2020: A review

This year's happenings are like those that happen once in a lifetime. It can be like those faced during world wars. With the imposition of lockdown in the country to tackle the covid pandemic, we could not go out for days together, and then we hand night curfews, limited mobility, etc. We do not have any idea about the extent to which the virus can harm. Hence, there were rifts even families about measures to be taken. 

Coming to industrial safety, with the shutdown of operations, movement of many migrant workforce to their native places, these persons suffered to reach their destination. And then the organizations too suffered due to lack of working hands. 

In some organizations, due to not following safe procedures for shutdown, emergency maintenance, or safe restart, a few incidents took place leading to loss of lives or injuries. Still, many organizations are having problems reaching the state of pre-covid. 

And, then a covid variant surfaces now, as a parting gift of the year. What comes in the new year, we have to wait and see. 

However, some benefits are also accrued as organizations tried to have work from home wherever possible, or implementation of remote work methods to avoid movement/contact and in the process reducing operational costs. 

There is a saying which goes, whatever happens, is for our good. May be present phase is also like that. Let us hope for the best.

Job / work related stress - injuries

A good article (in a blog) on injuries from work related stress is available in the link below.

https://blogs.lawyers.com/attorney/workers-compensation/stress-and-workplace-injuries-49091/

Stress results in burnout quickly and performance can be affected. Further to this, one is prone to accidents from lack of concentration / clarity due to so many thoughts lingering in mind to meet the demands.

At least 8 students, 1 teacher injured in chemical fire at Hendersonville school

At least 8 students, 1 teacher injured in chemical fire at Hendersonville school: An official with the Hendersonville Fire Department said 17 students and one teacher were either triaged at the scene or transported to local hospitals.

During an experiment in lab by students to see change of flame colours of different salts, the incident happened. The incident appears to have happened to demonstrate rainbow flame by adding different salts to ignited ethyl alcohol. A flash fire occurred lasting 3-5 seconds.

In laboratories, will be working with known/unknown materials. The awareness on lab safety particularly in schools/colleges is generally low compared to industrial safety. Knowledge on properties of chemicals, methods to avoid hazards, control and mitigation measures, use of personal protective equipment, etc will help in avoid consequences from the work. Making safety principles as a topic in every subject let it be science / engineering / arts can help improving awareness.


https://www.washingtonpost.com/news/education/wp/2018/05/09/a-classroom-science-experiment-turned-into-a-chemical-fire-injuring-17/?noredirect=on&utm_term=.f3e0c55beb7f


http://www.wsmv.com/story/38149598/principal-8-students-1-teacher-injured-in-fire-at-hendersonville-school

https://www.washingtonpost.com/local/education/high-school-chemistry-lab-fire-prompts-warnings-for-science-teachers/2015/11/05/eb78543e-8312-11e5-9afb-0c971f713d0c_story.html?utm_term=.4025ee47ffa1

http://www.wkrn.com/top-news/chemistry-safety-experts-warn-schools-to-stop-unsafe-science-demonstrations/1172474948

Blast/explosion during welding on oil tanker dismantling causes deaths/injuries

Loud blast due to explosion during welding on a oil tanker parked in ship breaking yard, caused more than 10 deaths and injuries to about 50 persons. 8 explosions took place during the incident. A fire followed the explosion. Rescue efforts were hindered due to explosions and fire.
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.

Construction scaffolding collapses, killing 74 at Chinese power plant - World Socialist Web Site

Construction scaffolding collapses, killing 74 at Chinese power plant - World Socialist Web Site

It is reported that during construction work in a power plant, a tower crane collapsed. This caused a 70 m high scaffolding collapse leading to more than 74 deaths and injuries to others. Reports say 90% of the workers at site died in the accident. The accident occurred during shift changeover at about 0730 hr, resulting in more deaths.

Speeding up of the work, possibly with bypassing of safety procedures to cut costs appears to be the cause, as per the reports.

One has to know that safety is not cost addition, but a cost saving measure. Any work completed without accidents by safety procedure violations, is only by luck. And, one can't depend on luck for ever. Companies will face the consequences leading to closures with this type of attitude.

One can sacrifice productivity, but not safety of persons.

It is stated that in the year 2015, about 66000 persons died in the country during industrial accidents at 181 per day (appears exaggerated, but reports say so).

13 persons were arrested in connection of with this accident as per the report.
http://www.nydailynews.com/news/world/chinese-officials-detain-13-construction-accident-kills-74-article-1.2887359

Photos of the scene can be seen in the link above.

Accidents, injuries, loss of property, some causes

As per a report, many accidents are happening in China due to poor safety conditions, lack of implementation of regulations and inspections, lack of training, etc.

If enforcement is not strengthened as per the needs of growing economy, it becomes very difficult for regulators to monitor the activities of lakhs of industrial units. The situation may be such that it becomes difficult even to inspect atleast once in lifetime because of huge number of factories, and dismal number of inspectors.

http://www.scmp.com/video/asia/1849125/huge-explosions-rock-tianjin-northeast-china

http://www.theguardian.com/world/2015/aug/13/tianjin-explosions-china-sends-troops-cleanup

Ammonia tanker stuck up under flyover, valve damage, 5 deaths, 140 injured near Ludhiana

In an incident of liquefied ammonia tanker driver trying to go through under a flyover, at 11.00 PM, the lid and the valves at the top got damaged, causing release of ammonia affecting several persons nearby.
See the photo here.
5 persons died and 156 got injured in the incident.

It appears that there are no warning signs or no height barriers to prevent overheight vehicles going under the flyover.

The tanker was carrying 22 T of anhydrous ammonia.

Police and fire brigade officials reached the spot to control the situation. 

Some of the affected had breathlessness, eye irritation, choked voice, etc. Few had bleeding from mouth and nose.

A senior police official and others controlling the situation were also affected in the incident as per the reports.

Tanker was moved to a vacant plot.  

Ammonia solubility in water is very high and is instantaneous at temperatures below atmospheric. Water was used to absorb leaking ammonia.

The odour was present for more than eight hours. The affected areas was about four kilometer radius around.

Dead animals/birds and vegetation/plants were seen.

Heavy rain later subsided ammonia in the environment by absorbing and washing.

A case was registered under Sec 304 of IPC (culpable homicide not amounting to murder) on the absconding driver.

http://www.ibtimes.co.in/ludhiana-ammonia-gas-leak-tanker-kills-6-over-100-affected-635709

For information - safety statistics by ILO from The Nation, Nigeria

The link to the information is here.

http://thenationonlineng.net/new/6000-die-daily-in-work-related-accidents/

As per ILO, following are the work place related injuries, deaths, accidents and loss.

1. Every second 15 persons die, 6000 a day and 2 million a year due to accidents/diseases. This data is from reported data. There can be many more.
2. In addition, 268 million non-fatal accidents and 160 million new cases of work related illness also occur.
3. The direct and indirect loss due to accidents and diseases is 4% of global gross domestic product or USD 2.8 trillion.

Safety Rules and Regulations - there will be blood stains behind

It is quite common for safety professionals to be at receiving end, bombarded with questions, when suggestion / advice is given based on rules and regulations. Leave apart general advice when given, safety professionals are questioned for the basis. 

But, everybody should remember that nobody is interested in slowing down the work pace. Nobody is interested in doing additional work. Nobody wants to take blame, knowing fully well that any safety advice communicated will have questions directed back to them. Still, it is rendered for the reasons of doing their mandated job. A safety professional is not a namesake fellow  to be shown to factory inspectors during their visits. There are some good organizations, national and multinational, who follow safety in toto. And, they proved that in the end, safety aids in increased production. 

But, to realize this, we have to sweat initially, should have thinking and application in the conceptual and design stage itself. Okay, it is not there initially. Then, let us struggle for some extra time, to implement during operational stage. 

But, during this stage, if incharge sees this work of implementing safety retards production during his period and he will not be recognized, then it should be made known to this incharge by top management that goals will be set considering all factors. Give, sometime for seeing the results of implementation of safety procedures (if implemented late, not required if implemented during design stage itself). Do not encourage the ideas of shopfloor employees to bypass safety systems for achieving higher production in a short time. This will be shortsightedness. One will get higher production initially for some time, as there may not be deterioration of culture quickly. However, with time, with changing mindset and taking roots, joining of new recruits who learn such bad practices from first day, one can see the signs of near misses and later accidents resulting in injuries and property damage.

Study of such accidents leads to internal regulations which when published and / or goes to the notice of regulators, will turn into legislations. Slowly, one forgets the reasons for a rule or regulation and then questioning of basis for such rule begins (wheel needs to reinvented).

This becomes like one chanting mantras and then getting involved in all acts against the meaning of these great mantras (pseudoism).

Crashing of false ceiling in the airport

During early hours, false ceiling of a portion of the airport near arrival area fell down and no injuries were reported. And, such incidents happened about eight times in the last two years. Recurrence of such incidents in such areas where large crowds gather during busy hours requires immediate action for integrity assessment and repair/replacement.

Bullying safety officer is like hitting under your own pants

Those who do not like safety officers to inspect their areas for identifying hazardous conditions and also pick up arguments to make/scare them not to visit their works areas will not help to improve the situation. It will only spiral the hazardous conditions and can lead to accidents on a large scale at a later date.
Clearly, there are provisions in related regulations to penalize and also punish the works managers for violations. It is a matter of time before the law catches up with the violators.

Unless these works managers realize the importance of safety and learn the punishments that await the (willful) violators, there is no light for the safety of the persons working in  work areas managed by such persons who are no different from murderers.

Injuries / deaths to employees in those work areas can be compared to planned murders/attempts to cause injuries as works managers neither take action to prevent unsafe conditions not help the safety professionals to identify and suggest safety measures.

Unfortunately, safety officers are not vested with powers like that of regulators and thus will be at the receiving end unless the in-charge of the facility gives unconditional support. Else, at some time or other, the safety department officials either will keep quiet leaving the matters to the fate or will look for better opportunities in other companies. Either way, it is the loss to the company having such safety culture.

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.

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


LINK

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.

Reasons for injuries

Four states of mind are responsible for 90% of injuries at home and work place.  The four states are rushing, frustration, fatigue and complacency. The errors they lead to are failure to keep eyes on task, failure to keep mind on task, moving into or being in the line of fire and somehow losing balance, traction or grip.

Read the full article here.

What is the level of safety followed in advanced countries and others?

It is common to read / hear about the accidents all over the world. However, what is surprising me is that the number of accidents, type of accidents, deaths / injuries due to accidents are occuring in advanced countries as well as in developing countries.

Though governments of developing countries claim about poverty, illiteracy, lack of resources to implement safety, need for development as the reasons for inability to control accidents, I am unable to find the reasons for the accidents in advanced countries. In these countries, as I understand, greater transparency exists, unions are strong and are powerful that question the managements about poor conditions w.r.t safety, huge amounts are spent for ensuring safe conditions, providing PPE, doing audits, etc. Prosecutions are also carried out on erring companies and punishments/penalties are imposted. Still many accidents take place in advanced countries like those in the other world. Most of the accidents appear to be preventable. I am not really getting any reason for this phenomena.

Whether this indicates that the attitude to safety is same whether the country is advanced or not. The motive is to gain short term benefies i.e profits. Accidents are taken as part of the job and the victims are compensated. Only the amount of compensation varies from country to country. Paying compensation appears to be a better business model compared to spending money on accident prevention.

Safety nets - test before use!!!

It is a good practice to have safety nets for works at height to prevent injuries during fall of persons. Small time contractors usually avoid provision of safety nets and even if they were forced, they will provide nets only below the place of work and shift the net as the work proceeds. Because of the cost, the quality of these safety nets also is questionable. In case of doubt, it is better to test the capacity of the nets by dropping sand bags of sufficient weight from height and see whether the net is intact or strands are broken or the net sags. This will also give confidence to the workers and will be an eye opener for the contractor if the net fails. Normally, safety nets should withstand 2200 kgf. They should be provided such that the fall of person is restricted to 2 m and the width of the nets is atleast 6 m from the place of work. There should not be any gap between the wall and the net. Any construction material / debris that falls should be removed immediately to avoid injuries to persons falling on to the net. At many construction sites, I saw construction debris accumulated on the nets with nobody to remove them.

If the floor is good, then one can provide mobile nets which I saw at a construction site. A scaffold structure is made with the net tied all around. This will be located below the place of work at height and is moved as per requirement.

A few construction engineers question about the need for providing the safety net or its practicality to provide. At many places, I saw even for a small work, scaffold is erected (11 storyes height at one software company building, 5 storey height at one super speciality hospital). Therefore, what is required is commitment to ensure safety. Else, we get 1000s of excuses for not providing the scaffold / safety net.

Hazard Communication - One more idea to warn to about dangers

In my earlier post, I mentioned few things to communicate hazards to machine / equipment operators. In addition, it will also be effective to caution about hazards, if photos of persons injured are displayed on every equipment / machine. I feel such reminder will have the desired effect on the minds of operators and shopfloor supervisors so that they will not bypass safety procedures. It is like having photos of our loved ones in the house to remember about their affection. In the shopfloor, it is like remembering the mistakes made by the persons in the photos and the injuries suffered by them.