 3786-1983)
Investigation and analysis go together. The facts found from the investigation are first
analysed. The analysis should reveal one hypothesis to explain all the facts adequately If the
accidents are classified as per IS 3786, by taking two years or three years or five years

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accident statistics (data), then it is easy to find out the weak or key areas or target areas
where accidents are more and upon concentrating on those area it is possible to reduce the
rate considerably in coming year.
FACTORS THOSE ARE CONSIDERED IN ACCIDENT ANALYSIS
1. Agency.
2. Unsafe mechanical or physical condition.
3. Unsafe Act.
4. Types of accidents.
5. Nature of injury and.
6. Location of injury.
In analysis following factors are also considered. 1 Department.2 Category.3 Age.4 Time

EXAMPLE :- A lathe operator lost his two fingers of lett hand when it was trapped in the
nip of unguarded speed changing pulley belts when the start switch lever war accidentally
turned to on position by striking his body to the layer. Analyze the accident as per I.S
classification.
Classification Key Factors (causes)
1 Agency Speed-changing pulley-belt of the lathe
2 Unsafe Act Taking unsafe position or posture
3 Unsafe condition Unguarded pulley-belt and,

Start switch of thewrong type.

4 Type of accident Caught between moving objects
5 Nature of injury Amputation of two fingers.
6 Location of injury Fingers

e) Explain HIRA procedure in details.

The identification, analysis and assessment of hazards are different than the identification,
analysis and assessment of risks, though both are interrelated. Factors of tune, frequency or
ill effects (consequence) are added in 'risk' distinguishing it from 'hazard'. Some definitions
relevant to risks are as under.
1. Exposure to Risk: A situation created whenever an act or omission gives rise to
possible gain or loss that cannot be predicted.
2. Cost of Risk component parts are The cost imposed upon organization because of the
presence of risk. Its
(1) the cost of losses that do occur and
(2) the cost of uncertainty itself

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3. Risk Management A general management function that seeks to identify, assess,

address. control and review the causes and effects of uncertainty and risk on an
organization. It includes assessment control, financing and administration of risk as
defined herein below
4. Risk Analysis Technical process of identifying understanding and evaluating risk
(analyzing cause and effect wise).
5. Risk Assessment. It is a judgment of significance or activities that enable the risk
manager to identify evaluate and measure risk and uncertainty and their potential
impact On the organization. identify, evaluate and measure risk and uncertainty
and their potential impact on the organization. This judgment can be taken when
the measured value of hazard or risk is compared with the value or standard legally
or otherwise prescribed. This calls for an expertise of an industrial hygienist.
6. Risk and Uncertainty Assessment: All activities associated with identifying,
analyzing, measuring, comparing and concluding risk and uncertainty.
Fundamentals of Industrial Safety and Health 19 49 Hazards & Risk Identification,
Assessment and Control Techniques
7. Risk Control: All activities associated with avoiding, preventing, reducing or
otherwise controlling risks and uncertainties.
8. Risk Financing Activities providing means of reimbursing losses (ie finance for the
cost of risks and losses) that occur and that fund other programmers to reduce risks
and uncertainties.
9. Risk Administration Activities and strategies associated with the long-term and
day-to-day operation of the risk management function.
10. Risk Selection: The control technique best described as the conscious acceptance
of risk in accordance with an organization’s overall goals, objectives and risk
taking philosophy.
11. Risk Avoidance: A risk control technique whereby a risk is proactively avoided or
abandoned after rational consideration.
12. Loss Prevention Those strategies and activities intended to reduce or eliminate the
chance of loss
13. Loss Reduction Activities minimizing the impact of losses that do occur
14. The Risk Chain Five elements or links connected with accident 1.e. hazard,
environment. interaction, outcome and consequence
15. Subrogation Risk transfer by legal document as a loss reduction tool

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f) Explain process of ISO 18001:2007.

Managing health and safety (OH&S) issues in the workplace represents an enormous
challenge due to varying human nature, skills set, process complexity & local culture
and have implications for everyone at the workplace. Effectively managing these issues
means taking account not only of legal requirements, but also the well-being of your
personnel in the organization. Purpose of OHSAS 18001 Management of health &
safety issues for an organization considering all interested parties concern is the main
challenge of the business while working with significant hazardous process & risk.
Achieving OHS performance with improved well-being is the need to assure the regulatory
bodies, customers and other stack holders due to high premium cost for any incident.
Certification to OHSAS 18001 show the commitment to the health and safety of employees,
demonstrates your ability to manage risk & hazards associated with the activities and
provide assurance to all concerned including customers and management that legal
compliance is effectively managed Implementation of OHSAS 18001 policies gives
systematic approach to minimizing health and safety risks and provide a framework for an
organization to manage its legal compliance and improve occupational health and safety
performance, including risk and opportunity identification, analysis, target setting, and
measurement Organizations are improving the health &amp, safety status by implementing
the universally valid international standard along with best practices beside their own
country specific health & safety legislations OHSAS 18001 is basic and globally
recognized standard for occupational health and safety management systems and is
applicable to any organization in any business sector.

2. Attempt any FOUR of the following:

a) List out the safety precaution required to work on fragile roof.
Requirements can be found here Completing and having an excavation permit approved.
Working On Fragile Roof:- Due to their inherent danger, access to all roofs is restricted to
authorized personnel only. This document sets out the intended policy for the safe access to
roofs of University buildings..
1. Working on university roofs has been identified as a potentially hazardous activity.
2. A formal procedure of roof access and safety management has been put in place to
manage this risk.
3. Each roof must be specifically inspected and risk assessed so that anyone visiting a
roof is not put at undue risk. See the Roof Hazard Sheet.
4. Access to university roofs is via an authorization process.

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5. Doors leading to roofs will be kept locked at all times. All locks and keys will be
distributed by Facilities Management. Only certain personnel will be assigned
keys.
6. Doors leading to roofs will have a warning sign "Authorized Personnel Only"
7. All work on roofs will require a written risk assessment.
General procedure:- Safe work permits are usually made out in either duplicate or triplicate
When a duplicate system is used. one copy of the permit is retained by the issuer at the work
site and the other is held by the worker department doing the work. The permit should
always be available at the work site The permit is handed back to the issuer at the end of the
shift or when the work is completed In a triplicate permit system, the third copy is used by
the safety department to audit the work to see if the requirements of the permit are being
met.

b) Write down the conditions for reportable accidents under FA 1948, BOCW Act 1996
and ESI Act 1948.
REPOTABIE ACCIDENT (REPORTING TO STATULORY AUTHORITY)
In any factory an accident occurs which causes death or which causes any bodily injury by
reason of which the person injured is prevented from working for a period of 48 hrs or more
immediately following the accident.

1. MINOR INJURY ACCIDENT Reportable Minor injury accident to be reported to

statutory authority in Form 24 within 24 hrs.
2. Accident of serious nature Reportable Accident of serious nature, to be reported to
statutory authority in Form 24 within 4 hrs.
3. Dangerous occurrence Reportable Dangerous occurrence to be reported to statutory
authority, in Form 24 A within 4hrs.
4. Poisoning or Disease Poisoning or Disease to be reported to statutory authority in
Form 25 within 4 hrs. A register in F-30 format is to be maintained to record the
reportable accidents
Separate register is to be maintained for non reportable accident

Accident Reportable under various statues

Sr.No. Under Act Required form No.
1 Factory Act 1948 Form No. 24
2 ESIC Act 1948 Form No.12
3 BOCW Act 1996 Form No.18

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c) Write down accident investigating procedure .

TECHNIQUE (PROCEDURE) FOR INVESTIGATION

The basic steps are: Observation at site, interrogation, findings and recommendations. Some
objective questions to be considered and answered by the investigator are: Who was injured,
what was he doing at that time, where he was, who was with him, what he has to say about
happening, what part of the injured is involved, how was he injured, what was unsafe the
condition, the method the action of the injured, what does the medical report The first
requirement for the injured person is to provide him medical treatment. It is a mistake to
make him up by questions. It is advisable to wait till he recollects his thought and gets his
nerves under control. Initial story should be collected from spot-checking and interrogation
with co-workers and eyewitnesses. They should not be delay in initial inquiry. The
conditions should be kept unaltered pending the investigation, Photographs, sketches, notes
etc. will help much. Chronological questions should be ask and the concerned facts should
be collected viz. testing report. Registers, documents, instructions, defective or damage parts
etc. The facts finding should aim to determine exact causes of the accident. All causes
should be considered classified according to severity and responsibility for preventive
purpose. As the last step, suggestions and recommendation for the prevention should be
submitted in the writing emphasis should be given put to suggest engineering controls then
to suggest human responsibilities.

d) List out priority wise immediate actions of supervisor after an accidental injury.

Employee safety matters a great deal and the last thing anyone wants is to see a
coworker hurt. However, the reality is an injury can happen to anyone at any time and
without notice. The most important thing is to have a plan in place before an incident
occurs. This way your organization can spring into action and help those who are
hurt. It’s also important to ensure your organization is in compliance with federal safety
regulations. We compiled a seven-step action plan to help get you started:

1. Care for the injured employee:- The first step when an injury happens in the
workplace is to assist the injured employee and prioritize their immediate needs.
You will want to ensure the employee receives the proper medical attention and
you will need to determine what type of care is appropriate given the severity of the
incident. Minor injuries like a cut or a sprain may not require medical assistance,
whereas more severe injuries may require you to call for an ambulance or provide
transportation to a licensed medical professional. You can either consult the

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medical provider designated by your workers’ compensation carrier, or you can

bring the employee to an urgent care facility nearby.
2. Notify management and other team members:- Once you have attended to the
immediate needs of your employee, the next step will be to contact your
management team to communicate that the incident has happened and communicate
the pertinent details. You will want to make note of the location, the people that
were involved, the injuries sustained, and the medical treatment that has been
administered. Communicating this information to your management team allows
them to then notify other team members that need to know, and it allows them to
take the proper steps for ensuring team safety going forward.
3. Secure the scene:- Once an employee is on their way to receive medical treatment
for injuries, you should secure the scene of the incident as quickly as possible.
Blocking access to the location of the event ensures the safety of your other
employees and prevents a repeat incident from occurring. Securing the scene of an
accident is crucial for both safety and reporting purposes. By limiting access to the
area of the incident, you will preserve the scene and this will allow you to have
more accurate and thorough incident reporting. With less people on location, you
have a greater chance that the scene is left untouched, and this can give you a more
accurate picture of the events that contributed to the incident.
4. Complete the incident report:- Beyond ensuring individual employee and total
team safety, completing an incident report is one of the most critical steps to take
after someone has sustained an injury at works. Claims placed on hold becau se of
delayed incident reports typically also cost more than claims that are reported
promptly with the completed paperwork. Delayed claims can cost businesses
thousands in increased premiums or penalties for late reporting.

5. Implement safety protocols

After an accident happens at work, you will want to do everything you can to
ensure it never happens again. Employers hold a unique position that allows them
to influence their entire organization for the better and they can cultivate a culture
of safety in the workplace by implementing safety protocols and safety education
for all team members. Leadership teams can show employees that safety is
paramount to the organization by prioritizing safety, providing education and
training, and praising good safety practices. You can use the incident as a learning
tool by asking yourself what could have been done to prevent the injury and by
asking yourself how the response could have been more effective. By locating the
gaps in workplace safety, you can implement changes to address those gaps and
prevent other lapses in security and safety.
6. Establish a return-to-work program:- Many workplace injuries result in time lost
on the job. As an employee spends more time in recovery, the return to work can
feel physically and emotionally daunting.If an employee has a long-term injury,
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you can set up a transitional or modified job so they can return to a work routine
sooner rather than later. These transitional roles can be temporary and don’t
necessarily need to be the same as before the injury occurred. Providing a program
like this enables workers to regain their footing as an employee, while allowing
them to maintain an income and continue their connection with the company.
7. Follow up with your employee:- At the end of the day, your employee is more than
just a number; They are a vital part of your team and you want to communicate the
value they hold on a personal level. A good employer should do more than take
care of the logistics after an injury. They should also follow up with employees to
ensure they are emotionally and physically healing. Using clear and compassionate
communication with your employee can show them that you care and that you can
work together to create a realistic plan of return.

e) Write down the importance of Corrective Action and Preventive Action (CAPA).

Corrective Action:- Action taken to eliminate basic cause of accident to avoid

reoccurrence of similar type of accident.

Preventive Action:- Horizontal Deployment of the corrective Action at other similar

places & situation to avoid recurrence of the accident occurred.

Corrective Action Process:-

1. Locate and document the root cause of the nonconformity.

2. Scan the entire system to ensure no other similar nonconformity could occur.
3. Analyze the effect such nonconformity may have had on a product or service
produced before the nonconformity was discovered, and take action appropriate to
the severity of the situation by either recalling the product, notifying the
customer, downgrading or scrapping product.
4. Establish thorough follow-up to ensure the correction is effective and recurrence
has been prevented.

Preventive Action Process:-

1. Take proactive steps to ensure a potential nonconformity does not occur.

2. Employ process and system analysis to determine how to build in safeguards and
process changes to prevent nonconformance For example, use a failure mode and
effects analysis to identify risks and potential deficiencies and to set priorities for
improvement.

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f) Define- Accident, Incident, Near-miss and dangerous occurrence

Accident - Accident is an unintended occurrence arising out of and in the course of

employment of a person resulting in an injury.

Incident: an instance of something happening, an event or occurrence.

Near miss Accident:- Near miss Accident: When an Incident takes place without an Injury,
it is termed as Near miss Accident.

Dangerous Occurence:- A near miss that could have led to serious injury or loss of life.

3. Attempt any FOUR of the following:

a) Compare the safety performance of the following two factories and give your
comments.

Factory Man hours Reportable injuries Man days lost

worked
Non-fatal Fatal
A 24 24 0 720
B 35 35 1 250

b) Discuss safety sampling and safety surveys.

SAFETY SAMPLING:- It is method of measuring hazard or accident potential by random

sampling procedure sampling procedure and by conducting safety survey while louring
specific location. The survy team, experienced in safety sampling, walks through specific
(decided) location in the plant and observes all the workers doing their task. Safety sampling
team records number of workers those performing their task safety those performing task
unsafely.
STEPS:-
1. Team meets at desided location and decides route for survey.
2. Takes round for 15 minutes.
3. With the use of "check-list" list out the safety defects & hazards in that area Results
of sampling are added to summary & plots a graph Previous and present graphs are
compared and safety performance is measured.
SAFETY SURVEY:- A safety survey is a detailed examination of a narrow or specific
major key area identified by safety inspection or audit, individual plant, procedure or
particular problem common to a works as whole. It is followed by a formal report. Action

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plan and subsequent monitoring. Its different with safety audit is evident. Safety audit covers
all parts of a plant one by one, while safety picks up out bu an expert team. In case, if
employees of a chemical plant, complaint about ill-health, then expert team carries safety
survey in that plant and study the procedure of handling of chemicals, their storage
conditions, safety system in the plant to take care of gases/vapour and also team refers the
medical reports of such employees. After carrying out in depth study of that pant, team
submits their expertise comments. If toxic chemicals are really affecting the health of
exposed employees, then measure are recommended to provide safe working conditions.
C) Write down the methods of collating and tabulating data.
Methods of Collating and Tabulating Data:-
For analyzing and filing a large number of reports, key sort cards may be used. This card
contains the information of the original report. The code numbers assigned to the various
factors may be punched in the cards so that they can be sorted by a special needle. Sorting is
a hand operation
A third method of tabulation uses card tabulating machine. Here the code numbers only are
punched into the cards which can be quickly and accurately arranged into various groups.
This methods is very useful when the number of reports is very large, when many
classification and cross or sub classifications are required or when tabulation of numerical
data such as days lost etc. are necessary
Modern method of computer processing can also be utilized for such tabulation. See part 13
of Chapter5 for management information system (MIS)
Record Keeping:- Record of accidents reported to the plant management and to the
Government authorities, facts collected as a result of investigation, analysis of the facts,
conclusion about remedial measures necessary and status of implementation of those
measures must be kept in a well documented form. Computer is more useful in this regard.
In DCS system, printouts of accident situations at the time of accident should be kept out
and preserved. Safety department should design formats of safety records applicable to the
factory, train personnel to fill such records and maintain them. Records keeping may be
ordinary or computerized and in much details. Good record is always useful for,
1. Studying past accident causes and remedial measures concluded.
2. Monitoring status of implementation of safety measures
3. Taking decisions regarding future action in the matters of safety Period of maintaining
record should be decided depending on the utility of the subject matter.

D) Define Partial disablement, temporary partial disablement, permanent partial

disablement, total disablement.

Partial disablement:- This is of two types;

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(i) disablement of a temporary nature which reduces the earning capacity of an

employed person in any employment in which he was engaged at the time of the
accident resulting in the disablement and
(ii) disablement of a permanent nature which reduces his earning capacity in every
employment which he was capable of undertaking at the time.

Temporary partial disablement :- If your injury prevents you from doing your usual and
customary Job while recovering, you may be eligible for temporary disability benefits, if
Your treating physician issues a report stating that you are unable to perform your usual and
customary job for more than 3-days, or you are hospitalized, or your employer does not offer
you alternate or modified work that pays your usual wages. If you are entitled to temporary
disability, you will receive a check.

Permanent partial disablement:- These are benefits paid if your injury or illness results in
permanent impairment which impacts your ability to compete in the job market. After your
last medical appointment, your primary treating physician will issue a final report, known as
a permanent & stationary report (more commonly known as a P&S report)
Contained within this report will be any permanent impairment that your physician indicates
based upon his or her final examination Next a permanent disability rating will be calculated
based upon your age and occupation at the time of your injury or illness, which is added to
your whole person impairment rating. The injured worker receives TD at the PD rate.

Total Disablement: Disablement, whether of a temporary or permanent nature, which

incapacitates a workman for all work which he was capable of performing at the time of the
accident resulting in such disablement, provided that permanent total disablement shall be
deemed to result from every type of injury specified in Part A of Appendix A or from any
combination of injuries specified in Part B of Appendix A where the aggregate percentage of
the loss of earning capacity, as specified in that part against those injuries, amounts to one
hundred percent found worsening.

E) Explain time charges in the Employee's Compensation Act 1923.

Save as provided by this Act no lump sum Or half-monthly payment payable under this Act
shall in any way be capable of being assigned or charged Or be liable to attachment or pass
to any person other than the *[employee] by operation of law nor shall Any claim be set off
against the same.
Notice and claim.- (1) No claim for compensation shall be entertained by a Commissioner
unless
Notice of the accident has been given in the manner hereinafter provided as soon as
practicable after the
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Happening thereof and unless the claim is preferred before him within two years of the
occurrence of the
Accident or in case of death within two years from the date of death:
Provided that where the accident is the contracting of a disease in respect of which the
provisions
Of sub-section (2) of section 3 are applicable, the accident shall be deemed to have occurred
on the first of the days during which the *[employee] was continuously absent from work in
consequence of the
Disablement caused by the disease:-Provided further that in case of partial disablement due
to the contracting of any such disease and Which does not force the *[employee] to absent
himself from work, the period of two years shall be Counted from the day the*[employee]
gives notice of the disablement to his employer: Provided further that if a *[employee] who,
having been employed in an employment for a Continuous period, specified under sub-
section (2) of section 3 in respect of that employment, ceases to be
So employed and develops symptoms of an occupational disease peculiar to that
employment within two Years of the cessation of employment, the accident shall be deemed
to have occurred on the day on which The symptoms were first detected: Provided further
that the want of or any defect or irregularity in a notice shall not be a bar to the
Compensation to be first charge on assets transferred by employer.- Where an employer
Transfers his assets before any amount due in respect of any compensation, the liability
wherefore accrued Before the date of the transfer, has been paid, such amount shall,
notwithstanding anything contained in Any other law for the time being in force, be a first
charge on that part of the assets so transferred as Consists of immovable property.

f) Explain the leading and lagging indicators of safety performance with example.

Lagging indicators are typically "output" oriented, easy to measure but hard to improve or
influence while leading indicators are typically input oriented, hard to measure and easy to
influence.
Leading and lagging indicators are two types of measurements used when assessing
performance in a business or organization. A leading indicator is a predictive measurement.
for example: the percentage of people wearing hard hats on a building site is a leading safety
indicator A lagging indicator is an output measurement, for example, the number of
accidents on a building site is a lagging safety indicator. The difference between the two is a
leading indicator can influence change and a lagging indicator can only record what has
happened.

4. Attempt any FOUR of the following:

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a) Describe the procedure for Job Safety Analysis (JSA) Give any one example.
It is a procedure of analyzing job for the specific purpose of finding the hazards and
developing suitable remedies to over come the same.
Procedure:
1. Select the job.
2. Break the job into basic elements or steps as per the sequence of operation.
3. Identify the hazards and potential accidents situations in each step
4. Develop ways or means to eliminate hazards to prevent the potential accident.
Select the Job:
1. Jobs which have caused frequent serious accident or which has got serious accident
potential
2. New Jobs.
3. Maintenance Jobs.

Breaking the Job:- Job should be broken down to basic steps or elements in proper
sequence. Steps should not be too general or too detail but should be described adequately to
explain what is being done. Persons conducting the JSA should observe closely and examine
all possibilities for accidents in each step. For identifying the hazards one may observe the
operations as many times as may be required. They also have discussion with concerned
shop floor personnel.
Solutions can be developed after analyzing the hazards and other relevant particulars
collected during JSA.
Solution may be (a) develop a new or alternate method, (b) reducing the frequency of
hazardous operation or step (c) changing the physical/ mechanical conditions that creates the
hazard, (d) suggesting suitable personal protective equipments
Job Safety breakdown sheet consisting of the following:- Four headings can be used for
JSA.
1. Name of Operation for JSA
2. Description of the operation.
3. Hazards (Potential existing)
4. Precaution/ remedies Based on JSA conducted prepare fresh job sheets/ process
sheets.
Job safety instruction sheets re issued to the supervisors and workers Supervisors are to take
action to ensure the compliance of his section.
Who is to do JSA:- A person well conversant with the job operation or process should do
JSA. A supervisor in association with senior personnel or officer can do it or a supervisor in
association with safety officer can do it or a small committee can do it.
If accidents happen even after the implementation of the remedial measures suggested in the
initial JSA revision of JSA is required.

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b) Describe the concept Maximum Credible Accident Analysis (MCAA).

Maximum Credible Accident Assessment (MCAA):

MCA means maximum credible accident i.e. an accident with a maximum reasonable
damage distance possibility MCAA means maximum credible accident analysis or
assessment Here probability of accident occurrence is not calculated but the probability of
maximum damaging effect (potential and distance) is calculated to assess injury to people
or/and properties in the surrounding area
(1) Type of material stored/processed (toxicity, flammability etc)
(2) Quantity of the material (it affects distance)
(3) Process or storage conditions (temperature pressure, flow etc)
(4) Location of the unit or activity with respect to adjacent population Based on
above factors. units activities are selected, accident scenarios established and
effect (domino or cascade) and damage calculations are carried out.
Following steps are employed m MCAA
1. Chemical Inventory Analysis
2. Identification of hazardous processes in individual units
3. Identification of chemical release and accident scenarios
4. Data acquisition for MCAA
5. Latest and damage calculations for the primary events
6. Analysis of past occident-of similar nation
7. Short listing of maximum credible accident scenarios These steps an explanted bens
in Brief The inventory so he identified MSIHC Rules or Rule J s of the Gujarat
factories rule (see part 10.8 of chapter -28), short listed and priorities on the basis of
hazard potential.
The chemical are classified as non-boiling liquids, gases/vapour and solids, Hazardous
processes- are also identified by above statutory provisions. Runaway reactions need due
consideration during preliminary MCAA.

C) Explain Critical Incident Review Technique (CIRT) What are its advantages"

CRITICAL INCIDENT REVIEW TECHNIQUE (Before the event approach):

The Critical Incident Technique by W.E Tarrant’s, is a method of identifying or reviewing

potential accident causes by collecting information on unsafe conditions and actions, near-
misses, hazards etc. from experienced plant personnel. It can be used to study man-machine

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operation relationship and to use the information to improve equipment, operations and
procedures.
An experienced reviewer or surveyor first explains key personnel what he wants to know.
Then he asks each worker individually questions on safety matters. Workers involvement in
accidents, near misses,
mistakes, errors, difficulties in performance and probable causes of accidents are thoroughly
discussed. Their comments including preventive measures are also asked.
It has been estimated that for every mishap there are at least 400 near-misses. Information on
possible accident causes can be obtained from participants of accidents and non-participants
but having knowledge
When interviews report similar difficulties hazards or near misses with similar types of
operation or equipment's, it indicates an area to be investigated and results of investigation
can suggest the remedial measures necessary.

Advantages of the Critical Incident Method:-

The critical incident method has the advantage of being task-focused. It focuses on the
essential duties of an employee’s job and how well she performs those duties. It is based on
direct observation by the manager and not second-hand accounts.
In this approach, managers gather information over time. They keep a log of positive and
negative incidents, recorded at the time they occurred. So, the annual performance appraisal
is not overly influenced by an employee’s most recent accomplishments or problems.
It is an effective relationship building tool because the manager must spend more time in the
work area observing and interacting with employees, rather than in her office. This gives her
the opportunity to get to know each worker, to provide coaching and guidance; and to get
feedback on what is working well and what is not.
In addition, the critical incident log provides the required performance or behavior
documentation necessary for a manager to take disciplinary action with an employee.

d) Explain Management Oversight and Review Technique (MORT).

The methodology of Management Oversight and Risk Tree (MORT) was developed in the
early 1970s as part of the overall system safety effort for the US Department of Energy (at
the time the Atomic Energy Commission) to systematically and logically analyze a system,
or an accident, to examine and assess detailed information about the process inner-workings
and the involvement of management.
MORT applies a pre-designed logic tree to the identification of total system risks, both those
inherent in physical equipment and processes and those which arise from operation/
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maintenance inadequacies. The symbols used on a MORT are basically those used in fault
tree analysis. They include the rectangle as the general event symbol, the circle as the base
event symbol, the diamond as an undeveloped terminal event, the “and” gate, the “or” gate,
and the ellipse as a constraint symbols. The pre-deigned tree is intended to be a comparison
tool that generally describes all phrases of a safety program and is applicable to systems and
processes of all kinds.
The technique is of particular value in accident/ incident investigation as a means of
discovering system or program weaknesses or error which provide an environment
conductive to mishaps.
A variant of MORT is called the Safety Management Organization Review Technique
(SMORT). This technique is structured by means of analysis levels with associated
checklists. While MORT is based on a comprehensive tree structure, owing to its structured
analytical process, SMORT is recognized as a tree based methodologies.
SMORT analysis includes data collection based on the checklists and their associated
questions, in addition to evaluation of results. The information can be collected from
interviews, studies of documents and investigations. This technique can be used to perform
detailed investigation of accidents and near misses. It also served well as a method for safety
audits and planning of safety measures.

e) Prepare work permit for working confined space.

Safe entry or vessel entry permit:- A Vessel entry permit will only authorize entry into
vessel; separate hot work permit should be issued, if such work is done on the vessels.
Examples of vessels are tanks, drums, boilers. Furnaces reaction towers, barrels, pipe lines,
sewers, pits etc, The hazards may be presence of toxic/ inflammable vapours or gases,
suffocation due to lack of oxygen, slipping and falling etc,

Precautions:

1. Isolate entry equipment/vessel from all source through which any energy, stock or
harmful substance can get introduced by disconnecting, blanking etc, Drain clean,
wash and purge the equipment vessel to make it free from toxic/inflammable gases
and other harmful substances, Test the vessel inside and determine the presence of
explosive mixture, oxygen content etc. in case of presence of explosive mixture and
deficiency of oxygen it should be further ventilated till such time explosive mixtures
are removed or oxygen content is increased to the minimum level of 19%.

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2. In case of deficiency of oxygen cannot be improved, entry should be restricted to

persons wearing safety belts, self contained breathing apparatus. Vessels purged with
inert gases require test for CO2 and oxygen.

As far as possible two main ways or other openings on the equipment/vessel should be kept
open for cross ventilation. Display copies of work permit at each entry point of vessel; if
required additionally suitable signs may be used.

f) Explain the concept Quantitative Risk Assessment (QRA).

Quantitative Risk Assessment: Here hazard potential is quantified, possible risk is also
determined if failure rate data available and then it is compared with the 'permissible
standard'. This will indicate whether calculated risk is lower or higher than the permissible
limit. Based on this, new control measures or modification in existing control measures can
be decided.
Values of following "Hazard potentials' can be quantified
1. Properties of the material.
2. Storage parameters.
3. Process parameters. Fundamentals of Industrial Safety and Health 19 53 Hazards &
Risk Identification, Assessment and Control Techniques
4. Manual exposures.
1. 5.Visible or measured hazards.
5. Transportation hazards.
6. Pollution hazards.
These values give 'severity' part of the risk.
Similarly values of "Control Measures provided" can be quantified depending on the poor
controls to the best controls. Proper classification of good, better and best control measures,
is necessary. These values give 'probability' part of the risk.
Then by using the formula.
Risk Severity x Probability,
The existing risk level can be calculated and identified as low, high, higher or highest risk.
This method is useful to carry out 'material wise' risk assessment. This method and other
methods using ranking matrix are used to carry out 'activity wise' risk assessment also.

5. Attempt any FOUR of the following:

a) Define MAH Explain the ILO which is used for MAH.

As per "THE MAHARASHTRA FACTORIES (CONTROL OF INDUSTRIAL

MAJOR ACCIDENT HAZARDS) RULES. 2003", major accident means, an incident
involving loss of life inside or outside the factory, ten or more injuries inside and/or one or
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more injuries outside or release of toxic chemicals or explosion or fire or spillage of

hazardous chemicals resulting in on-site or off-site emergencies or damage to equipment
leading to stoppage of process or adverse effects to the environment.
MAJOR ACCIDENT HAZARDS (MAH) FACTORY
MAH factory means an industrial activity ordinary handling hazardous chemical equal to or
in excess of the threshold quantities specified in Column 3 of the Schedule 2 of "The
Maharashtra Factories (Control
international Labour Organization (ILO):
 Establishment of a Major Accident Role of DGFASLI & DISH through ILO
(DGFASLI). Important achievements of the project are-
 Setting up a three-tier Major Accident Hazards Control Advisory Division in Central
Labour Institute (CLI), Mumbai and its cells in Calcutta, Chennai and Kanpur.
 Identification of (MAH) Installations in different States and Union Territories &amp,
bringing .
 them under a programme of intensive inspection.
 Establishing Computerized Data Bank at CLI for storage, retrieval and dissemination
of information on hazardous chemicals, MAH installations, specialists on MAH
Database on OSH etc. The Data Bank has two software's WHAZAN and TNO for
calculation of physical effects and con sequence of release of toxic and flammable
chemicals.
 Expansion of the Factory Inspection Services and enhancing their capabilities through
setting up of laboratories and training of inspectors .
 Training of the inspection and advisory staff and key personnel from industry to
develop their competence on HAZOP study Risk Assessment Safety Audit etc.
 Extended the system of MAHC to the port sector. The project had succeeded in
enhancing

b) Describe the procedure of identification and assessment of

MAH installation:

Definition and identification of MAH installation based on types of hazards.

Information about the installation safety report; safety manual etc. Information should be
given to workers, public and authorities.
Assessment of major hazards, by works management and competent authorities Cause,
effects, consequences and safety measures must be assessed.

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Control of the causes of major industrial accidents by detecting causes and following sound
engineering and management practices e.g. good design, fabrication, installation, Operation,
maintenance, inspection and use of good safety equipment and instrumentation.
Safe Operation of major hazard installations by training to workers, following SOPs and
investigating accidents and near misses.
Emergency planning i.e. on-site and off-site emergency plans and their regular rehearsals.
Sitting and land-use planning by ensuring safe separation distances.
Inspection of MAH units by the plant management and also by the Govt. authorities at [Op
priority and more frequently. Causes of major accidents to be studied include component
failure, deviations from normal operating conditions, human and organizational errors,
outside accidental interference, natural forces, mischief and sabotage.
C) Explain the role of Government and Management in MAH control system .

Millions of chemicals are handled in industry cause harm to human beings, other living
creatures, plants, micro-organisms, property or the environment referred to as hazardous
chemicals Industrial Installations healing these chemicals have the potential to give rise to
serious injury or damage beyond the immediate vicinity of the workplace. These are known
as major accident hazards. The Ministry of Labour, Government of India, responsible for
administering the Factories Act, 1948 amended it in the year 1987 Important objectives of
the amendment were, to regulate the location of hazardous process industries in such a
manner that they do not cause adverse effects to the public in the vicinity and provide
measures for safe handling of hazardous substances. Also, the Ministry of labour
implemented through DGFASLI and Inspectorates of Factories an ILO Project.
Establishment and Initial Operation of a Major Accident Hazards Control System in India' in
the manufacturing sector in the later part of 1980s. A great deal of awareness was created
through this project among all concerned about the prevention of major accidents and
mitigation of adverse effects of such an accident.
DIRECTORATE GENERAL FACTORY ADVICE SERVICE & LABOUR
INSTITUTES
(DGFASLI) It is an attached office of the Ministry of Labour Government of India was
set up in1945.
It serves as a technical arm to assist the Ministry in formulating national policies on
occupational safety and health in factories It Itoplements ILO project on MAH Units
DGRASLI advise State Governments and factories on matters concerning safety, health.
efficiency and wellbeing of the persons at workplace. It also enforces safety and health
statutes in major ports of the country. Institute dealing with the scientific study of all aspects

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of industrial development relating to the human factors The Directorate General Factory
Advice Service & Labour Institutes (DGFASLI) comprises:
Headquarters situated in Mumbai
Central Labour Institute in Mumbai
Regional Labour Institutes in Calcutta, Chennai, Faridabad and Kanpur
DGFASLI organization in CLI, Mumbai functions as a socio-economic lab. &amp, is a
national.
d) List out the guidelines for on-site emergency response plan.

ON-SITE EMERGENCY PLAN

INTRODUCTION:- SAFE Modern industry, characterized by complex process and

technology is open to an ever increasing danger form disasters, which can seriously affect
the safety, security and stability of the organization. Some of these disasters are natural such
as earthquakes, floods, tsunamis, cyclones, lightening, while others are man-made. The man-
made disasters included dangerous spills &amp, leak of chemicals, fires &amp. explosions,
hit by external objects, contamination & poisoning of food, terrorist attacks, etc. All of
these have occurred several times in industries, when unprepared for such disasters creating
panic, disorder and confusion. The result has been extensive damage to men and material
Major accidents/disasters in a factory is one which has the potential to cause serious injury
or loss of life. It may cause extensive damage to property, loss of life and serious disruption
both within and outside the works. A number of chemicals produced and used in the
chemical industry are one of hazardous nature. This hazard arises as a result of three
properties, viz.: toxicity, flammability and corrosives. Sudden and uncontrolled leak of
contaminant will give rise to a disastrous condition, magnitude of which will depend on the
type of chemicals as well as its inventory. An emergency plan is an informative document,
which acquaints the occupants of a factory or an occupancy with procedures to be
implemented, during an emergency. It details standard operational guidelines to emergency
controllers and their personnel, who may be required to fulfil a key functional role, during
the various stages of an emergency. In other words, it contains critical information, which
can assist emergency services personnel to formulate appropriate incident management
strategies and tactics, when attending on an emergency at a plant. Since it is a critical
document in implementing appropriate management strategies, it is important that the plan is
comprehensive and easy to read and use Each works shall formulate an emergency/disaster
management plan, detailing explicitly what action will be taken in the event of a major
accident occurring on site, to prevent further escalation and to ensure rapid control. The
emergency planning within the factory premises is known as On-Site Emergency Plan This

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is to be dovetailed with Off-Site Emergency Plan. This article will deal with the details of
On-Site Emergency Plan.

e) Identify the hazards associated with hot work and cold work.

Hot work Permit

Hot work permits are used when heat or sparks are generated by work such as welding,
burning, cutting, riveting, grinding, drilling, and where work involves the use of pneumatic
hammers and chippers, non explosion proof electrical equipment (lights, tools, and heaters),
and internal combustion engines. Three types of hazardous situations need to be considered
when performing hot work: (a) the presence of flammable materials in the equipment; (b)
the presence of combustible materials that burn or give off flammable vapours when heated;
and (c) the presence of flammable gas in the atmosphere, or gas entering from an adjacent
area, such as sewers that have not been properly protected (Portable detectors for
combustible gases can be placed in the area to warn workers of the entry of these gases.)
Cold Work Permit
Cold work permits are used in hazardous maintenance work that does not involve "hot
work". Cold work permits are issued when there is no reasonable source of ignition, and
when all contact with harmful substances has been eliminated or appropriate precautions
taken.

f) Explain local and state levels control system for major accident

Composition and functions of local crisis group (LCG):

Composition:-
SDM-Chairperson
Inspector of Factories - Member Secretary
2 Transporters of Hazardous Chemicals Fire Officer
Station House Officer
BDO
Civil Defense - Rep.
Primary Health Officer
local Press
Sarpanch-nominated
2 Eminent Doctors - nominated
2 Social Workers – nominated

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Functions:-
 It shall be the body in the industrial pockets to accidents.
 To prepare local emergency plan.
 Train personnel involved
 Educate the population likely to be affected.
 Conduct at least one full scale mock drill of a chemical accident at a site every six
months.
Composition and functions of state crisis group (SCG):
Composition:-
Chief Secretary -- Chairperson
Secretary (Labour) - Member Secretary
Secretary Environment, Health, Industries, Public Health Engineering, Transport Chairman-
SPCB
4 Industrial Safety & Health Experts. CIF
Fire Chief
Commissioner of Police
Functions:-
 Apex body in the state to deal with chemical accidents.
 Review all off-site emergency plans of the state.
 To assist State Govt. in managing chemical accidents, planning, preparedness and
mitigation of major chemical accidents.
 To monitor post accident situation.
 To review progress report of DCG. Respond queries from DCG.
 Publish list of expert of officials.

6. Attempt any FOUR of the following:

a) Write down the contents of “safety report” w.r.t rule 10 of MSIHC 1989.

(1) Subjects to the following paragraphs of this rule, an occupier shall not undertake any
industrial activity to which this rule applies, unless he has prepared a safely report on that
industrial activity containing the information specified in Schedule 8 and has sent a copy of
that report to the concerned authority at least ninety days before commencing that activity.
(2) In the case of a new industrial activity which an occupier commences, or by virtue of sub
rule (2) (a) (ii) of rule 6 is deemed to commence, within 6 months after coming into
operation of these rules, it shall be sufficient compliance with sub-rule (I) of this rule if the

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occupier sends to the concerned authority a copy of the report required in accordance with
that sub rule within ninety days after the date of coming into operation of these rules.
(3) In The case of an existing industrial activity, until five years from the date of coming into
operation of these rules, it shall be a sufficient compliance with sub-rule (1) of this rule in
the occupier on or before ninety days from the date of the coming into operation of These
rules sends to the concerned authority in information specified in Schedule 7 relating to that
activity. Write down the contents of "safety report" w.r.t. rule 10 of MSIHC 1989.

b) List out the elements required under IS 14489

Element of IS 14489

 Occupational Safety and Health Policy

 OS&H Organizational set-up
 Education and Training
 Employees participation in OS&H Management
 Motivational and promotional measures for OS&H
 Safety manual and rules
 Compliance with statutory requirements
 New equipment review and inspection
 Accident report analysis investigation and implementation of recommendations
 Risk assessment including hazard identification
 Safety inspections
 Health and safety improvement plan/targets
 First aid facilities- occupational health centre
 Personal protective equipment
 Good housekeeping
 Machine and general area guarding
 Material handling equipment
 Electrical and personal safeguarding
 Ventilation, illumination and noise
 Work environment monitoring system
 Safety for Customers(including material safety data sheets)
 Prevention of occupational diseases including periodic medical examination
 Safe operating procedures
 Work permit systems

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 Fire Prevention, protection and fighting systems

 Emergency Preparedness Plans (On-site/Off-site)
 Process/Plant modification procedure
 Transportation of hazardous substances
 Hazardous waste treatment and disposal
 Safety in storage and warehousing
 Contractor safety systems.
c) List out the contents of Occupational Health and Safety audit as per IS14489-1998.

OCCUPATIONAL HEALTH AND SAFETY AUDITS IS-14489:

Safety Audit Report:

Safety audit with the help of an expert not associated with such industrial activities is to be
submitted within 30 days after the completion of such audit.
Looking to this need, BIS also published an Indian Standard - IS: 14489 in 1998 as standard
guideline for practice on occupational safety and health audit. This IS does not include rating
(points) system like British Standard. Therefore, it gives qualitative analysis and not the
quantitative.
1. Need of Safety Audit:
(A) Safety Requirement: It is utmost necessary for the purpose of maintaining safety
(accident free atmosphere) in industry that all systems of work should be thoroughly
checked from safety point of view at regular interval and deficiencies identified should be
removed by due compliance of safety recommendations.
(B) Legal Requirement: Rule 12-C & 68-0 of the Gujarat Factories Rules 1963 and
Rule 10 & 12 of the Manufacture. Storage and Import of Hazardous Chemicals Rules
1989 need
submission of safety audit reports to the concerned authorities within prescribed time.
2.Audit Procedure:
 Lead auditor along with his team may adopt following procedure:
 Constitution of Audit team (at least two members).
 Constitution of Audit representatives.
 Recording identification and brief history of the audit industry.
 Deciding audit goals, objectives and scope.
 Drawing audit plan with time schedule.
 Holding opening meeting with the audit.
 Study of process and applicability of safely laws and standards.
 Taking plant round and noting observations.

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 Examining records and documents. SAFE

 Filling checklists of audit points (e.g. filling of Annexure A. B &amp.C of IS14489).
 Clement wise (Annex A) files will be useful
 Holding of closing meeting and discussing findings.

d) Define Internal audit and External audit and its legal requirements.

Internal Audit:- Internal audit refers to the department located within a business that
monitors the efficacy of its processes and controls. The internal audit function is especially
necessary in larger organizations with high levels of process complexity, where it is easier
for process failures and control breaches to occur.
External Audit:- An external audit is an examination that is conducted by an independent
accountant. This type of audit is most commonly intended to result in a certification of the
financial statements of an entity. This certification is required by certain investors and
lenders, and for all publicly-held businesses.
Legal Requirement: Rule 12-C & 68-0 of the Gujarat Factories Rules 1963 and Rule
10 & 12 of the Manufacture, Storage and Import of Hazardous Chemicals Rules 1989
need submission of safety audit reports to the concerned authorities within prescribed time.

e) Explain procedure of IS0-45001

ISO 45001:specifies requirements for an occupational health and safety (OH&S)

management system, and gives guidance for its use, to enable organizations to provide safe
and healthy workplaces by preventing work-related injury and ill health, as well as by
proactively improving its OH&S performance.

ISO 45001: is applicable to any organization that wishes to establish, implement and
maintain an OH&S management system to improve occupational health and safety,
eliminate hazards and minimize OH&S risks (including system deficiencies), take advantage
of OH&S opportunities, and address OH&S management system nonconformities associated
with its activities.
ISO 45001: helps an organization to achieve the intended outcomes of its OH&S
management system. Consistent with the organization's OH&S policy, the intended
outcomes of an OH&S management system include:
a) continual improvement of OH&S performance;
b) fulfillment of legal requirements and other requirements;
c) achievement of OH&S objectives.

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ISO 45001: is applicable to any organization regardless of its size, type and activities. It is
applicable to the OH&S risks under the organization's control, taking into account factors
such as the context in which the organization operates and the needs and expectations of its
workers and other interested parties.
ISO 45001: does not state specific criteria for OH&S performance, nor is it prescriptive
about the design of an OH&S management system.
ISO 45001:enables an organization, through its OH&S management system, to integrate
other aspects of health and safety, such as worker wellness/wellbeing.
ISO 45001: does not address issues such as product safety, property damage or
environmental impacts, beyond the risks to workers and other relevant interested parties.
ISO 45001: can be used in whole or in part to systematically improve occupational health
and safety management. However, claims of conformity to this document are not acceptable
unless all its requirements are incorporated into an organization's OH&S management
system and fulfilled without exclusion.
f) Describe concept of plant safety inspection

Plant Safety Inspection can be defined as the monitoring function conducted in an

organisation to locate and report hazards, which have the potential to cause accidents in the
workplace.

Ambient measurement services to ensure workplace safety – including accurate monitoring

of indoor air pollution, chemical exposure, temperature, lighting, radiation, noise and
vibration
Mandatory periodical and non-periodical inspections of safety-related equipment in the
workplace
Technical advisory services on safety-related equipment in the workplace related to
remediation, conformity and efficiency
Providing customers with remote online monitoring, using the latest digital tools to ensure
workplace safety Digital industrial optimization services of workflow processes concerning
plant safety, using innovative tools to collect and transform data into services.

*****

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