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Material handling embraces the basic operations in connection with the movement of bulk, packaged and

individual products in a semi-solid or solid state by means of gravity manually or power-actuated equipment and within the limits of individual producing, fabricating, processing or service establishment.

Since injuries may result from improperly handling and storing materials, it is important to be aware of incidents that may occur from unsafe or improperly handled equipment and improper work practices when handling and storing materials. Extent literature indicated that approximately 30 per cent of all occupational accidents occur in materials handling. Chemical compatibility is an important factor when handling chemicals and packaging chemical wastes. Unexpected reactions due to incompatibility have caused serious injuries and severe damage to equipment and buildings in the past

INTRODUCTION„Material handling embraces the basics operations in connection with the movement of bulk, packaged and individual products in a semi-solid or solid state by means of gravity manually or power-actuated

Material Handling Safety Measures

The purpose of this article is to study safety conditions and procedures to prevent work risks caused by the handling of chemical materials. In this direction, this paper presents a general description of the work system of materials handling and its elements and safety characteristics and offers some examples of accident prevention possibilities.

equipment and within the limits of individual producing, fabricating, processing or service establishment (Telsang M., 2010).‰ Unfortunately, the improper handling and storing of materials often result in costly injuries. Since injuries may result from improperly handling and storing materials, it is important to be aware of incidents that may occur from unsafe or improperly handled equipment and improper work practices when handling and storing materials (OSHA, 2002). The basic goal of this article is to ensure the extent that worker is aware about the potential work hazards during handling of chemicals and the ways to recognise them and to protect themselves. This paper is designed to help reduce the possible incidence and injuries due to handling of chemicals in the chemical industry.

Elements of Material HandlingThe elements of material handling are as follows as given in „Industrial Engineering and Production Management‰ book by Martend Telsang.1. Motion: Move in most economic, safe and

efficient manner

2. Time: Provide materials on time3. Quantity: Ensure supply of correct quantity

cont inuously at each manufactur ing organisation

4. Space: Ensure optimum use of space (Telsang M., 2010).

HazardsHazards arising from human activity and interaction with social, environmental and technological systems are kind of technological hazard. Australian industry standards define a hazard as „A source or a situation with a potential for harm in terms of human injury or ill-health, damage to property, damage to the environment, or a combination of these (Desai Dushyant 2008).‰

In chemical processes: ÂIt is the combination of a hazardous material, an operating environment, and certain unplanned events that could result in an accident (Macdonald Dave, 2004).Ê

Different Types of Chemical HazardsChemicals cause health hazards if they are:1. Target organ chemicals·they injure

specific organs in your body.2. Toxic·cause i l lness or death. Toxic

chemicals are determined on the basis

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The label is the key to organising chemical products for storage. Tanks and container should be identified with signs indicating the name of the chemical product. No containers or cylinders of compressed gases should be accepted without ensuring identifying labels.

of tests on laboratory animals that are exposed to a given chemical through inhalation, ingestion, or skin absorption.

3. Corrosive·can destroy your skin or eyes.4. Irritants·cause reversible inflammation

when they make contact with living tissue.5. Carcinogens·have been known to cause

cancer or have the potential of causing cancer in humans.

6. Sensitisers·can cause an allergic reaction on subsequent repeated exposures.

7. Neurotox ins·produce tox ic e f fec ts primarily on the central nervous system.

8. Nephrotoxins·Produce toxic effects on kidneys.

9. Reproductive toxins·have the potential to adversely affect the reproductive system.

10. Hepatotoxins·can adversely affect the liver.11. Lung hazards·can irritate or damage

pulmonary tissue.12. Skin hazards·can affect the dermal layer of

the body, resulting in rashes and irritation.13. Eye hazards·can adversely affect the eye

or diminish the visual capacity of a human.14. B lood sys tem hazards·caused by

chemicals that decrease the hemoglobin function; depriving of oxygen. Chemicals that present physical hazards and are covered by the Hazard Communication Standard include combustible liquids, f lammable mater ials, all compressed gases, explosives, organic peroxides, oxidizers, pyrophoric materials, unstable materials, and water-reactive materials.

15. Fire hazards·chemicals that have the potential for creating a fire or aiding an ongoing fire. These materials are f lammables, combustibles, oxidisers, py r o p h o r i c m a t e r i a l s a n d o r g a n i c perox ides. Some of these mater ia l are Flammables·catch f i re quickly; Ox id isers·capable o f in i t i a t ing o r promoting a fire in other compounds by the re lease o f oxygen o r o ther gases; Pyrophoric materials·can be ign i ted as a resu l t o f contac t w i th oxygen in the absence of an ignition source at temperature below 130 F; Organic peroxides·contain both fuel, in the fo r m o f carbon, and excess oxygen, and thus can pose a severe f i re hazard; Compressed gases·all compressed gases pose a physical hazard; Explosive mater ials·can be decomposed in a v io len t chemica l reaction with the production of heat, pressure, and large quantities of gas; Unstable materials·certain compounds

in their pure form can undergo vigorous d e c o m p o s i t i o n o r p o l y m e r i s a t i o n under moderate conditions of shock, pressure, or temperature; Water-reactive compounds·can react vigorously with water to produce a toxic or flammable gas (abctlc.com, 2008), etc

LITERATURE REVIEW Material handling represents about 50 per cent of production-cycle time, an equal amount of the conversion cost, and about 25 per cent of product cost. It is one of the few areas where costs can be substantially reduced (Gopalkrishnan P. 2005).

Health and safety is, for many managers, a difficult subject. It requires a broad knowledge of many disciplines, such as psychology, engineering, chemistry, ergonomics and medicine, each of which is a subject of study in its own right (Stranks Jeremy, 8th edition).

According to several studies and statistics, approximately 30 per cent of all occupational accidents occur in materials handling. This article presents a general description of the work system of materials handling and its elements and safety characteristics and offers some examples of accident p r e v e n t i o n p o s s i b i l i t i e s ( H a k k i n e n Kari, 1981).

The Problem Areas in Material HandlingThe problems are arises in Material Handling Safety in chemical industry;1. d u e t o l a ck o f s a fe t y aw a r e n e s s

and safety.2. training of the employees.3. due to less frequency of safety audit by

the safety officer.4. improper co-ordination between safety

department and other departments.

drug we consume- we are inextricably linked to it (KPMG India, Survey Report 2010).

Chemical CompatibilityChemical compatibility is an important factor when handling chemicals and packaging chemical wastes. Unexpected reactions due to incompatibility have caused serious injuries and severe damage to equipment and buildings in the past. A well maintained inventory and labelling system is the best method of ensuring hazardous materials are being managed effectively and safely. The inventory process allows one to check whether chemicals are being stored properly, and if not, provides an opportunity to segregate according to their respective hazard classes.

In general, chemicals can be separated into the following hazard classes:

1. Flammable Liquids

2. Oxidisers

3. Reducers

4. Concentrated Acids

5. Concentrated Bases

6. Water-reactives

7. Toxic

8. Peroxidisables

9. Pyrophorics

10. Compressed Gas Cylinders

11. Inorganic Solids

12. Organic Solids

13. Non Flammable Liquids

Ideally, each group above should be stored on a separate shelf with the most hazardous combinations spaced well apart. Flammable liquids must be stored in an approved flammable storage cabinet

The Indian Chemical IndustryThe Indian chemical industry is an integral component o f the Ind ian economy, contributing around 6.7 per cent of the Indian GDP. It touches our lives in many different ways. Whether it is thermoplastic furniture we use or a synthetic garment we wear or a

or explosion proof refrigerator (The University of Western Ontario, 2009). Although some chemicals are harmless, most of them are hazards to personnel safety and must be closely guarded. An injury caused by chemical exposure can be extremely serious.

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Protection against chemical exposure or contact by personnel can be accomplished to a great degree in the design stage of an installation. Further protection in the form of protective clothing, respiratory protective devices, or emergencies devices is essential (Ireson and Grant Second Edition).

Labeling and Re-labeling RequirementsThe label is the key to organising chemical products for storage. Tanks and container should be identified with signs indicating the name of the chemical product. No containers or cylinders of compressed gases should be accepted without ensuring identifying labels such as Identification of content; Description of principle hazard (eg, flammable liquid); Precautions to minimise hazards and prevent accident; Correct first aid procedures; Correct procedures for cleaning up spills; and Special instructions to medical personnel in case of an accident (ILO, Volume 3).

at least annually. Chemicals with expired shelf lives and deteriorated or leaking container should be disposed of safely. A Âfirst in, first outÊ system of keeping stock should be used.

The storage of dangerous substances should be supervised by a competent, trained person. All workers required entering storage areas should be fully trained in appropriate safe work practices, and a periodic inspection of all storage areas should be carried out by a safety officer. A fire alarm should be situated in or near the outside of the storage premises.

It is recommended that persons should not work alone in a storage area containing toxic substances. Chemical storage areas should be located away from process areas, occupied buildings and other storage areas. In addition, they should not be in proximity of fixed sources of ignition (ILO Encyclopedia Vol. 3)

Case Study of Medilux Laboratories Pvt Ltd PithampurMedilux is serving as back end support to Pharma industry across the globe since 1988. The plant of Medilux Laboratories is located at Pithampur, Madhya Pradesh, well connected from all corners of India.

They used some hazardous material including solvent (Flash Point less than 32 degree) which is very hazardous as well as very sensitive to catch the fire because flash point is less than 13 degree. The list of some hazardous materials which is used in plant are Mono Choloro Benzene (MCB), Thionyl Chloride, Meta Toluidine and Ethyl aceto acetate. During visit of Medilux Laboratories Pvt Ltd some unsafe condition and unsafe act is found in handling of chemical which is hazardous for human as well as plant. Couples of the unsafe conditions which were identified during visit were 1. Flame proof exhaust fan is not provided in the solvent storage area; 2. Compatible storage is not provided for HAZMAT; 3. Hydrant system is not installed as per the TAC; 4. The space between boiler room and D.G. room is adjacent to the solvent storage area; 5. Mobile phone is prohibited in solvent storage area but some workers donÊt bother about this and use mobile phone in solvent storage area; and 6. Many labours do not use PPE during the manually handling of chemicals.

Suggestions for Improvement1. Flame proof Exhaust fan should be

provided in case of emergency when high rate of fumes release.

2. Compatible storage should be provided for HAZMAT.

3. Fire extinguishers should be install as per IS: 2190.

4. Hydrant system should be installed as per TAC for effective fire protection.

5. During visit it is found that boiler room and D.G. room is closed to the solvent storage area and it is suggested that solvent storage area should be away from boiler room and D.G. room (At least 30 m).

6. Solvent storage should be isolated and storing of other chemicals with solvent should be avoided.

7. Highly reactive chemicals should be stored separately.

8. During handling of hazardous chemicals use of personnel protective equipment should be in practiced by the workers.

All workers required entering storage areas should be fully trainedin appropriate safe work practices, and a periodic inspection of allstorage areas should be carried out by a safety officer. A fire alarmshould be situated in or near the outside of the storage premises.

Safety Management in Handling and Storage of ChemicalsBefore a new hazardous substance is received for storage, information concerning its correct handling should be provided to all users. Planning and maintaining of storage areas are necessary to avoid material losses, accidents and disasters. Good housekeeping is essential, and special attention should be paid to incompatible substances, suitable location of products and climatic conditions.

Written instructions of storage practices should be provided, and the chemicals Material Safety Data Sheets (MSDSs) should be available in storage areas. Locations of the different classes of chemicals should be illustrated in a storage map and in a chemical register. All substance should be received at a central location for distribution to the storerooms, stockrooms and laboratories. A central receiving area is also helpful in monitoring substances that may eventually enter the waste disposal system. Stored chemicals should be examined periodically,

OBJECTIVE The objective of this research is to study the principles and practices of material handling; to study the various risks during material handling; to analyse the accident rate during material handling; and to evaluate the level of prevailing safety measures for material handling in chemical industry.

METHODOLOGYHazard Identification/Risk Assessment Hazards analysis is done by observing practical hazard analysis during industry visit. A site investigation easily can produce a huge amount of data, necessitating that steps be taken in the hazard identification stage to facilitate subsequent analysis. The purpose of Risk assessment is to identify the unsafe condition and unsafe act during the material handling operation in the chemical industry. Risk assessment requires a clear understanding of what chemicals are present at a site, their concentration and spatial distribution, and how they could move in the environment from the site to potential receptor points (Buckingham Phillip L. 2010).

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9. Workers should be trained of handling of hazardous chemicals and a lso aware of chemicals proper t ies which they are daily handling.

CONCLUSIONMaterial handling is a very sensitive issue in the chemical industry because it deals with various types of chemicals which may be hazardous or non-hazardous but always requires safe handling during the plant operation and also requires following various safety standards. These standards require employee training, personal protective equipment and written procedures, programmes and plans for insuring worker safety when working with hazardous material or in hazardous work environment.

References[1] U.S. Department of Labor, OSHA 2236, 2002 (Revised) Materials Handling and Storage, Chapter 1, pp.1[2] Kari Hakkinen, MSc (Eng), Safety in Material Handling (1981)[3] Martend Telsang, 2010, Industrial Engineering and Production Management, Chapter 9, pp. 127-128[4] Dave Macdonald, 2004, Practical Industrial Safety, Risk Assessment and Shutdown Systems, Chapter 2, pp. 34[5] Jeremy Stranks, The ManagerÊs Guide to Health & Safety at Work (8th edition)[6] The University of Western Ontario, HAZARDOUS MATERIALS MANAGEMENT HANDBOOK (Revised Nov. 2009), Chapter 5, pp. 6.[7] KPMG India (Survey Report) 2010, The Indian chemical industry, p.p. 47[8] P. Gopalkrishnan, Handbook of Material Management (Edition 2005), p.p. 131[9] ILO Encyclopedia of Occupational Health and Safety (Vol.3) p.p. 61.10[10] W. Grant Ireson and Eugene L. Grant, Handbook of Industrial Engineering and Management (Second Edition) p.p. 131[11] Dushyant Desai, Industrial Risk Assessment for Planning and Emergency Response: A case of Ahmedabad (2008), p.p.7[12] Buckingham Phillip L., Hazardous Waste Management (2nd Edition), pp.869[13]Technical Learning College, Payson, (2008), „Chemical Handling‰ browsed on 14th March from http://www.abctlc.com/PDF/Chemical%20Handling%20Assignment.pdf

Author Details Md Sadik Khan

Risk EngineerUniversal Sompo General Insurance Co Ltd

Email: khansadik2211@gmail.com

Dr A Dalpati Associate Professor

Department of Industrial and Production EngineeringSGSITS

Email: adalpati@gmail.com