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Seminar Report on Industrial Accidents and Its Safety 2011-2012

INTRODUCTION

Accidents are mishappening which result in loss of life and property. In our

day to day life accidents are very common. Air, railway, road accidents are sometimes very

severe. Accidents can be reduced but cannot be eliminated. Accident affects the individual

and his family life. Different job situations have different accident rates. A bus driver who

drives through busy streets is more likely to have accidents than a driver driving crowd free

roads. The accidents more occurs in mines shop floor than clerical work.

1.1. INDUSTRIAL ACCIDENT:

Accidents occurring in the industries are called industrial accidents. These are

generally due to faulty equipment and machinery or negligence on the part of the workers.

Proper precautions can reduce the accidents. There are always some causes for the

occurring of the accidents.

There are always some chances of accidents while working on the machinery and

equipment. All industrial operations increase the chances of accidents. Proper training and

knowledge should be given about the dangers of accidents. Accident occurs in industries

due to faults of the workers. They can be negligent dis-interested in jobs and under the

influence of intoxicants resulting in a higher number of accidents.

1.2 DEFINITION OF ACCIDENTS

An event or mishappening that occurs unexpectedly is called an accident.

1.3 CHARECTERISTICS OF ACCIDENTS

Accidents are unfortunate sudden happenings about which nothing is known

in advance.

Life and property are affected by accidents.

Due to accidents work is stopped for a certain length of time.

Dept. of Mechanical Engg - 1 - G.P.T.C, Muttom


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CLASSIFICATION OF ACCIDENTS

There are several methods of classifying the accidents. some of the methods are as

follows:-

According to length of recovery from injury.According to cause of events.

According to nature of events.

According to damage caused.

According to nature of injury.

Accidents caused on construction work.

ACCORDING TO LENGTH OF RECOVERYThis is an important method of classifying the industrial accidents. This is further

divided into three categories.

FIRST AID CASES

The injuries due minor accidents are not serious. The workers are given first aid at

the factory hospital. After getting the medical treatment at factory hospital, the worker can

again start the work. In this type of accidents no time is lost except when the worker is

receiving first aid treatment. No compensation is paid to the injured worker.HOME CASE ACCIDENTS

The injured worker is given preliminary treatment at the factory hospital and is

allowed to go home. The worker recovers in this period and is ready to resume his duties.

So, the worker loses the day, shift or turn of work in which the accident has taken place.

This type of accidents do not involve any compensation to the workers as the workers do

not fall under the preview of workmen's compensation act.

LOST TIME ACCIDENTS

For these accidents, the factory has to pay compensation. The worker has to

leave the work on account of accidents for more days in addition to the day, shift or turn in

which the mishappening has taken place.

The worker is generally admitted to the hospital. In this case temporary type

permanent type of disablement may result. The accident may lead to enquiry and

investigation if difference of option is found regarding the causes of the accidents. For

example, the hand, arm, leg or any other part of the body is injured seriously or cut by the

machine.



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ACCORDING TO CAUSE OF EVENTS:-

MACHINE ACCIDENTS:

Some example of machine accidents are given below:-

Catching of fingers, arms, clothing etc. in machine.Catching of tool, guides etc. in machine.

Catching of fly objects or particles.

NON-MACHINE ACCIDENTS:

These are common but generally less serious type accidents. Some examples are given

below:-

Falling objects.

Objects on floor.

Pushes, bumps etc. by other persons objects.

ACCORDING TO NATURE OF EVENTS:-

TRAFFIC ACCIDENTS:

Collisions with pedestrians.

Collisions with cars or buses.

Collision with motor vehicles.

PASSENGERS ACCIDENTS:

Boarding moving car or bus.

Caught or struck by doors.

Trips, slips, stumbles, fall etc.

ACCORDING TO DAMAGE CAUSED

This classification is based on damage caused. Damage can be that of property, material or

building.

Some examples are given below:

Damage to the store material.

Partial or complete loss of container or contents.

Damage to hand trucks.

Damage to trolleys.

Damage to belt conveyors, cranes or machines.



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ACCORDING TO NATURE OF INJURY:-

This classification is as follows:-

FATAL ACCIDENTS:-In such an accident, one or more persons are killed.

PERMANENT DISABLEMENT:-

Due to accident the worker loses earning capacity. The worker is not capable of

earning that much money, which he was capable to earn before accident. Compensation is

paid to the injured worker and the amount depends upon the disablement. For example this

may cut his finger, arm or hand etc. So, permanent disablement is of two types.

1. Total disablement.2. Partial disablement.

TEMPORARY DISABLEMENT:-

These accidents are less serious than of previous category. The worker is unfit

temporarily and he loses his earning capacity for short time compensation is to be paid

according to the workmen's compensation act. Fracture of an arm is an example of

temporary disablement.



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ACCIDENTS ON CONSTRUCTION WORK:-

Some examples are given below -

Falling of person.

Slipping results inner strains of the body.

Accident because of flying objects.

Accident due to traffic.

Burning and fire accidents.

Electric shocks.

Explosions.



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CAUSES OF ACCIDENTS:

Accidents do not just happen but there are always some causes. If we want to decrease

the accidents, then the causes of accidents must be studied in details. The various causes

can be divided as follows:-

Physical causes based upon unsafe conditions of work.

Physiological causes based upon defects of physical body of the worker.

Psychological causes based upon mental disturbances of the worker.

PHYSICAL CAUSES:-

These are linked with the machinery and surroundings. These are beyond the control of the

worker. The conditions are likely to cause accidents.

This is further classified as follows:-

Physical causes related to machinery and plant:

Following can cause accidents:

Unguarded and unfenced moving machine parts.

Unbalance, noisy and improper adjusted machine parts.

Space between the machines is less.

Old and worn out machines.

Improper insulation of electric circuit and machinery.

Unlubricated moving parts get heated.

Improper plant layout.

Causes Related To Tools And Materials:

The following will more number of accidents:

Dull or damaged tools.

Tools without handles.

Very sharp edged tools.

Inflammable and hot materials.

Poisonous and toxic materials.

Breakable materials.

Causes Related to Dress:



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Loose or improper dress.

Slippery foot wears.

Not wearing personal protective equipment e.g. goggles, gloves, screen required

during welding.Causes related to working conditions:

Lighting is not proper.

Improper ventilation for the exit of dust and gases.

Slippery floors and stairs cases.

Severity of work. For example mines, constructions of tunnels,

Building of sky scrapers is quite risky.

Working hours are too long resulting in tiredness.

Bad discipline.

Defective buildings and projected objects.

PHYSIOLOGICAL CAUSES OF ACCIDENTS:-

The causes of accidents are related to physical body of the worker e.g. a weak man cannot

lift a heavy load. Weak eye sighted person cannot do the work on machine. An old man

cannot do heavy work. Some of causes of accidents are due to following physiological

defects:

Weak eye-sight.

Poor listening power.

Weak health.

Any part of the body may be defective.

Fatness and high blood pressure.

Fatigue and exertion of work.

Older employees.



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PSYCHOLOGICAL CAUSES OF ACCIDENTS:-

These are linked with the mental disturbance of individual worker. This is not some

external environment but the internal characteristics of the employee that the accident

occurs to him. The worker is regarded as careless and is victim of an accident. He does not

give proper attention to safety rules and regulations. The worker may involve himself in the

accident on account of following:

His habit of ignoring the things that is carelessness.

Frustration, worry or depression.

Emotional unequilibrium due to mental tension.

Improper co-ordination between body and mental faculties.

Nervousness and impulsiveness.

Over confidence.

MISCELLENOUS CAUSE:

Lack of training and experience.

Intoxication- use of wine, opium etc.



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EFFECTS OF ACCIDENTS:-

The accidents are always undesirable. They result in loss of life and property. They

produce evil effects on workers, families, employers and on the society. The bad effects faccidents are as follows:

EFFECT TO THE INDUSTRY:

Direct cost of an accident:

Compensation has to paid to the worker for temporary or permanent

Disability.

Cost of medical care and hospitalization.

Cost of damage to equipment, materials (improcess inventory) and Plant.

Indirect cost of accident:

Loss of well trained and efficient employee and cost to replace the worker by

providing training to the new one.

Cost of time lost by other employees who stop work:-

a) Out of curiosity.

b) Out of sympathy.

c) To assist injured employee.

d) For other reason.

Cost of time lost by supervisors, safety engineer or other executives in post-

accident activities.

Cost of interruption and delay in production.

Downtime of machines, particularly in product layout.

EFFECT ON WORKER: -

If the worker dies in the accident, the family looses the bread earner.

Injury compensation never equals his earnings.

Accident also affects the morale of employee.

If the worker gets injured, he looses his efficiency and the workmanship. His rating

gets lowered due to handicap ness and therefore looses the incentives due to not performing



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at higher level.

After the accident, the worker is psychologically hesitant to work at the same place

and even reluctant to exert himself in the job.

COST TO SOCIETY:

Work connected injuries also put a considerable burden on society as whole as under:

Even though a victim receives compensation, he may require additional help

From the society.

Loss of production hours causes fewer products in market.

Employers necessarily include the costs of accident to the selling prices of their

products. Therefore, the society has to pay more prices for the products.

If the worker is involved in social activities, then his replacement is difficult to

achieve.



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ACCIDENT PRONE WORKER

The worker who involves himself in more number of accidents than the average

worker is called accident prone worker. There are two causes of accidents. First cause is

the situational factor and the second cause is personal factor due to which a person is

victim of an accident. Different persons have different accident rates under similar working

conditions.

If the personal factors are responsible for accidents and the number of accidents does not

change even under changed conditions, the concept is called accident proneness.

CAUSES OF ACCIDENT PRONENESS:

There can be many physiological and psychological causes of accidents.

Sometimes a random happening of an accident may create proneness. If a person on shop

floor just happens to cut his finger with cutting tool, he loses self-confidence. Whenever he

will again hold a tool, he will become nervous and will lose control of himself and repeat

accident. He will become an accident prone worker.

Accident prone workers should be given more attention and training. Posters and safety

publicity should be given importance. Efforts should be made to change an accident prone

worker to accident safe worker.

METHODS TO REDUCE ACCIDENT PRONENESS:-

Only suitable should be selected depending upon the job requirements.

Transfer the accident prone workers to comparatively less dangerous job

situations.

Give sufficient training to new workers before putting them on the job.

Encourage employees and see that they do not get unnecessarily disturbed and

frustrated before starting the work.



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INDUSTRIAL HAZARDS:-

DEFINITION:-

Hazards are defined as the chance risks which surround the workers to cause

accidents.

A person working amidst pressure vessels is said to a be working in hazardous conditions.

A pressure vessel may burst out causing a serious accident. People working in mines are

also working in hazardous conditions. Improperly insulated wire, uncovered switch and

inflammable materials are industrial hazards.

The hazard is the base whereas accident is the result. Safety precautions are taken so that

these hazards which are potential sources of accidents may be eliminated or reduced.

CLASSIFIATIONS OF HAZARDS:-

FIRST DEGREE HAZARDS:

These hazards have the inherent potential for accidents. These set a stage for the

occurrence of accidents. In normal circumstances these hazards do not cause any damage to

life and property. Some of the examples of this class of hazards are given below.

Inflammable or combustible materials in the vicinity.

Presence of sources of ignition.

Presence of poisonous materials.

Possibility of mechanical failure of the objects.

Production of excessive heat.

Materials placed under compression just as an in pressure vessels.

Possibility of human error.

Transport of men and material in the plant.

Reduced visibility and vision obstructed.

SECOND DEGREE OF HAZARDS:

These hazards are those which are capable of inflicting injuries or cause accidents.

The second hazards take place when the first degree hazards are out of hand. The second

degree hazards can directly cause loss of life or property or both.

The following can be considered as the few examples of this type of hazards.

Falling as from a stair case.

Fire due to inflammable materials.



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Explosions of compressed materials in pressure vessel.

Poisonous materials are released.

Collisions with traveling equipment or vehicles.

DIFFERENCE BETWEEN FIRST AND SECOND DEGREE

HAZARDS:

First degree hazards are not harmful directly. But the second degree hazards

directly affect the health and property.

First degree hazards set the stage of accidents. These are the step towards accidents

whereas the second degree hazards are the accident itself.

Supposing an electric switch has spoiled the insulation and is uncovered in the

shop. This will be called first degree hazard. But supposing some worker touches, the result

will be accident and switch becomes second degree hazard



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SAFETY:-

CONCEPT OF SAFETY

Safety is opposite to accidents. If accidents are harmful, safety is beneficial. Man's

greatest desire is security. He wants longer life. Accidents are one of the major causes of

deaths. So accidents should be minimized. Safety is beneficial in all respects. Safety has

become an essential feature of all walks of life. The maintenance of safety has become a

major program in the industries. Specially trained persons known as safety engineers areappointed in the industries. The government has also framed rules and regulations towards

safety. The factories act has special provisions on safety. Violation of these provisions is

punishment. Some of the factories conduct special programmes in first aid treatment. The

workers are acquainted with the preliminary treatment to be given to the injured.

Programmers like extinguishing fire, removing the people from the building on fire are also

carried out.

SAFETY CONSCIOUSNESS

"The awareness and carefulness of the workers to prevent the accidents is known as safety

consciousness While at work, the workers must be always conscious of accidents and

must take all the precautions for enhancing the safety. A bus driver while driving is always

safety conscious and avoids the accidents.

Safety consciousness should be increased by adopting the following methods:

1. Display of safety posters and boards to remind the workers about safety.

2. Workers should be educated to use safety devices.

3. Organizing safety competition and awarding prizes to the winners.

4. Give due respect and recognition to safe workers.

5. Send information and literature about the safety at the homes of the employees.

6. Welcome all safety suggestions.

7. Cross mark and identify all accident areas.

8. Conduct safety training lecture periodically.



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NECESSITY OF SAFETY:

Safety helps the industries and workers in following ways:

Production is increased.

It reduces the cost of production.

Reduces damage to equipment and machines.

Prevents premature death of trained workers.

Prevents needless pain and sufferings to the employees.



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SAFETY PROCEDURE:

There are two ways of looking at this problem - one is from, the point of view of an

engineer and the other from point of view of a psychologist. The engineer can remove the

hazards from the work introducing the following measures:

a. Designing and formulating of safety devices.

b. Procedure and methods of work on the dangerous machines should be changed.

c. The safety of the factory and machinery should be inspected by a safety engineer and

change it from structural and functional point of view, if required.

Simple improvements can be made in this regard which are given below:

Moving parts should be enclosed with guards and covers-such as belts, gears,

clutches etc.

Moving and stationary parts should be distinguished adopted suitable colors.

Rotating saws should be guarded properly to avoid the workers to come in contact

with them physically.

Safety devices should be reliable.

Safety devices should not be easily detachable.

Safety dress, protective glasses, gloves, shields should be suitably designed.

To reduce chances of falling slipping from stair case, floors etc.

Prevention against receiving electric shock. Every electric installation should be

properly insulated.

The psychologistalso plays very important role in avoiding the accidents and

increasing the safety. It has been observed that many of the accidents are due to

psychological problems of the workers. The human factor in case of accidents should be

analyzed and corrected.

The psychologist adopts the following procedure:-

Making the worker safety conscious.

To make men aware of hazards.

To train them to use safety devices.

Reducing the fatigue and exertion of the worker.

The attitude of co-operation should be developed among the workers.



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SAFETY MEASURES:

To ensure and enhance the safety in the factories, the various steps are to be taken. The

safety Engineers and the shop in charge will take the following measures according to their

experience and guide lines of the factories act:

PERSONAL PROTECTIVE EQUIPMENT:-

Protective dress should be worn where ever necessary. Gloves are worn by the operator

to save his hands from cuts, splinters and chemicals.

PERSONAL PROTECTIVE EQUIPMENT

Aprons protect the trunk of the body. Metallic foot and leg guards are also

available. Where falling objects can pose a problem, one can safely use the protective

helmets. The women workers use hair pin and nets so that their hairs are not caught in the

gears, drills and spinning shaft.

In welding, goggles and face shields are used. If the noise is unbearable, ear

plugs should be used. Safety shoes are used where the feet are exposed to heat and pricking

substances.



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MACHINE GUARDING:

The running parts of machines should be properly guarded. The machine guard should

provide full protection, they should be of permanent nature and it may be difficult to

remove them. The rotating part should not be operated at speed higher than the

recommended speed.

Figure: 9(b)To reduce accidents of machines, the manufacturing processes should be modified

and their operational efficiency is increased. In case of presses and shears, hazards are

reduced by using, automatic feeds..

PROTECTION AGAINST RADIATION HAZARDS:

Two type of radiations such as heat produced in steel manufacturing and radiations of

radio active particles, cause health and safety problems. The people suffer from exertionand over perspiration and skin irritation. The plant and equipment should be designed that



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radiations are minimized.

Air conditioning, ventilation system, protective clothing can decrease this problem.

Figure: 9(c)

NOISE CONTROL:

Excessive noise is not only uncomfortable but also harmful. The measure of noise is

decibal (db). Where conversation produces only 40 db, the office work may produce 50 db.

If the noise level exceeds 100 db, it becomes harmful and dangerous if not checked. The

working efficiency is decreased. The forging hammer produces high noise.

FATIGUE ELIMINATION:-

Fatigue is also one of the causes of accidents. Fatigue is caused if one is doing

hard work continuously or if one feels bored at the work. It has been found out that during

the end of the working hours, the number of accidents tends to increase, which is due to

fatigue. A driver if asked to drive the bus for long hours, he may be fatigued and fall asleep

on the steering and cause the accidents. Fatigue is eliminated by providing rest pauses to

the workers, reducing the working hours, and severity of the work.

PROPER LIGHTENING:-

Many accidents are the result of poor lighting. So every work place should have

proper light. There are two sources of light- Natural light and artificial light from bulbs

and tubes.



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SAFETY PUBLICITY & SAFETY QUOTATION

The followings are some of the steps regarding safety publicity taken by the industries:

1. Safety posters are installed on the walls of the industry.

2.Every accident prone situation should be well marked as cautions for the safety of

the workers.

3. Safety programmes should be conducted to educate the worker and make them

safety conscious.

4. Safety pamphlets and magazines should be published and distributed free of cost.

5. Documentary films on accidents and safety should be shown to the workers.

6. Safety committees consisting of trade union and management should be set up to

promote publicity.

7. Workers should be encouraged to suggest the methods to ensure safety.

8. Safety contests my have occasionally.



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SAFETY QUOTATIONS:-

1. Make safety a habit.

2. Where cautions ends accidents begin.

3. Accidents do not happen they are caused.

4. Better late than never.

5. Safety is the pride of good workman.

6. Machines are good servants only if handled carefully.

7. Safety promotes productivity.



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CASE STUDY:-.

BOILER ACCIDENT:-

EVENT:-

In Ford Rouge Plant established in Michigan City had accident due to blasting of

boiler established in the plant. This accident happened in the year 1999.

In that accidents near about ten workers were dead and about fifty others were

injured. This caused the shutdown of that plant.

CAUSES:-A state agency said that natural gas ignited in a giant boiler, caused the explosion. "The

explosion was what is termed 'a furnace explosion,' where the firebox inside the boiler that

heats up the water had a buildup of gas in the chamber," according to a statement by state

officials. "This gas then ignited, causing the boiler to explode." A former supervisor of the

powerhouse said the only possible heat source that could detonate a natural gas buildup in

the boiler is small embers from coal dust, another fuel source for the boiler.

At the time of the explosion, the boiler was being shut down for annual inspection, aprocess that takes several hours. worker had already stopped the boiler from operating and

were in the process of completing safety procedures designed to prevent fuel leaks,

especially through two large natural gas pipes leading to the firebox.

In the morning, the men "blanked" the flow of the blast furnace gas, which means

they inserted a piece of metal into the pipe, physically preventing the gas from entering the

boiler. A valve is used to control the flow, and that is shut off first. But the physical metal

barrier is also needed.



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After lunch, the men planned to blank the natural gas line. Gas was building up

somewhere. The fuel was building up and not being burned. The water temperature was

probably about 400 degrees at the time of the explosion. The fire shot across the room to

other boilers, and seemed to catch the coal that is delivered next to the boiler No. 1 on fire.

REMEDIES:-

In earlier correspondence suggested that blanking is unwise. Double shut off valves is the

proper way to secure a gas line with venting. This bit map schematic is an approximation

of what would expect as a minimum arrangement for the gas piping for igniters.

This schematic suggests there are safe guards of at least two levels. They are Block valves

and Vents. If either of the block valves leaked by, then gas pressure could build-up and

pour into the furnace only if the vents are plugged. If the work order required the workers

to replace the IHSSV (Igniter header safety shut-off valve) then the gas line header in the

steam/power plant should have been shut down. This line also has a safety vent.

http://www.hilbornlaw.com/RougePlant/gasignitors.htmhttp://www.hilbornlaw.com/RougePlant/gasignitors.htm


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CONCLUSION:

Accidents are mishappening which results in loss of life and property. So, to avoid

these accidents safety must be an integral component of an overall business plan for any

company. Safety control must be designed in to every aspect of a job, thereby promoting

awareness and continuous improvement in the program. The aim of safety is to completely

eliminate all events that result in an injury, property damage, or lost workday case. It

should be a company goal vision rather than a target or performance goal.

Finally, with the full support of management and employees, the goal can

become a reality. Many people do not believe that it can be achieved, but If you never try,

you will never know.



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REFERENCES

Classification of accidents : web source:-www.ilo.org/

Cause of accidents:

1.websource:-

www.onlinelawyersource.com/personal_injury/ia/cause.html

2. elements of workshop technology, S.K. hazara chaudhury

http://www.ilo.org/http://www.ilo.org/http://www.onlinelawyersource.com/personal_injury/ia/cause.htmlhttp://www.ilo.org/http://www.onlinelawyersource.com/personal_injury/ia/cause.html


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CONTENTS

CHAPTER PAGE

1. INTRODUCTION 1

2. CLASSIFICATION OF ACCIDENTS 2

3. CAUSE OF ACCIDENTS 5

4. EFFECTS OF ACCIDENTS 8

5. ACCIDENT PRONE WORKER 10

6. INDUSTRIAL HAZARDS 11

7. SAFETY 13

8. SAFETY PROCEDURE 14

9. SAFETY MEASURES 15

10. SAFETY PUBLICITY

& SAFETY QUOTATION 21

12. CONCLUSION 24

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