We are nothing after our death. Let us donate our body organs for the poor.

Be not afraid of anything. You will do marvelous work The moment you fear, you are nobody - Swamy Vivekananda

If you think safety is expensive, try an accident... - O.P.Kharbanda

Preventable accidents, if they are not prevented due to our negligence, it is nothing short of a murder - Dr. Sarvepalli Radha Krishna, 2nd President of India

Zero accidents through zero unsafe behaviors. Do not be complacent that there are no accidents. There may be near miss accidents (NMAs). With luck/chance, somebody escaped knowingly or unknown to the person. But, we can't be safe, if we depend upon the luck.

Safety culture is how the organization behaves when no one is watching.

We make No compromise with respect to Morality, Ethics, or Safety. If a design or work practice is perceived to be unsafe, we do not proceed until the issue is resolved. - Mission statement by S&B Engineers & Consultants Ltd. http://www.sbec.com/safety/

Human meat gets least priority - A doctor's comment on accidents

CSB video excerpts from Dr.Trevor Kletz, http://www.youtube.com/watch?v=XQn5fL62KL8

Dec 14, 2013

Ensuring use of PPE (personal protective equipment) by employees - whose responsibility?

Recently, in a conversation during an audit, I heard the following instructions to supervisors and employees about the use of PPE:
  1. Tell the shopfloor incharge to check for wearing safety shoes by all as there are some visitors.
  2. Tomorrow, audit team is coming. Tell everybody to wear safety shoes and goggles.
  3. Arey baba, wear shoes. Otherwise, we will get non-conformity (NC) by the audit team.
  4. If you don't wear safety shoe, unnecessarily, safety man will write letter.
  5. etc
The above will only show (shoe) that we have to wear safety gear only to please somebody and that the manager will not get any remarks from visitors or audit / inspection team. Nobody thinks that PPE are required for our own safety. The way we wear our clothes without being told by anybody, why don't we tell that PPE are required to protect our body parts, but NOT to protect the skin of plant manager / supervisor.

This shows that though we shout from roof top that safety is our first priority, it is, in fact first from last. It is in a way, an abusive word. Or, hatred term. Some managers may even have hatredness by seeing the safety persons even from distance and may be cursing the fellow.

In such organisations, who can save the workmen. Even GOD can not save them, as they want to inflict injuries to their own workmen from whom they want to get better production. 

Here, even workmen should be blamed for not wearing PPE. Else, why one should tell or keep on telling wear this, wear that, and so on. Don't they know? Supervisors / managers / safety officers should only do monitoring job to correct the mistakes made unknowingly, not to tell everyday same thing to those who do not want to follow. Such persons should be removed from the work. Then only, others can be protected. Otherwise, youngsters who join the organization may pick up or learn the work to do in a wrong way. 

Here, the issue is not about wearing only safety shoe or helmet or something else. This way of working leads to wrong work practices and poor safety culture. 

And an expert defined safety culture as the way we work (or do things), even when nobody is watching.

Dec 8, 2013

Starting problem with vehicle not used for some time

I am having scooter which I sparingly use as I my regular use vehicle is a motor cycle. Today, I gave my motor cycle for servicing and I had the problem of starting my scooter. When I took it to mechanic, he examined and on enquiry with me about its use, told me that we should not leave petrol in the vehicle which is not in use for a long time. Instead, he suggested to fill the petrol as and when required and use it. He said that the evaporation of petrol coupled with degradation of lubricating oil which will be mixed with it during filling leads to this starting problem.
Another problem I find with battery start vehicles is discharge of battery.

This is a lesson learned today.

Nov 30, 2013

Safety education - a subject to be made compulsory at all levels in schools and colleges

Even after so many years of industrialization, with all available knowledge, still, accidents are taking place. This only shows that managements pay only lip service for safety in their organizations. 

It appears managements think that having a safety department means that it is the responsibility of safety department to ensure safety and that other departments like production, maintenance, quality, etc need to be told what is to be done for ensuring safety of all. 

This also means that safety is not part of all activities and it is seen as an additional activity like an extra organ in a body, which nobody likes. 

Though people like to remove the extra organ, if it is not possible to remove for any reason, then people bear with it, cursing it or their fate. It appears, safety department is also in a similar situation. One can not avoid it because it is mandatory to have certain number of safety officials as per the local government's legislation. At the same, like the extra organ people don't like it. 

The fact that there is lot of friction between safety and other departments in the organizations shows that there is no safety culture. And culture is defined by experts as the activity which one does even when nobody else is watching. Good culture leads to safe work behaviors and no accidents.

This is all because, it appears to me that safety is not taught from the childhood. If it is included as a subject like language / maths / science / etc, then it is imbibed in the minds and is treated with all respect it deserved. Safety management should not be thought as the work of safety department. It should be an integral part of all activities. 

Nov 15, 2013

Cockroach chase leads to factory fire - how to eliminate cockroaches in your place?

Today, I read in a forum, i.e indiansafetyprofessionals@yahoogroups.com, that a house wife died of burns when she sprayed a cockroach killer in the kitchen near the gas stove which was ON. The spray, being flammable caused explosion.
Husband of the lady who tried to extinguish flames is still in the hospital due to burns.

I too had similar experience, though without injury, which I posted earlier. http://safetychat.blogspot.in/2010/09/safety-of-cockroach-killing-sprays.html

Then, when I searched internet for similar incidents, following links were found.

1. Man sets his factory on fire to kill cockroaches.
http://blogs.wsj.com/japanrealtime/2010/11/15/no-factory-smoke-without-roach-fire/

2. http://www.abc.net.au/news/2011-06-27/cockroach-spray-sparks-house-fire/2772730
http://www.mfb.vic.gov.au/News/Killing-cockroaches-with-aerosol-spray-starts-house-fire-.html


Best solution I found to get rid off the cockroaches is to use the latest HIT GEL and I am not finding any cockroach in my flat for the last few months (more than three months). Occasionally, when I find something, I use it and my house is free. Otherwise, there were hundreds of cockroaches, hidden behind tiles / corners / books / papers, etc and being in apartment complex, I thought no amount of treatment will solve my problem as they can come from other flats, even if I eliminate in my house.

The youtube video of the company can be seen in the following link:
http://www.youtube.com/watch?v=8Z9kv40SNpk

Some solutions given below:
1. http://housewifehowtos.com/clean/how-to-get-rid-of-cockroaches/
2. http://www.unce.unr.edu/publications/files/nr/2000/sp0007.pdf

Nov 12, 2013

Double riding on forklifts - is it acceptable?

Questions are raised on whether one can have a ride on the forklift apart from the forklift operator? Or, for that matter on any other material handling equipment like pallet truck or tractor, etc.
Anybody sitting next to the operator of the vehicle causes inconvenience that may lead to road accidents. Unless, the equipment is designed such that the vehicle controls are within the reach of the operator and that the sitting position of co-riders in noway obstructs operation/control of the vehicle, one should not permit riding on the vehicle.
It is quite common to see persons sitting on either side of the driver of tractors and sometimes on the connecting attachment between the tractor and the trailer, causing inconvenience to the driver. These person apart from causing inconvenience also cause diversion of driver's attention by talking among themselves and with the driver.
We should not add seats or modify the design of the vehicle on our own, unless it is permitted by the supplier. As said above, one should see whether the vehicle can be operated safely by the driver, with the changed design i.e addition of seats. Otherwise, we will be creating hazard for the persons in the factory.

I read sometime ago, that in some places, double riding is a punishable offence. A case study in the form of judgement teaches us that factory management also got responsibility  to create awareness among employees about do's and don't's for forklift use/operation.

Nov 11, 2013

Chemical burns - why to wash a spilled chemical on the body for atleast 15 minutes?

Recently, during an interaction with some trainees, nobody could understand the reason for washing a body part splashed with acid/alkali for atleast 15 minutes.
I read long ago that the studies showed removal of chemical by 93-95% even for washing this much time. Once, the reason is known, one will remember and follow the guidelines. Else, it will be like washing something that has fallen on the body which will not last more than a minute.
Time should not be lost between the splash and wash with water as damage will increase.
Further, any alkali in the eyes should be washed with more care as alkali can cause eye damage even to the extent of blindness.
As per standards, emergency shower and eye wash fountain should be located within 15 meters and atleast 16 lpm water in eye wash fountain and atleast 110 lpm in the shower at 196 kpa pressure. There should not be any obstruction the approach to the shower/eye wash should be straight so that the affected can quickly reach and use it.
The 15 m distance is not the straight distance (aerial), but it should be the total distance to be covered by the affected person.
The persons in the area should ensure its availability by testing in every shift and to allow the water to run off for sometime so that there will not be any foreign particles (rust, etc) that can cause damage to the person while using in real emergency.

Trade off between production and safety

Safety is our first concern, so say, everybody in public forums. But, there is also something called, ALARP (As Low As Reasonably Practicable). What is the measure of this ALARP. What is ALARP for me need not be the same for others. Still, we have to put our wisdom so that we do not endanger the lives of workmen, public and the environment. One should not go by apparent/immediate effects. Instead, one should see for invisible but disastrous and also long term effects.
Mostly, shop floor managers see the the visible effects whereas safety professionals see the invisible effects. Here comes the friction and safety managers will be pressurized to yield to the arguments of "there are no effects and not to imagine wildly".
Safety managers are treated as untouchables / non-entities and ridiculed at every next opportunity. It is known that every known hazard will not lead to a disaster and this gives strength to the arguments of short sighted shop floor managers and safety managers have to watch in despair.
One does not try to learn from the case studies and safety managers are shouted when pointed about similar occurrences and may be branded as brainless fellows.
But, when something happens, the black sheep will be the safety manager. At that time, again, safety managers are ridiculed for not foreseeing the hazards and that they do nothing.

The solution is to fix responsibility. If safety manager is lax, he should be responsible. If production  manager doesn't listen in spite of pointing out by safety, he should be responsible. Management should not try to protect production managers in those situations. And, every near miss/incident, irrespective of its severity, should be investigated and responsibility should be fixed. Only then, I feel that everybody understands safety and its benefits.

Oct 9, 2013

Government proposes safety rating system for chemical plants | Business Standard

Government likes to rate chemical plants based on 19 key performance indicators in order to create need for zero accidents in their plants with respect to safety and security and also to provide incentives to good organizations.

I feel this is a beginning and new idea from government. Government should further extend this and ask insurance companies to use this rating while assessing the premiums. Erring companies should be charged high premiums.

But, care is to be taken to ensure that (risk) assessment will be carried out by experts and these experts are selected based on strict parameters. Else, poor assessment leads to wrong faith in the capabilities of chemical plants and its management.

Government proposes safety rating system for chemical plants | Business Standard

The draft document is available from the link as below. Interested parties can send suggestions by  end of October 2013. Such suggestions can be sent by e-mail at dirrt1@rediffmail.com; arun.agarwal@nic.in or by post. The department after receiving the comments will incorporate to prepare final documents on “Chemical Plant Safety and Security Rating System”.

http://chemicals.nic.in/Forwd30092013.pdf


Sep 20, 2013

WTF Facts : funny, interesting & weird facts about probability, risk

WTF Facts : funny, interesting & weird facts

The above link gives information about the probability of some events (mostly death). Cancer death is most probable among the listed events and chance of being hit by a falling satellite is the least probable.


Sep 1, 2013

Chemical leak in Shanghai kills 15, sickens dozens

Chemical leak in Shanghai kills 15, sickens dozens

Ammonia leak from a food processing company led to deaths and many more were affected. About 200 fire fighters were involved in water spray to dissolve ammonia.

It is stated that earlier in June in some other company, an ammonia leak led fire and more than 100 died.

Incidents of ammonia fire are rare to find compared to toxic deaths.
LINK

Aug 22, 2013

NFPA fire statistics for the year 2011

http://www.nfpa.org/research/fire-statistics

One can see fire statistics, statistical reports, major causes, etc by clicking through different links. Very much useful to caution the people.

Aug 21, 2013

Rescue of persons from height in China - videos from Yahoo

http://in.screen.yahoo.com/dramatic-high-rise-rescues-caught-180152688.html

Person dies after long hours of work

An intern died after reportedly spending long hours of work. Legislations specify certain number of hours of work per day, per week, etc and limits on overtime hours also. However, these rules are mostly applied to factory workers and I am not sure whether they are applied to supervisors and blue collared employees in the same organization. 
This leads to spending long hours at work place by these people, either by force, or even if there is no requirement, may be to learn the work, or to get attention of higher authorities. This type of work is not possible forever. If somebody joins as trainee/apprentice and even for regular employees, managements of any establishment should strictly enforce working hours, instead of being a passive onlooker. Only then, these types of incidents can be avoided at the work place. It is all in work culture which is guided by safety culture of the organization. 



610 kg Saudi man forklifted to hospital

This may be an exceptional case. But, people should not draw inspiration to use forklift for personal movement. Forklifts are for material handling. A number of persons got injured while riding on forklift. If the person standing on the forks near mast does not remove his hand, he may get finger amputation during mast movement.
Remember the injury to Imran Khan, famous cricketer and politician in Pakistan who fell down and got injured due to imbalance while standing on a forklift.
610 kg Saudi man forklifted to hospital

Saudi Civil Defense members use a forklift to move Khaled Mohsen Shaeri from his apartment in the Saudi city of Jizan, and to be airlifted to the capital Riyadh for medical treatment, on August 19, 2013.
LINK

Aug 20, 2013

Stress management

In the childhood, we do not know what we are doing, though we are pleasurable (or nuisance) to others by our deeds. Later as we grow, we may not remember what enjoyed or suffered at that age. In the childhood, we are influenced / disciplined by others.

The day we start realizing what we want, we put lot of efforts voluntarily to reach the goal. This leads to stress when we are controlled by others also, like, parents, teachers, friends, bosses, etc.

We put so much effort to get good work/job, and once we get work, we become eligible to have a life partner. So much advice pours in from all directions, and one day, we marry some one.

By the time we understand each other and settles in the married life, offspring will lead to pleasure initially associated with stress on their studies and future. All along with this, we will have constant work pressure. Any headache from work place also will lead to troubled life at home as we find it difficult to put a stop or zip the thoughts of work. Though, people preach we should balance work and family life, our craving for excellence in both will not lead to any happiness anywhere.

To climb up the steps in work place, we do more work and a performer will always get more work and any drop will wipe out all hard work done all long till that time. So continuous stress will be there on us from work place activity.

Family pressure to take care of spouse and children and sometimes unnecessary fears, only compound our stress.

Experts advise to visit religious places, do exercise, take breaks from routine life, change food habits, develop hobbies like book reading, social service, etc but nothing will relieve stress permanently and bring happiness. Whatever we do, we keep on thinking about work and family in the mind.

We have to take stress part of life and live with it. If we observe others, for a given task, stress levels are not same in all persons. Again, with age and experience, our stress levels will change.

Something stressful today may not be causing same level of stress tomorrow. Many suicides can be stopped, if persons with suicidal tendency do not take hasty decisions. Just leave the so called  problem to its fate. May be solutions can be found in a day or two. Sometimes, the problem on its own disappears. Other times, it may persists, but we may get some more time to solve. At the most, we may loose something, like, money, reputation, etc. But, definitely, we will get much more later by our hard work. At this point of time, i.e. after lapse of time, when we look back, we may laugh at our own rash decisions/thoughts.

Just sit back and think about future. After all hard work, at the end of our active work life, what we want. We might have lost all our valuable time (read personal happiness), by the time we reached the fag end of our work life. The way we left our parents, in pursuit of our goals, our children also will leave us. May be spouse also, will leave us forever, or will stay with the children and we have to spend lonely life.

With all money and so called higher prestigious positions we reached, nothing will be useful when we are at say 55 or 60 years. In the young age, while spending long hours at work, we would have missed many lunches. But, when we reach certain age, even if we get time, we can't eat because of the health problems.

Finally, our hard earned money will be useful to family members and others. May be we derive satisfaction that they are happy. But, they too will be unhappy and you will not get any appreciation for your efforts, because their ambitions are much higher as their start point is more than yours.

A disciplined life, without too much ambition, will make us to live with peace of mind. Though, people advise to dream to achieve, our dreams should be in line with our limitations. Building castles in the air will not help us, unless we don't mind with the results and be happy with whatever we get.



Aug 18, 2013

Understanding self may help to reduce violence

Greed and ambition are turning us to go to any length to get what we want. Short cuts are taken in the form of physical abuse in this regard. This is making us to be like beasts in the wild life.

If we sit quiet and think what is that we want, whether really we should have those and whether possession of the same will bring happiness forever, and if we compare with those already we possessed by similar desire, we find we are not having happiness and peace of mind.

Whatever we already possessed by various means would have brought only momentary or short living pleasures.

For these temporary gratifications, we go to any extent, if we are not in proper frame of mind. As the media reports we see, many killings are happening, to steal or to settle some issue.

All these to satisfy this body. But, do we really know what is our body and what is that inside. If we know, probably, violence may come down, because our beautiful body on outward appearance is actually containing parts which we may not like to see, if our skin is not present.

Imagine the world, where we don't have skin and have to live without skin. In such an imaginary condition, if it is real, whether we really try to behave the way what we are doing now. It is my belief that our mental state will become balanced and try to live without harming others. What we have to struggle is to satisfy our hunger and minimal needs.

Mahatma Gandhi said that this world is having enough to satisfy our needs but not the GREED.

If, one sees medical education videos available in youtube, like, https://www.youtube.com/watch?v=qTbhWxEu27I, and similar ones, our thought process will change and definitely, it will be for a better world than what is today.

Aug 17, 2013

Fire while working on a gas line

A fire erupted when persons were working in a hole (pit) on gas line. A person with minor burns on face and hands went to hospital. The flames caused damaged to electric lines above.
It is reported that the crew searched for nearby shutoff valve to stop the fire. It appears that the crew did not do their job hazard analysis properly. Whether any safety permit is taken also is not clear.
This work, ie. working on a gas line that too in a pit is nothing but a confined space work and also working on line filled with gas.
One should have stopped gas flow and evacuated the line with inert gas before start of work. For safety, slip plate also should be inserted on either ends of the gas line to avoid passing or accidental flow. Emergency plan also should be in place which prepares the persons involved what to do in real emergency situation.
Searching for shutoff valve only indicates poor planning.

http://www1.whdh.com/news/articles/local/north/10011420876346/gas-main-break-leads-to-manhole-fire-in-bedford/

Aug 14, 2013

Hazards in the job of trainers?

Recently, I delivered a talk in a safety training programme. After the lecture, I went out of the training hall, and tried to talk to my office for vehicle pickup to my workplace. One of the participants came to me and advised me to remove portable microphone, which was given to me before the talk. My phone conversation was audible in the training hall.

This is a lesson for me. I should have switched off the mic and handed over to the program coordinator. I forgot this. The other side is whatever I utter also will be audible and any loose talk (which may happen) would have put me in shame, if not in trouble.



Aug 12, 2013

Picture This! Shocking Video Debunks Workplace 'Accidents' » SafetySmart

Picture This! Shocking Video Debunks Workplace 'Accidents' » SafetySmart

In the video, a woman carrying hot water slips on a smooth surface having some spillage and the hot water splash on her body causes scalds.
The video in the above link is old and seen earlier also. However, it is important to note that many do not care about smooth slippery surfaces that are because of surface finish, spillage of liquids, etc. Use of improper shoe, or presence of congested areas, etc add to the hazard. Many even question about considering such surfaces as hazard.

Pray God that nobody should undergo such punishment.

Aug 11, 2013

Dangers of hydro fluoric acid HF

Recently, I had an interaction with some persons in a training programme. During the discussion, a person narrated his experience with HF handling three decades ago.

The person was asked to take a plastic bottle from one place to another. He held the bottle at the top and it crumbled and in the process, he had splashing of some contents on his thumb. Not knowing what it is, he washed and continued his work. Later, in the evening he had swelling and pain for which he consulted the doctor.

On enquiry, it came out that the bottle contained some HF.

After a week of exposure to HF, the injured could see the bone of the thumb and it took a long time for recovery.

Though, I could not make out the injury from the normal appearing thumb, but the pain underwent is visible, when he narrated the incident to the audience.

Search from internet shows incidents, wherein, innocent persons just washed off the spillage with some water and continued their work, but were found dead in the sleep.

As per standard practice, in case of any chemical splash, remove the clothing and wash the affected organs for atleast 15 minutes and consult the doctor. Even after 15 minutes wash, only about 95% of the chemical is removed and thus care is very much required. One should not ignore the advice by experts.

Jul 28, 2013

Industrial accidents - No value for human meat?

Today, I attended a one-day medical education programme. In one of the sessions, a speaker, while speaking about industrial injuries and care to be taken, lamented that we value animal meat whereas no importance/value is given to human meat. 
This statement is very much appropriate considering the fact that little care is taken to protect workers and this is the reason for occurrence of so many injuries every year in industrial establishments. Lucky are those who retire, without disfiguring their organs.

Jul 25, 2013

Road safety - impatience of heavy vehicle drivers

Today, I went out to take admission for my son. My wife was on the wheel. While returning, on a busy road, a state government bus driver kept honking and we could not give way, as the road ahead is not free. After a while, that driver overtook us from left side and drove to right past of our vehicle, threatening to crush our car. While overtaking, he waved his right hand furiously.
I could not understand, how one will get moving space when the road is full of traffic. All vehicle drivers need psychology classes, road accident data, reasons for road accidents and stress levels to all on the road. As per data, most of the road victims are due to hit by state buses.
Recently, a college girl died (see my previous post) when hit from behind by a state run bus. 

Jul 24, 2013

Road safety: Heavy rains - pot holes - accidents

A school girl died when she fell from pillion seat due to pot holes and was hit by the bus behind. The roads were damaged due to rains and municipal authorities say that they have to wait for dry weather for road repairs.
The quality of the road is very important and it should not be some temporary patch work. Otherwise, this will repeat with every rain.
Though some quality professionals do not agree that quality and safety are interlinked, the above incident shows that both are linked. No quality means no safety.
The contractors should be penalized for bad work and bank guarantees should be obtained for specific period.

Jul 11, 2013

Manholes: an open sore - The Hindu

Manholes: an open sore - The Hindu

Manholes like bore wells are death traps. Poor maintenance, removal of manhole (possibly clogged) cover by somebody to allow draining of water stagnated in front of their house/building, theft of manhole covers, not putting back after dechoking, etc are some of the reasons which lead to fall of persons when it is even dry or not known to persons when covered with water, particularly in rains.
Few years ago, a person was washed off through the coverless storm water drain and his body was found few kilometres away in open canal.

Jul 10, 2013

Radiological Safety Officer - training programme

 http://www.iarp.org.in/wp-content/uploads/2011/04/details_about_nucleonic_gauge_training_course.pdf

The above gives details of eligibility, course topics, application form, etc about training course on "Radiation Safety Aspects of Nucleonic Gauges" conducted in Mumbai. Qualifying the training course makes one eligible to work as Radiological Safety Officer (RSO) which is a statutory requirement for facilities dealing with radiation.

Jul 4, 2013

Control room safety - Hospital 'Alarm Fatigue' Killing Patients » SafetySmart

Hospital 'Alarm Fatigue' Killing Patients » SafetySmart

Control room safety issues:

How much is TOO MUCH? There is a limit for everything, but what is the limit is the main question and it may depend on person to person.
Lack of or overdose of information also do lead to dangerous practices in a workplace.
Few years ago, I saw a number of information bulletins in a factory which I visited as a part of my safety diploma course and I thought that nobody will see those bulletins as people will not find time unless 15-30 minutes is spent in that place. And shop floor supervisor will not allow his worker to stand and read for so much time.
Information should be crisp and to the point.
Similarly, number of indications and alarms in control room of a plant also should be judicious. If more number are to be provided, then there should be more number of persons in the control room, i.e limit the indications and alarms to be taken care by each person. May be 3-5 monitor screens (monitor size also matters!!!) per person to be viewed for action.
Else, one will not be attentive and is lost in the maze of so many parameters to be monitored, leading to a dangerous situation.

Jun 25, 2013

Burn injuries - an article from The Hindu titled "A burning question"

A burning question - The Hindu

LINK

In an article on burn injuries in The Hindu, following are stated:
  1. Out of 30 lakh burn injuries every year in India, 10 lakh victims die and most of them are women and children.
  2. Burn injuries can be from heat, electricity, chemicals, light or radiation. 
  3. First degree burns involve upper skin (epidermis) and need about a week to heal.
  4. Second degree burns involve upper skin (epidermis and and portions of dermis), sweat glands, hair follicles, etc leading blister formation, swelling and pain and require two weeks to heal.
  5. Third degree burns involve deeper skin, charring the tissues and structures and may require three weeks to heal.
  6. Fourth degree burns involve subcutaneous tissue, tendons and even bone damage.
  7. Hot air inhaled during fire incidents damage respiratory tract and swelling and lead to complications.
  8. Beyond 40 degree centigrade, protein in the skin is coagulated causing tissue destruction.
  9. In chemical burns, protein is converted rapidly to salt causing same damage.
Burn injuries also affect psychology of the persons and require care and counselling.

During acid splash, generally persons wash with some water and do their business. But until unless total chemical is washed, it will continue to cause destruction. There can be delayed effects from inhalation of vapors from the dress material that is soaked with the chemicals like HF, phosgene, etc leading to deaths in the sleep.
Alkali burns cause more destruction to eyes even to the extent of blindness.
Therefore, removing the clothes with chemicals, continuous washing for atleast 15 minutes (even then only about 93-95% chemical is washed off) is necessary and this information should be spread among all persons working with chemicals.
In case of flash burns from arc flash, the temperature can be 20000 degree centigrade and can lead to deaths.
Then, immediate treatment to burn victims is also a must. As it gets delayed, damage will be more and chances of recovery will come down. One should know, whom to contact, which hospital to be referred and action should be taken to quickly shift the victim with care.

Jun 23, 2013

Mixing of chemicals - chlorine release


Chlorine gas released in to atmosphere affected persons, when staff of a health club accidentally mixed polyaluminium chloride with the swimming pool disinfectant sodium hypochlorite
 
Poor management and control of hazardous substances was found as the cause for the occurrence of the incident during investigation.
        
Proper training, testing of understanding and retraining are most important in handling chemical substances and only those who qualify and are certified for hazardous substance handling should be engaged in such works.      


http://www.heraldscotland.com/news/home-news/health-club-fined-over-toxic-gas.21393479

New NIOSH Smart Phone App Addresses Ladder Safety

The following links to the subject matter. While I copied this application in my android tablet and phone, I found a number of android applications useful for safety professionals, like checklists, API pressure vessel questions, dangerous goods manual, physics equations, chemistry equations, heat exchanger, cylindrical tank volume, valves, sound meter, light meter, speed meter, HSE news, etc. And all these and many more are free.

http://www.cdc.gov/niosh/updates/upd-06-17-13.html

Jun 16, 2013

Scaffold erection - work at height - construction safety

I booked a flat and work is in  progress (for last three years!!!). Today, I attended a meeting of flat owners with the builder. Like earlier times, again date for handover was extended by a month. The reason told was that because of rains and high velocity winds at height, and as it involves erection of scaffolds i.e work at height, construction activity was stopped.

Whatever was in other owners' minds, as a safety professional, I was glad to hear such a thing that builder stopped his work inspite of project delay. Already, he is running beyond the agreed possession date which was almost two years ago and is liable to pay some compensation as per the agreement.

How many will take such a decision though it is well known fact that any untoward incident will lead to project delays due to enquiries by police and municipal authorities.

Construction is an activity in which large number of accidents take place and the work force is also mobile with little protection for their lives.

Jun 13, 2013

Bank employee takes a nap on keyboard, transfers millions | The Hindu

Bank employee takes a nap on keyboard, transfers millions | The Hindu

293 million US dollars were transferred by a bank employee who was asleep while on the job. Imagine what can happen if somebody on the job in the control room of a chemical plant sleeps.

All plant employees should be healthy, and had sufficient rest before attending their duty. In some plants, workers have long working hours and on few occasions, they have to continue if reliever does not come, doing overtime.

Legislations specify number of working hours (8-9.5 hr) with rest in between and also the number of hours which a person can work continuously in a day and number of hours in a week, quarter and so on to ensure that they get sufficient rest and are not forced or lured for extra money they get. It is not possible to work more hours continuously and this will lead to mistakes and accidents.

May 8, 2013

Forklift for transport of persons

 Most famous cricketer and politician, Imran Khan fell from a makeshift platform on the forks of a forklift, while moving up to reach election campaign stage. The video (http://vimeo.com/65647621) and (http://www.youtube.com/watch?feature=player_embedded&v=AlUH9vqCf5g)  show clearly that already, it was used to move some people on to the stage before the incident happened. There were 6-7 persons including Imran Khan on the forklift, and while fifth person tried to go up, the group lost balance and fell from a height of about 5 m.
The idea of using forklift instead of erecting steps to reach the stage is a misconceived one and in the process caused injuries to the cricketer and politician. In industries, use of forklift for other than material handling/movement is viewed seriously.

May 1, 2013

Bursting of empty plastic chemical drum while removing the lid with a hot rod




Three children aged 8, 10 and 12 years were mildly injured when they tried to remove the cover of the empty plastic drum that was used for storing chemicals. As soon as they inserted a hot rod through the top cover, the drum got burst.   The children were offered Rs. 10/- to remove the top cover by a person. The hole mark is visible near the ruptured portion. 




Safety work permit - violation of conditions

 Safety work permits are issued after ensuring that the site conditions are suitable for safe work. Check points are verified and are certified for start of work. However, still sometimes accidents take place indicating that either job hazard analysis is not done properly, conditions are altered during the course of work, workmen are not briefed about hazards and measures to be taken, many times they are not aware of what is written in the permit and simply do the work as they were told or as they can do, lack of supervision, etc.
In a huge manufacturing facility, a number of works will be going on and generally, the supervisor will be monitoring more than one work at any given time. In such a condition, at least, emphasis should be given to training to the persons engaged. All are not of superman category.
But, when earnings are motive, all other aspects take back seat. Many times, procedure for selection of the contractor or agency to do the outsourced work is the culprit. If selection is made without assessing the competency of the person/agency for safe execution of work, without checking the credentials, without giving proper description of the work, then we will get a wrong person in most of the cases.
In some cases, trainees are placed directly on to the job without proper class room training and supervision. This also leads to accidents as they are in the organization to learn, initially in the class room and then to have on the job training under supervision. Sometimes, these trainees even will be manning the shifts, particularly at night times when availability of regular work force is less and may be when nobody watches. Though, this is disastrous, shop floor managers take such decisions without taking the concurrence of higher ups. If seniors also give consent, then it is silly and such persons should be terminated or they should be asked to supervise instead of posting trainees for manning the shifts / works.

ATTENTION ONLY TO PRODUCTION CAN LEAD TO DETENTION.
ATTENTION TO SAFE PRODUCTION WILL SURELY LEAD TO CONGRATULATIONS.

Apr 29, 2013

Sun burns on banana - Banana burns???

I went out with my family for some work and parked the car under direct sun as it was open ground and there is no shaded parking available. I carried some banana with me and left the remaining inside the car. After coming back 4 hours later, I found banana peels got burnt as above. For comparison, two bananas which I carried with me are shown adjacent. Only peels turned black and inside, fruit is good though some softening took place. Outside temperature was 40 degree Celsius. The window panes were kept about 0.5 inch down from the top instead of fully closing while leaving the car to allow escape of hot air. Still, the above incident took place. I do not know what will happen, if we sit for four hours in the car in those conditions. Atleast second degree burns!!! We have to give a thought about safety against sun exposure and sun stroke.

Banana peel that got burnt after exposure to sun at 40 deg C for about 4 hours


Investigators: Rail car, ammonia tank did not explode at West plant - WacoTrib.com: Fire

Investigators: Rail car, ammonia tank did not explode at West plant - WacoTrib.com: Fire

LINK

At the end of the article in the above link, it is stated that there is no water in the hydrant.

Apr 28, 2013

Playing in the mud is good for health

An article in a vernacular daily says that allowing children to play outside is good for them in all respects. Playing with others leads to developing bond. Mud smell keeps the mind pleasant. Playing outside helps them to understand nature. The brain activity increases as they make some pictures, dolls, etc with mud. Further, the mud contains good bacteria that increases body resistance to diseases. So, says the article as per the doctors in Mumbai.
Whereas video games make the children to be aloof, to stay indoors, eating all junk food while playing leading to obesity and other health problems.

Disastrous effects of sitting for long hours

 Sitting is the new smoking - a health alert in Times of India daily reads. As per research for 15 years studying the effects of sitting for long hours, it is found that sitting for more than four hours causes obesity, diabetes, high blood pressure, cardiovascular disease, multiple cancers, etc. It is advised to set an alarm to go around and have some exercise. Sitting makes metabolic system to sleep whereas small movements will help to keep metabolic system recharged.
My ex-boss (20 years ago), used to take water as soon as he comes to office and relieves pressure in half-hour to one hour. Before coming to seat, he will take a glass or two of water and resumes work. This makes him to get up again after sometime. I find this is very good method to avoid sitting for long, immersed in the work.
However, with my personal experience, I used to hold the pressure for sometime (even 3 hours) because of work pressure. I do not know the health effects, but definitely not good for the body.

Apr 25, 2013

Let us thank those who find our mistakes

We will be hurt and get irritated too when somebody points out our mistakes. This happens in our annual performance assessment report, audits, discussions (arguments?) with colleagues / partners / spouse / children / etc.

However, there is a saying, "It is easy to find mistakes in others, Difficult to find our own mistakes".

When we take it positively, look at it with a peace of mind, we feel we should thank those who find our mistakes because they have done our job.

As per another saying, " a problem found is as good as half of the work is done, we only have to find a solution". The problem is our inability to find the problem.

Recently, I watched a movie titled, "Hot Shots! Part Deux" in TV. A dialogue in the movie is, 'we all have permission to make mistakes. It is called learning".

A long time patient sometimes, is better than a doctor.

Learning from past accidents (mistakes) is what we should do. Like we can't have life long schooling, we can't be continuous learners, making same mistakes again and again. We have to learn from our mistakes and those of others who suffered.

Safety officers/inspectors during inspection / audit find the deficiencies and communicate to plant in-charges. Plant in-charges should thank these lot for finding the deficiencies and for helping them to work for a better workplace.

Apr 8, 2013

Actions speak the truth

 People, particularly those in higher positions say, 'do what you speak and speak what you do'. But, we find many times in reality that only people speak and do not demonstrate. It is hypocrisy. 
Audience, particularly those who are not from the same organization, feel and think great about the speaker by listening to the tall claims. But, insiders will have pessimism about talk by such leaders.

When some lower level employee speaks, nobody cares. But, when same of even lower level employee of some other organization speaks, people will be attentive and give respect. This leads to heart burn among the employees of the organization to which this leader belongs.

Sometimes, when talks are given by employees of same organization in which the show is conducted, higher level people go out to do their business, but this is not the case with talks from employees of other organizations. This leads to wrong impression among employees as participants that boss does not care about the speaker (and his work) and thus they too need not bother in future. This is particularly harmful to the organization when the speaker is from safety department. Similarly, questioning (or ragging) safety department employees in front of others for whatever reason it is, leads to wrong projection of importance to safety and this will only spoil safety culture.


Apr 2, 2013

Accountability for safety

In an article in Safety Center on accountability for safety, Bob Lapidus, Safety Management Specialist gave following five steps.
  1. Create written safety policies and procedures
  2. Train employees on the safety policies and procedures
  3. Provide all the necessary equipment to do the assigned work
  4. Hold everyone accountable for compliance
  5. Both supervisors and employees provide feedback as to how work is being done Corrective action is taken as necessary

Accountability means, in his words, praising when correct things done and correcting when things are done the improperly. It should not be like knee jerk reaction to punish people when something goes wrong.
While writing safety policy and safety procedures, I feel, it should be written by involving all concerned employees. If it is written by manager or consultant in his office without interaction and active participation of employees, the ownership for the document will not exist with the concerned shopfloor employees and it is likely that they may not like to read and follow.
 

Apr 1, 2013

Safety: Can You Have Too Much of a Good Thing? » SafetySmart

Safety: Can You Have Too Much of a Good Thing? » SafetySmart

The article is about the experience of Australian psychologist during his interaction with employees of a corporation. Some opined that too much safety (directives, guidelines, procedures, initiatives, etc) will lead to safety saturation and employees may try to take short cuts like those in traffic jams where motorists try to ignore signals out of frustration of feeling obstructed, that they are unable to make move, and so on.
How much is too much is a debatable point and requires efforts of all heads in important positions along and CEO of the organization, I feel, should be biased towards safety rules and regulations, while taking a final call for implementation of safety systems, so arrived.
Being a safety professional, I am unable to agree with the statement that too much safety (is there really such a thing) works against safety culture. But, I should be open to ideas and lack of knowledge or understanding  should not make me not to listen to ideas.

Mar 27, 2013

Domestic LPG cylinder leak - lights ON - explosion - deaths and injuries

In an incident of LPG leak from domestic gas cylinder five days ago, 8 persons died and 3 more are undergoing treatment.
In a housing complex, sensing gas leak in the opposite house, neighbors opened the house by getting the keys from the house owner and when switched ON the lights, the sparks caused gas explosion.

Gas detectors are the need of the hour and any gas leak detection should lead to display of warning sign of "DO NOT USE ELECTRIC SWITCHES-DO NOT USE MOBILES-SPARKS CAN CAUSE EXPLOSION" prominently so that even in panic condition one will not try to use electric switches.
Gas cylinder / piped gas distribution agencies can distribute do's and don'ts along with the cylinders by printing behind the bill or if somebody is paying online, these instructions should be displayed on the billing page and only after checking the boxes on each of the instructions, should lead to payment page. Further, distribution agencies and community centers may take up periodical training of residents and those who fail to attend the training programmes should be penalized by way of higher billing or in the worst case, cutting off of gas supply.

http://timesofindia.indiatimes.com/city/hyderabad/Entire-family-wiped-out-in-Vikarabad-gas-leak-blast/articleshow/19233935.cms

Mar 26, 2013

Wrongly labelled bottle - causes fatality (from SafetySmart)

Wrong Bottle Proves Deadly for Worker » SafetySmart

Two workers drink from a bottle labelled as beer, but actually it is a wind shield washer fluid containing methanol. One worker who consumed good amount died whereas the other survived.
Wrong labelling in this case caused death. In some incidents, reagent bottles after use are reused for storing chemicals. If the bottle after use is not emptied and washed thoroughly before reuse, pouring some other chemical may lead to runaway reactions / explosions, etc and can injure the workers. Proper labelling is a requirement under various legislations and compliance will only help us.

Pushing up the cable roll on the stairs - fall and breaking of glass doors down below

Unsafe material handling:

Picture This! Gravity 1, Workers 0 » SafetySmart

The link above takes us to a video wherein two persons unsuccessfully try to move a cable roll by rolling it up over stairs, leading to its roll down to the ground, shatter the glass panes of the entrance, speeding past to the street road. Though it is funny by watching the video, it is most dangerous act that could have endangered many lives in the building and on the road.

Mar 25, 2013

Unruly behavior of employees with safety officers

 I heard many times from my friends in safety department in various government and private organizations about the tough talk and occasional insulting behavior by those in the production line when discussions take place on safety issues. The hazards identified are ignored with a sarcastic remark that safety officers do not have any other job other than pointing out and the hazards pointed out are often not considered fit for action. They do not try to learn from incidents happened elsewhere saying that it is too theoretical and will not happen in their plant because of their confidence on their management skills.
We have ignore the unruly behavior of others as it is not in our control and we should not get disappointed and stop doing our job. We have to collect case studies of other organizations that resemble situations in our work place and keep circulating to all employees including top management for information.
We have to be bold and if required we have to take up to the notice of higher authorities when junior level people do not listen. Most of the time, people will sit straight when issues are put in writing with a copy marked to group heads and CEO or MD. I am sure this will help over a period of time in controlling unruly managers.

Mar 24, 2013

Long hours on computer - impact on health

 Following is the link on the above subject appeared in The Hindu news paper y'day. Sitting in front of computer (desktop/laptop/tablet/smart phone, etc) lead to different kinds of health problems like neck pain, back pain, wrist pain, finger pain, joints pain, shoulder pain, headache, tears from eyes, numbness in bottom limbs, etc.
Some tips on ergonomics issues are provided in the article  including taking breaks for every 30-60 minutes for five minutes, looking at distance for every 10 seconds, closing the eyes for 5 minutes for every hour work, etc.


http://www.thehindu.com/features/magazine/boot-up-your-health/article4541693.ece

Mar 22, 2013

From Yahoo - Stress contributors

An article in yahoo states about factors that cause stress in human beings.
http://in.lifestyle.yahoo.com/10-habits-contribute-stress-071639766.html

Amont them are lack of sleep, irregular meals, long hours of work, family/work place problems, no exercise, not giving time to self, etc.

In the name of getting in the eyes of bosses, some spend long hours at work place, sometimes even when there is no work. This reduces the time available to family members, affects the health in sitting idle for long hours without exercise, may be leading to commuting back to house in busy hours, no relaxation (spending time at office is definitely as good as spending the same at home), missing friends/relatives, etc. Similarly not having time for self like for leisure reading, entertainment, spending time in happy surroundings, etc will lead to stress buildup. Piling up of personal jobs due to more office work also increase the stress levels.
Spending time on internet without purpose also causes stress and after spending for few hours, we might have felt that we wasted our time without any gain. Further, sitting for long hours for surfing will also cause health problems due to sitting in same posture.
As recommended by experts, observing no phone / no internet / etc will bring some peace of mind. We should also take our leaves to be away from routine office works so that we can concentrate better rather than working continuously without even consuming our eligible leaves. This will also help the organization for which we are working. May be some shortsighted bosses think that the person on leave is not committed, but we have to take care of our health also.

Mar 21, 2013

Cheaper ammonia detectors from IGCAR scientists

Here is the link on the above subject. Cheaper ammonia detectors are developed by scientists from IGCAR, Kalpakkam. The news item appeared in The Hindu on 21.03.2013.
http://www.thehindu.com/sci-tech/science/cheaper-way-to-detect-ammonia/article4530105.ece

It works in the range 0-525 ppm.

Mar 17, 2013

Safety goes off the rails - The Hindu

Safety goes off the rails - The Hindu

The above link is about safety issues related to Indian Rail system. There were 4999 rail and weld fractures during April 2012-January 2013 over 64000 km rail network. Alert gang men identified these problems and thus could prevent rail accidents. Government requires 1.4 lakh rupees over next five years and expressed its inability provide this money to address safety issues. There are about 90000 vacancies related checking of safety issues which the railway minister promises to fill up.

There will be huge cry whenever fares are increased. However, one should realize that there will be compromise mostly with safety when we try to cut costs. Those who raise voice when fares are increased also should not raise voice when their wages are not raised or allowances are not raised. Where from anybody gets money to meet the costs without raising the income. Corruption should be fought and one should ensure and be vigilant that we do not get cheap quality product or service for the money spent.

But, we should understand and help the authorities also when charges are increased and cooperate so that our own safety during travel can be taken care.

Else, the bleeding companies (in road, rail, air, sea transport related) will only risk our lives.

Feb 27, 2013

Ego - obstacle to safe practices

Generally, safety professionals have advisory role. Any advise from company's safety professional(s) may be taken with good heart, reluctantly accepted because of pressure from top management or will be rejected vehemently. Sometimes, safety professionals will be questioned about their knowledge/experience/capability in matters of production activities and production managers try to draw a line saying that they are more capable of taking care of their work and also of safety in their work place and that they do not need any advise from safety professionals.
However, when some incident happens, safety professional of the company will become the first target of these production managers, saying that they were not sufficiently warned about the hazard, that the safety professional slept without doing his job, and so on. This will be the case even if there were some incidents in the work place.
Surprisingly, sometimes, even regulators too question safety professionals of the company instead of engaging the production managers for safety related lapses in the work place.
The ego in the minds of production managers (and down below) is an obstacle to listen to the voice of safety professional and this endangers safety of employees in the work place. They do not accept the fact that there is something (mindset to see the dangers and to learn lessons from events) missing on their part leading to occurrence of nearmisses, incidents and accidents. Any occurrence is taken as onetime affair and is not acknowledged for system deficiencies. Even efforts will be made to cover up the issues or not to bring to the notice of safety professional for investigation and thus do not want to learn lessons.
The case studies, lessons from occurrence that are freely available in the internet are taken as too theoretical or that these are not applicable to their work place. Nobody can help such managers and those working under them will only become easy prey to the hidden dangers.

Vitamin D deficiency - exposure to sun helps

In a report published in the news paper, it is stated that vitamin D deficiency can cause weak bones, obesity, chronic pains and depression. Exposure to sun helps in increase of vitamin D levels in the body which helps in quick recovery in case of fractures, and so on. Lack of vitamin D manifests itself through acute pain in the feet, shoulders, neck and joints in some individuals, as per the report. Also there is possibility of low immunity levels, diabetes, etc.
One can have sufficient vitamin D simply by exposure to sun without paying extra money.It is reported that fair skin people need about 20 min/day exposure to sun 3-4 times a week, whereas for dark skin people, it is 30-40 min exposure a day for 3-4 times a week. The ultraviolet-B radiation from sun which is intense during mid day helps to make this vitamin. One should keep moving while having sun exposure and stationary people will receive sun burns.
From the above, for working people who have to put long hours (forced/voluntary) by going to office early and coming out in the late evenings; spending the day in cubicles; not venturing out, etc are more prone to side effects of this vitamin D deficiency. Thus, though we may be in the good books of the boss for  EXTRA hard work by spending more hours in the work place, after few years when we become sick due to vitamin D deficiency, we will be sick and also fall  from the grace (of the boss).

http://www.thehindu.com/sci-tech/health/diet-and-nutrition/soak-up-some-sun/article4455404.ece

Feb 10, 2013

Fatal prank

In a prank played by a friend, a person playing cards jumped from third floor and died later. When a group of friends playing cards on the third floor of a house, suddenly a friend shouted 'police'. Fearing for the worst, a person in the group playing cards jumped from third floor, fell on insulated electrical wires and then on the ground. Though, there were no visible external injuries, the person died due to internal injuries while undergoing treatment.
Such pranks or horse play anywhere are dangerous, particularly in shop floor areas and shop floor in-charges have to warn all employees particularly those who are fresh from school/college as their awareness about workplace hazards is poor.
http://timesofindia.indiatimes.com/city/hyderabad/Man-plays-deadly-prank-on-friend/articleshow/18424161.cms

Feb 9, 2013

Human error-power supply failure to air traffic controller radar screen at IGI, New Delhi


In an incident involving human error, an electrician at Indira Gandhi International (IGI) airport, New Delhi switched off a miniature circuit breaker (MCB) while fixing an electrical fitting. This MCB as it is reported, is on the line supplying power to air traffic controller (ATC)  radar screens and screens went blank. The standby power (may be diesel generator) came into line in a few seconds and rebooting of all consoles and restoration took about 45 minutes.
Meanwhile, the air traffic controllers having tough time,  guided the planes for safe landing with their experience. All departures were put on hold in between. As it is during such emergency times, Murphy's law showed its application once again. But the experienced personnel guided even a plane or two, low on fuel to land safely without panic.

From various reports in the internet about the incident, there seems to be failure of, or no uninterrupted power supply (UPS) / inverter backup directly connected to ATC radar system, as the screens went blank. That it took sometime for standby power to come into line, indicates that this is a diesel generator (DG) set power supply. This takes about 30 seconds as we experience in apartment complexes or cinema halls. Generally, people use UPS even for domestic computers, because of fear of losing data. Also, because of power cuts,  people use inverter widely at home and business houses. For critical systems, normal power supply should be through inverter/UPS so that any failure of power supply on upstream side will not affect the operations. Now-a-days, solar powered inverters are also available in the market. This should be in addition to the other backups for use. MCB/any other switch should be located on upstream side of these UPS/inverter, rather than on the downstream end so that mistakes like these will not happen. May be the authorities were confident of their backup systems.

Generally, risk assessment is same for aviation and nuclear industries. The risk assessment should be reviewed and measures should be taken to reduce risk levels. It is horrible to think of so many planes in the air without guidance for landing. 

To avoid such mistakes as in this case, there is a need for safety work permit system as practiced in all industrial facilities, for carrying out any job having impact on human lives, property and or environment. Also, that this important MCB could be switched off by mistake indicates that critical safety systems are not protected or its importance is not recognized. Authorities have to review entire safety practices, identify critical systems having impact on persons/property/environment and prepare documented procedure for implementation. Suitable caution boards/warning signs/names and contact numbers of authorities to be contacted in case of need should be displayed near these critical items. A nodal authority (safety officer) should be identified for entire ATC under  whom, permission/approval should be given for various works so that there will not be any lapse. If more than an authority is identified, there may be a situation that one will not know about permission/approval given by the other. Also, lockout/tagout (LOTO) system, if feasible needs to be put in place. 

Apart from power failure like above, it is possible that due to hardware or software glitch or even entry of insects/lizards, the screens can go blank or computer system can hang and for such a situation also, one has to plan for diverse redundant systems to avoid surprise/panic. Whenever, there is no communication between computers or computer and signal receiving/emitting towers or no change in data for a specified time (may be a second or milli second or some other duration depending upon the criticality), audio-visual alarms should be incorporated to alert the concerned personnel for immediate action.

Feb 6, 2013

Design changes - no compromise for safety

Operating facilities, in order to increase capacities, try to carry out modifications in the equipment, replace some, change process parameters, etc. This can also be done through bypassing of safety systems, to achieve quick gains. While doing all these, if the consequences on safety of the personnel, environment and property are not analyzed, then it is likely that some foolish action will lead to total closure of the plant one day. Any change proposal should undergo HAZOP/WHAT IF/ETA/FTA studies. The design should be carried out only by experienced persons and safety studies should be carried out by safety professionals. If it is done by some entry level person and is endorsed by higher ups without review, we may be inviting the disaster.
Even though the safety studies will be time consuming, it is worth doing before carrying out changes rather than repenting later. Top management should recognize this and support the safety programmes. Else, shortsightedness will shut the plant at a later date. Though, it is easy to blame safety department at that time for not doing their job, one should introspect whether the advise of safety officer was given due importance or not.
Management of change is an important activity and shall be followed by all facilities, irrespective of their size, nature of work and product.

Jan 30, 2013

Emotions - health effects

I read the following in a local magazine.
  • Brain contracts with increase in age and leads to forgetfulness. However, physical exercise compared to metal exercise and social activities will help to keep the brain active.
  • Happiness and heart are linked. More happiness increases heart beats and one will not get sleep. I experience this, when I got good marks (beyond my expectations) in my XII standard, engineering final year, receipt of appointment letter (25 years ago) in the organization of my choice where I am continuing still and my first promotion. Similar is my experience, I was under pressure. 
  • Anger affects liver which leads to generation of bile juices and headache. Blood pressure too raises.
  • Tension, stress affects lungs and one feels suffocation.
  • Depression/sorrow reduces energy levels which affects lungs and leads to associated respiratory problems.
  • Fear affects kidneys and one looses control over urination.
  • Threat affects heart and at higher levels it can affect kidneys also.

Jan 24, 2013

Problems of touch screen operations on desktop/laptop

Touch screen operations on desktop computers/laptop became a reality with Windows 8. Those which can't be imagined earlier, have come into market now. We are not new to touch screens and are using it on mobiles and tablets. Also, we used to limited extent, in the control room monitors of sophisticated industrial facilities.  

I feel computer use by touch screen, particularly desktop and laptop, may lead to aching of shoulders, wrists and forearm after some period of use, when we have to lift our hand every time for touching the icon on the screen. Unless, we rearrange the position of the monitor/laptop to a lower level (needs to be checked and verified before put into use), users may face such problems over a period of time. Operation with mouse/key board and on the screen are thus different and ergonomics experts' advice for suitable placing of monitors is to be obtained.

I had personal experience of such pain in shoulder, wrist and palm when I used my tablet of 7" for about 4 hours continuously once. That pain lasted for more than a day and I learnt my lesson.

Jan 23, 2013

Hi-Tec - by how much?

Some product advertisements mention about manufacturing through computer based technology. Some bill boards for spectacle shops mention about computerized checkups and tests.Some new plants are known as hi-tech facilities.
In all these, what we understand is that they use some software or some techniques that run on computers. However, unless rigorous checks are not made to the software before its use, hi-tec can lead to complex problems, which we can't understand. For this, the programmer should understand fully the requirement, which should be specified by the engaging agency in clear terms. If there is no clarity in specifications and the understanding of the same by programmer is not checked, glitches may come later, which may develop in to unimaginable proportions.
What we start with hi-tec, also can become low-tec after sometime, when changes are made but not tested fully.
Management of change, i.e checking the modifications in an existing procedure for achieving the desired output, if not done properly can manage us later.
Some plant facilities started on PLC based operations initially will be suspended and reverted to manual mode because of the glitches. This is because of lack of clarity in what we want, what we conveyed to the developers/suppliers, and what we got. Hardware problems also can lead to similar situation. Sometimes, because of the complex operations involved in operating PLC based plants and poor training, managers revert to manual operations.
If we are overconfident that nothing will happen because a plant is hi-tec and leave the caution to the air, then also we may find surprises.
Hi-tec will be safe only when we address above issues.

Safety officer - not a replacement for plant jobs

Some plant managers are of the opinion that conveying their safety issues to safety officer ends their responsibility. They expect safety officer to attend safety issues and hold him / her responsible for not working on it.

It is like blaming the police for theft in their house, or fire department for fire in their house. Question arises at first place, why the theft/fire occurred. What are the lapses/deviations in the house. Instead of setting own house in order, if other agencies are blamed for their problems, they will remain unsolved.

Conveying safety issues to safety officer is also not a solution. Safety officer can only offer advice, but can not work on behalf of the plant, as he is not the owner of the plant and he does not have the authority or influence. As long as this realization does not dawn upon plant officials, safety issues continue to pileup. 

Jan 20, 2013

Responsibility for property damage in a fire

It is common to read in news papers about fire incidents, property damage and accusations of fire services for delay in reaching the incident. But, the main culprit is the owner/tenant of the premises. One should check what measures are taken by the owner/tenant of the premises. There would not have been any fire incident, had all precautions like storing of the materials properly, using proper electrical wiring, avoiding ignition sources, etc are followed and maintained. Similarly, fire detection, warning and protection system should be in place so that even in case of fire, the damage can be minimum. However, hardly any of these measures are taken or followed.
Every building should have sufficient ground storage water and sufficient distance around the building free from obstructions. However, greediness overtakes fire safety measures and all available space is used for creating some more commercial space. Having water for fire safety is not thought at all. All these failures are overlooked and fire department is accused for not reaching the fire incident place quickly.

Who is responsible for safety for works in your plant?

In an operating plant, various works of maintenance, civil, erection/commissioning of new equipment/facilities, house keeping, etc will be in progress under the supervision of in-charges for respective agencies. However, in case of any lapse with regards to safety or any incident/accident, question arises to decide who is responsible for the incident. Though, safety permits may be issued in the name of the executing agency, plant in-charge also should be held equally responsible as it is the work in his plant and is being done by other agencies because of his request. If any incident occurs, brunt is to be borne by plant officials, plant operations may have to be suspended and in worst case plant may be exposed to damage.
Hence, plant officials can't escape from responsibility to ensure safety during works executed by other agencies. 

Booze + smoking = death

It is reported in a local daily news paper that a person was burnt to death while boozing in his room. It is suspected that he did not put off the lighter/match stick/cigarette due to the intake of huge quantity of liquor and this would have caused fire and death.
Lessons:

  1. Do not take liquor.
  2. If you have to, do it with others
  3. Limit your intake to your capacity, in worst case. 
  4. Keep the company of a friend/relation who will not consume liquor at all.
  5. Do not smoke.
  6. If you have to do it in the presence of a person/relation, who will not take liquor.

Jan 9, 2013

Attrocities on females - action needed

Last few weeks, we are seeing agitations all over the country in protest against brutal acts of some fellows on a girl. Many institutions of government and non-government are proposing several actions to avoid such attrocities in the future. Government has set up a fast track court to hear the case. Companies that hire vehicles were advised to verify the details of cab drivers engaged before employing them for ferrying them to office / home. May be this should be done for all employees like it is done in important government institutions. 
A common helpline is also being proposed in some states to receive the calls from those in danger and provide necessary help.
Companies too can set up their own helpline or can form an association with other companies in the city and operate a helpline in the city of operation. Big companies can have their own helpline set up and link it to their head quarters also. 
Why some persons are engaged in such unacceptable acts is that there is no fear in them as they would not have seen the punishments. This can be seen from the appearance of similar news reports even after the first incident and uproar against it. 
No normal person goes against a speeding vehicle or a train as he is sure that it will over run him.
Such an awareness should be brought among all by awarding quick stern punishments so that nobody dares to commit such acts. Fear is the key and this only will work. Once culprits are known, then immediate punishment as per applicable law should be awarded and implemented. If somebody commits a mistake, they should be punished irrespective of other factors. Otherwise, loop holes will be taken to their advantage and crimes will continue to grow. There should not be any hesitation in this regard to save fellow human beings.

Jan 8, 2013

Safe driving measures - a record achieved

The state road transport corporation of Andhra Pradesh (APSRTC) received a trophy for better performance on road by its drivers after achieving accident record of 0.13 and 0.11 accidents per every lakh kilometers driven in the last two years. The corporation has 23000 buses that ferry about 1.2 crore passengers every day with 82 lakh kilometer coverage whereas in the country about 1.5 lakh buses ferry 7 crore passengers every day.

This low accident record was made possible by putting  a family photo of the driver along with breath analysis of drivers for alcohol before boarding. Also, the corporation sacked those drivers found in intoxicated condition.

This strong message of zero tolerance to drink driving has worked as per the words of Managing Director of APSRTC. 

From the above, we can see that tough measures to the extent of termination and encashing family sentiment result in better safety for the people. Similar measures should be taken by all industries and regulators should act tough on erring industries even by suspending/cancelling the licence so as to ensure a safe work place and environment.

http://timesofindia.indiatimes.com/india/Better-drive-safe-wifes-watching/articleshow/17935143.cms

Jan 7, 2013

Loss from IOC Hazira fire - Rs 45 crores

In a blast and fire incident at the oil depot of Indian Oil Corporation (IOC) at Hazira on 05.01.2013 at about 1230 hr,  three persons were found dead (charred to death). It took 24 hr to extinguish the fire. Atleast 75 fire tenders and 30 water tankers of government and private organizations involved in fire fighting measures used 70 lakh liters of water and 80 lakh liters of foam. The fire incident after a blast reportedly happened during welding on tank no. 4 to arrest the leak. The tank contained about 55 lakh liters of diesel (or petrol ?). All three persons died were not regular employees and financial loss was estimated as Rs 45 crores.
The depot did not have any fire tender and its fire pump hose did not function at the time of fire incident.
Questions were raised about the reason for welding on the tank that contained diesel.
Earlier a fire in Jaipur depot on 29 Oct 2009 leading to 11 deaths and Rs 280 crore loss was attributed to not following normal safety procedures.
As per established safety procedures any where in the world, hot work will not be permitted unless the tank is emptied, washed to remove flammable material, tested for absence of flammables, tank is opened to avoid pressure buildup during hot work and safety work permit system is followed. Work will be carried out only under expert supervision.

As it is seen from the news reports, welding on diesel tank, absence/non-working of fire fighting system once again prove that Murphy's law holds good.


http://timesofindia.indiatimes.com/city/surat/3-killed-in-Indian-Oil-Corporation-Hazira-depot-fire/articleshow/17918547.cms
http://ibnlive.in.com/news/surat-fire-at-ioc-storage-tank-contained-2-killed-2-missing/314206-3-238.html

Jan 5, 2013

Do not permit permissible pollution

In many industrial areas, the surrounding atmosphere is filled with smell/odor of chemicals.  The residents in the area bear this and only when accidents take place, these residents and media complain about presence of chemicals, smell, health problems, etc. Otherwise, there will not be much coverage about the problems. 
Though, these pollutants are present below the AAQ limits, still they are a nuisance to the residents. Workmen may be exposed to pollutants below TLV because these limits are for occupational workers, and they are working knowingly that they have to work with chemicals. But, why the residents should bear the brunt even to a minor extent. 
Plants should be designed for effective 100% scrubbing and neutralization of all pollutants and discharge stacks are designed for release at highest level wherein the dispersion does not lead to even nuisance pollution. If this is not done, in the long run, industries may face the ire from local residents, NGOs, media, etc leading to restrictions/closure of their plants. 
In addition, industries should spend a part of their profits towards CSR activities to improve the life of local residents by providing facilities for drinking water, roads, schools, community centers, etc and educate them for leading a healthy life.

Jan 4, 2013

Manage Change before it manages you

I read above quotation somewhere and noted in a pocket diary. Today, while going through the book I found this again.
Many changes take place everywhere and we carry out those changes most of the times to meet immediate requirement rather than analyzing for hidden dangers (or side effects). My colleague's brother who was a scientist during his government service used to say, 'what is temporary today is permanent'.
Safety professionals will be facing problems in convincing the shop floor managers to carryout proper hazard analysis and many times, the reply will be that they need clearance to execute so and so job and later it will be removed or it will be taken up for study.
There were a number of examples listed by reputed safety professional Trevor Kletz in his books like, What Went Wrong, Still Going Wrong, Learning from Disasters, etc, where many incidents took place because of improper or no evaluation of hazards.  Management of change is an important aspect in industries without which, we may end up with unforeseen events.
Sometimes, even shop floor workers too will find safety department an obstacle to their production job because of questions raised on safety, though, if something wrong occurs, it is the safety professional who will be questioned for not being authoritative or not active.
Hence, whatever be the nature of change or modification proposed, let it be process parameters, raw materials, equipment, or its accessories, auxiliary services, supports, or even operators, one should carry out a detailed analysis for hazards, impact on operation due to lack of knowledge/training/behavior, etc and then only proceed if satisfied with the results.

Jan 1, 2013

New year resolutions - Incident reporting culture

Wish you all a healthy, happy and safe new year.

Everybody will be cheerful and resolve to do so many to have a good year. At the end of the year, when we review, there may be some misses and some are forgotten. Everybody wishes for zero accident status in every sphere of work. But, this is possible only when there is a good system of reporting each and every incident whether it involves or not, of injury, property damage and environment damage.
It is reported widely and is also observed that many incidents do not come to the notice of  colleagues, supervisors and managers. This can be due to the fear of rebuke, chiding and becoming a fool in the eyes of others. Sometimes, an enthusiastic employee is dissuaded from reporting. If the employee reporting the incident is issued notice for occurrence of incidents, then he will try to cover from next time. Or, if warned, to ensure that there are no incidents, then also he will not report, though he may try to take some measures to prevent recurrence of such incidents, or he will take care that it will not go to the notice of superiors.
I feel that unless the problem of not reporting all incidents, however minor in nature they are, is not addressed, there will not be any improvement in shop floor safety. And, this is possible and can be done only with the whole hearted commitment and support from the top man of the organization. Though, critics question getting results from the action of one person (i.e top man), being in-charge of all affairs and with his powers, he is the only person who can influence the thought process of all persons down below for a safe production.
One can ask why incidents should be reported? When an incident is reported, it will be investigated by a team comprising production, maintenance, safety and other experts and analyzed for root cause and suggest measures to be taken. If it is not reported, then it may not be investigated, and even if investigated, it will be the individual or his friends which may not lead to effective investigation. Then, each work place should have a mechanism for periodical review on action taken on  recommendations. There should not be any delay in implementing the recommendations. Otherwise, improvement can't be achieved and we will see repetition of incidents again and again.
Sometimes, it appears so simple to take action but will find inordinate delay in implementation. This reflects lack of concern for safety of persons and generally reflects organization's poor safety culture.
When performance of individuals is reviewed, inputs on number of incidents occurred, number of incidents reported, measures taken to prevent incidents at the work place, extra work done to ensure safe place in areas not of his concern also should be obtained along with production figures by the assessor, which will send strong signals to all employees about the intention of the management for a safe work place.
Else, employees will be bothered about reaching production targets without caring for preventive measures to ensure safety of persons and environment.
Jobs done routinely i.e accident investigation after occurrence will yield only limited results whereas a paradigm shift in thinking of the decision makers will help in achieving good results in improving safety culture and ensuring a safe work place.

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