A place for my personal thoughts/views on safety, with focus on industrial safety.
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
Jan 16, 2021
Repetition of similar incidents - need for continuous reminder
Oct 24, 2019
Question of cost of safety!
Any caution on safety is not costly. It may appear costly with respect to money, time, presumed slowness in reaching immediate targets, etc. But, if something is found to be missing w.r.t. ensuring safety and it needs resources to correct it doesn't mean it is added cost.
We have to thank our luck that nothing happened till such time and that somehow the deficiency or lapse was seen by somebody and got an opportunity to rectify it.
Nothing goes waste when we allocate resources meant for enforcing or improving workplace. Those who suffered due to incidents/accidents can tell the impact faced by them, till their memory retains.
Generally, people will forget the lessons and repeat the mistakes in same or different form.
Repetition of mistakes and resultant accidents make the interested parties sick of the way the organization is being run with shortsightedness.
Strict control only appears to work, but how long this can go on depends on mental stamina of the persons in controlling positions.
I think we are destined to suffer at different intervals due to failure to follow the procedures meant for safety of persons/property/environment/etc and when the loss is huge, then the whole organization suffers, may lead to closure.
Dec 30, 2018
Some thoughts on fall of safety standards - forgetfulness, over-confidence, complacency, arrogance
Even a student also makes such resolutions in or after an examination, which he did not do better.
But, in most of the cases, nothing will be done.
Some will start, but, the steam is lost.
Very few will sustain to a great extent. Even in such persons/organization will make exemptions, here and there.
This week, I attended a meet organized by a regulator. It was told in the opening remarks that regulators have to do the act of listening, observe the things and make informed decisions. This is applicable even to all those who are in the job of monitoring / advising and they need not be necessarily the designated regulators.
In case of individuals also, we are our own regulators and doers. As a proverb goes, we have one mouth, two ears and two eyes, indicating see and hear more, but talk less.
Coming back to the title, I observed that even in those entities who have developed highest standards, became role models and even are in the business of training, events have taken place for simple reasons which can be avoided / addressed totally before the occurrence of the event. Events in these places make me to think that whether they are wrong in the lessons learnt i.e. whether the lessons learnt for implementation are impracticable.
In many post accident recommendations, training and supervision aspects are listed routinely. Even if the training is good, absorption of the knowledge and its use in the day-to-day affairs is highly doubtful factor. Even those who understood the information too do not implement inspite of knowing that this may lead to incidents.
Like in financial sector, as I read somewhere, risk and returns are proportional. Low risk investments yield less returns and so high risk investments generate huge returns. I had my own experience in share market investment at two different periods and on both occasions, I had the opportunity (!) to learn the lessons to come out with some loss.
I think, it is in human behavior to take risk when it comes our activities, let it be on the roads or work place. And, it is the other way when it comes to our home.
I commute to my work place which is at 13 km from my house, by bike and these thoughts do occur generally, but I am yet to get any reason.
In nuclear field, ALARA (as low as reasonably achievable) concept is preached and is genrally followed to limit radiation dose to occupational workers and public. Whereas in industrial safety, it is ALARP (as low as reasonably practicable) implying that we have to be practicable in taking measures to ensure safety and health of the persons. This also implies (to me) that certain value is attached to human lives for dispensation. If an accident takes place leading to injuries / fatalities, generally we read declaration of compensation. Though enquiry takes place, hardly there are cases where the wrong doers i.e. those responsible for the occurrence of accidents are punished. Every year, lakhs of persons are dying in accidents (on the roads / work place), equal or similar number of persons responsible for these are not punished and it shows that human life got only some number and things will proceed as usual as if nothing happened. Reasons for recurrence are generally as in title of this post. This makes the job of the safety advisers / regulators, a difficult task.
If some disturbance takes place in an inhabited place, police will be blamed for not doing the job. If some emissions take place in a factory, pollution control authorities will be blamed that they are sleeping or accepted something. If some accident takes place, safety adviser will be blamed internally and factory inspectors externally. And so on.
But, little or no action is taken to identify the wrong doers and punish them.
Authorities for control of activities have a difficult task of facing pressures from all around and at the same time, not to succumb to these pressures. They have to be like stones not having any emotions to keep their health and family not to get affected by workplace pressures. Some will resign the post to look for different type of jobs or bade good bye forever (if they are financially resourceful to lead the rest of the life).
Any management would like to have highest productivity at minimal cost. Availability of qualified human resources is an issue face by many. Most of the educational institutions have become factories to churn out the students with good grades / marks but many of them fail miserably in getting suitable employment commensurate with the certificate as they can't answer the questions of the interviewers. Hence, they settle for jobs whatever they can get. They may get satisfied or may not. This can lead to dissatisfaction and doing the job for the sake of earning money only. It requires lot of efforts from the side of managements too train such people and I am not sure how many organizations have the policy of training their manpower before engaging them and then even doubtful case of retraining at regular intervals or change of job / modifications in workplace.
With these things, may be there is some optimal safe production i.e. under present set of conditions, it can deliver X numbers of their products. If we try to stretch production on higher side without commensurate additions / improvements, accidents / failures do take place, if not immediately, but definitely at a later date. This is because, it requires some time, even for the established systems to degrade. Now, if there is a change of management, persons at top can claim for success even at higher production in the beginning (higher production is initially possible because degradation also needs some time), but the person coming later can't deliver the same, because degradation process starts accelerating.
Hence, those with safety in mind have to conclude / decide what is their optimum safe production capacity and stick to it. Else, what we are seeing or reading in papers will continue to happen.
Dec 4, 2016
Blast/explosion during welding on oil tanker dismantling causes deaths/injuries
It is stated that about 100 persons were working in the ship tanker at the time of the incident.
To protect themselves, some of the workers jumped in to the sea, after the explosion.
The photos of the incident reveal massive destruction can be seen.
Earlier, three months ago, in another blast during explosion on a oil tanker in oil terminal, during welding, three persons died and two were injured.
Jun 2, 2015
Toxic gas leak from neighbor factory affects 60 in a garment factory
From the above, it is important to all persons working in a cluster of factories to know about hazards and emergency actions not only from their work place but from surrounding factories also.
Ammonia leak from food freezing system from the neighboring factory is suspected in this incident.
http://www.thanhniennews.com/society/60-garment-workers-faint-in-southern-vietnam-after-toxic-gas-leak-43833.html
http://www.thanhniennews.com/society/52-garment-workers-hospitalized-again-one-day-after-toxic-gas-leak-in-vietnam-43906.html
Feb 13, 2015
Orange colour toxic cloud formation in a chemical explosion
Short video can be seen here.
Feb 7, 2015
Sludge tank collapse - 10 sleeping persons nearby buried - Company directed to pay Rs 75 lakh to state government
Reasons for tank collapse and company procedures to check for its integrity need to be investigated.
Dec 31, 2014
Worker killed in accident at BHEL - The Hindu
Incident occurred while lifting a heavy object and failure of wire rope. An apprentice died and another worker suffered injury.
Nov 11, 2013
Trade off between production and safety
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.
Feb 9, 2013
Human error-power supply failure to air traffic controller radar screen at IGI, New Delhi
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.
Jan 20, 2013
Who is responsible for safety for works in your plant?
Jan 7, 2013
Loss from IOC Hazira fire - 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 1, 2013
New year resolutions - Incident reporting culture
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.
Nov 25, 2012
Hit by beam, person driving on the road dies
It is unknown as how a labourer can carry a 19 ft long iron pipe, where he was walking with the pipe (as it is stated that bike rider hit him) and whether the work area is marked or barricaded, or, not. Though, people can claim no negligence, then how the incident happened is to be investigated.
http://timesofindia.indiatimes.com/city/gurgaon/Engineer-21-killed-in-freak-Metro-accident/articleshow/17354580.cms?
May 13, 2012
Molten metal contact with water-blast-2 deaths
The furnace was commissioned recently.
http://www.thehindu.com/news/cities/Visakhapatnam/article3374003.ece
It is reported that the contract labour use for critical jobs also is a reason for such accidents. Unless proper training and supervision is not ensured, such incidents are bound to repeat.
http://www.thehindu.com/news/cities/Visakhapatnam/article3379616.ece
Jun 2, 2011
Case study - compressed air turns man into a balloon
Mar 10, 2011
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