Project Report

On

“HAZARD IDENTIFICATION AND RISK ASSESSMENT

IN MAHA HYDRAULICS PRIVATE LTD”

Submitted for the partial fulfillment for the award of the

DIPLOMA IN INDUSTRIAL SAFETY

2017-2018

Submitted by

R.NIVAETHA

Under the guidance of

Dr .R. K .ELANGOVAN

Deputy Director General

DGFASLI

&

SHRI. NIJALINGAPPA G.P

Director -Safety

Regional Labour Institute, Chennai.

Course Conducted by

Regional Labour Institute

Directorate General Factory Advice Service and Labour Institutes,
Government of India, Ministry of Labour and Employment
1, Sardar Patel Road, TTTI (P.O),
Chennai-600113

1
 BONAFIDE CERTIFICATE

This is to certify that this project work report titled “HAZARD

IDENTIFICATION AND RISK ASSESSMENT IN MAHA
HYDRAULIC’S PRIVATE LIMITED” is the bonafide work of
NIVAETHA.R who carried out Project work under my supervision? certified
further that to the best of my knowledge the work reported here in does
not form part of any other Term work report or dissertation on the basis
of which a degree or award was conferred on an earlier occasion on this or
any other candidate.

Dr. R.K. ELANGOVAN

Deputy Director General

DGFASLI,

Mumbai.

2
 BONAFIDE CERTIFICATE

This is to certify that the Term work report titled “HAZARD

IDENTIFICATION AND RISK ASSESSMENT IN MAHA

HYDRAULIC’S PRIVATE LIMITED” is the bonafide work done by me

submitted in partial fulfillment of the requirement for the award of

Diploma in Industrial Safety from the Board of Examination,

Directorate of Technical Education, Government of Tamil Nadu. I submit

that to the best of my knowledge the work reported herein does not form

part of any other Term work report or dissertation on the basis of which

a degree or award was conferred on an earlier occasion on this of any

other candidate

SIGNATURE OF THE STUDENT:

NAME OFTHE STUDENT: R.NIVAETHA

3
 ACKNOWLEDGEMENT

I am very much grateful to Dr.R.K.ELANGOVAN, Deputy Director

General of DGFASLI, for his valuable guidance and cooperation extended

to me throughout my study in the institute.

I am very much thankful to Shri. NIJALINGAPPA G.P Director

(Safety)In-charge & HOD and as a faculty guide, Regional Labour

Institute, Adyar, Chennai, for his valuable Guidance and cooperation

extended to me throughout my study in the institute.

I extend all my sincere thanks to Faculties of Regional Labour Institute,

Chennai for sharing valuable guidance to prepare the term work.

Last but not the least; I would like to dedicate my heartfelt appreciation to

my family for their invaluable support towards the success of this thesis.

(R.NIVAETHA)

4
 TABLE OF CONTENTS

Chapter Description Page no.

No.

1 Introduction 3

2 Conceptual framework 12

3 Review of literature 18

4 Methodology 247

5 Findings and recommendations 249

6 Conclusion 277

7 Annexure and references 281

8 Bibliography 283

5
 CHAPTER 1
INTRODUCTION

6
 CHAPTER 1.0 INTRODUCTION

1.1 INTRODUCTION

Indian industries are major aspects of rapid growth in modern India. They play a
vital role in Indian economy. India is an agrarian nation, but Indian industries
provide financial support to the country. After independence, India successfully
achieved sovereignty in manufacturing various products. Amongst the various
Indian industries, the most notable ones are involved in the generation of power
and transmission, production of heavy electrical equipment’s, computers, aircrafts,
automobiles, vessels, steam engines, chemicals, construction
machinery, communication instruments and precision equipment’s and tools.

Manufacturing Company should believe that NO JOB OR TASK IS MORE

IMPORTANT THAN WORKER HEALTH AND SAFETY. If a job represents a potential
safety or health threat, every effort will be made to plan a safe way to complete
the task in a safe manner. Every procedure must be a safe procedure. Shortcuts
in safe procedures by management and all other associates will not be tolerated.
If a worker observes any unsafe or unprotected exposure, which may pose a
potential threat to their safety & health, he or she must inform management
immediately.

Safety in any operation works best if the person or people in charge take a leading
role in managing safety and health. Many business enterprises have proven that
good safety management leads to increased productivity, and the same works for
farms.

By having a good safety management program, you can avoid not only farm
injuries, but also other incidents that are costly, time consuming, stressful and
inconvenient. This makes good economic sense.

7
1.2 HIRA – Hazard Identification and Risk Assessment study:

HIRA is a process that consists of several sequential steps such as hazard

identification, consequence & frequency assessment, risk estimation based on the
existing controls and recommendations to reduce those risks that are not under
acceptable limits. It is a collective term that encompasses all activities involved
in identifying hazards and evaluating risk at facilities, throughout their life cycle,
to make certain that risks to employees, the public, or the environment are
consistently controlled within the organization’s risk tolerance. These studies
typically address three main risk questions to a level of detail commensurate with
analysis objectives, life cycle stage, available information, and resources.

HIRA reviews may be performed at any stage in a project’s life cycle – conceptual
design, preliminary design, detailed design, construction, ongoing operation,
decommissioning, or demolition. In general, the earlier that a hazard is identified
(e.g., during conceptual design), the more cost-effectively it can be eliminated or
managed. Studies performed during the early design stages are typically done at
corporate or engineering offices. Studies performed once a process is near startup,
during operation, or before decommissioning are typically done in a plant
environment.

1.3 Objective of HIRA study:

• Carryout a systematic, critical appraisal of all potential hazards involving

personnel, plant, services and operation methods

• Identify the existing safeguards available to control the risks due to the
hazards

• Suggest additional control measures to reduce the risk to acceptable level

8
 • Prepare a Risk Register that will help in continuously monitoring these risks,
detect any changes and ensure the controls are effective.

1.4 Scope of the HIRA Study:

The areas of focus would be

• Study of the plant operations

• Identification of the individual tasks involved in carrying out the above

operations

• Identification of potential health and safety hazards in these tasks

• Determination of the level of risk by combining the likelihood of a hazard

occurring with its severity using the Risk matrix

• Analyzing the existing control measures available to control these risks

• Provide recommendations for additional risk control measures to bring the

risk to acceptable level

• Compilation of the Risk register

1.5 Aim of HIRA study:

• The overall aim of Hazard Identification and Risk Assessment (HIRA) is to

identify the potential hazards associated with the activity and assessment
of the impacts of all probable accidental hazards to facilitate the decision-
making process for mitigating measures to reduce hazards As Low As
Reasonably Practicable.

9
1.6 Importance of HIRA study in an industry:

A HIRA can:

• Help you to prepare for the worst and/or most likely hazards.
• Save time by isolating any hazards which can not affect your community.

• Allows for the creation of emergency plans, exercises and training based on
the most likely and/or highest risk scenarios.
• Helps your program to become proactive rather than just reactive.

1.7 Need for HIRA study:

• To manage risk, hazards must first be identified, and then the risks should
be evaluated and determined to be tolerable or not.
• The earlier in the life cycle that effective risk analysis is performed, the more
cost effective the future safe operation of the process or activity is likely to
be.
• The risk understanding developed from these studies forms the basis for
establishing most of the other process safety management activities
undertaken by the facility.
• An incorrect perception of risk at any point could lead to either inefficient
use of limited resources or unknowing acceptance of risks exceeding the
true tolerance of the company or the community.

1.8 Genesis of study:

It’s a straight forward technique designed to identify and assess the hazards of
conducting a simple walkthrough study of the plant in the research environment.

10
Once the hazard has been recognized appropriate risk minimization or mitigation
measures can be implemented by the responsible authority.

1.9 Area of study:

Maha Hydraulics Private Limited is the manufacturer of Hydraulic motors and

Power packs, having the state of art factory at Sriperumbudur in Tamil Nadu. It’s
a professionally managed organization having a rich experience in hydraulic drives
and systems and extending our specialized services since 2000. Maha Hydraulics
Private Limited is a drive system solution company with complete manufacturing
of Cam Curve Radial Piston Hydraulic Motor up to 150Lts/rev capacity & Power
units up to 1600KW capacity. The hydraulic motors are designed and
manufactured by Maha Hydraulics under brand name "MASCOT". The motors &
power units are extensively used in various industries.

11
 CHAPTER 2

CONCEPTUAL FRAMEWORK

12
 CHAPTER 2.0 CONCEPTUAL FRAMEWORK

2.1 Hazard:

Anything (e.g. condition, situation, practice, behaviour) that has the potential to
cause harm, including injury, disease, death, environmental, property and
equipment damage. A hazard can be a thing or a situation.

A hazard is an agent which has the potential to cause harm to a vulnerable target.
The terms "hazard" and "risk" are often used interchangeably. However, in terms
of risk assessment, these are two very distinct terms. A hazard is any agent that
can cause harm or damage to humans, property, or the environment. Risk is
defined as the probability that exposure to a hazard will lead to a negative
consequence, or more simply, a hazard poses no risk if there is no exposure to
that hazard.

2.2 Hazard Identification:

This is the process of examining each work area and work task for the purpose of
identifying all the hazards which are “inherent in the job”. Work areas include but
are not limited to machine workshops, laboratories, office areas, agricultural and
horticultural environments, stores and transport, maintenance and grounds,
reprographics, and lecture theatres and teaching spaces. Tasks can include (but
may not be limited to) using screen-based equipment, audio and visual equipment,
industrial equipment, hazardous substances and/or teaching/dealing with people,
driving a vehicle, dealing with emergency situations, construction. This process is
about finding what could cause harm in work task or area.

“Hazard identification” in reality can be viewed as “energy identification,”

recognizing that an unanticipated undesirable release or exchange of energy in a

13
system is necessary to cause an “accident” and subsequent system damage or
operator injury.

Therefore, an “accident” can now be seen as “an undesired and unexpected, or at

least untimely release, exchange, or action of energy, resulting, or having the
potential to result in damage or injury.” This approach simplifies the task of hazard
identification as it allows the identification of hazards by means of a finite set of
search paths, recognizing that the common forms of energy that produce the vast
majority of accidents can be placed into only ten descriptive categories.

The goal of this first step in the hazard control process is to prepare a list of
potential hazards (energies) in the system under study. No attempt is made at this
stage to prioritize potential hazards or to determine the degree of danger
associated with them – that will come later. At this first stage, one is merely taking
“inventory” of potential hazards (potential hazardous energies).

2.3 Risk:

The likelihood, or possibility, that harm (injury, illness, death, damage etc) may
occur from exposure to a hazard. Risk can be measured as the product of three
components: (a) the probability that an injury or damage producing mishap will occur
during any one exposure to the hazard; (b) the likely severity or degree of injury or
damage that will likely result should a mishap occur; and (c) the estimated number of
times a person or persons will likely be exposed to the hazard over a specific period of
time. That is…

(1) H x R = D, and since

(2) R = P x S x E, then

(3) H (P x S x E) = D

14
where:

H= Hazard
R= Risk
D= Danger

P= Probability
S= Severity
E= Exposure

In the evaluation of mishap probability, consideration should be given to historical

incident data and reasonable methods of prediction.

Use of this equation must take into account that an accident event having a remote
probability of occurrence during any single exposure, or during any finite period of
exposure to a particular hazard, IS CERTAIN TO OCCUR if exposure to that hazard
is allowed to be repeated over a longer period of time. Therefore, a long term or
large sample view should be taken for proper evaluation.

Determination of potential severity should center on the most likely resulting injury
or damage as well as the most severe potential outcome. Severity becomes the
controlling factor when severe injury or death is a likely possibility among the
several plausible outcomes. That is, even when other risk factors indicate a low
probability of mishap over time, if severe injury or death may occur as a result of
mishap, the risk associated with such hazards must be considered as being
“unacceptable,” and strict attention given to the control of such hazards and
related mishaps.

Exposure evaluation should consider the typical life expectancy of the system
containing a particular hazard, the number of systems in use, and the number of
individuals who will be exposed to these systems over time.

15
2.4 Risk Assessment:

Is defined as the process of assessing the risks associated with each of the hazards
identified so the nature of the risk can be understood. This includes the nature of
the harm that may result from the hazard, the severity of that harm and the
likelihood of this occurring.

2.5 Hazard Identification and Risk Analysis (HIRA):

Hazard Identification and Risk Analysis (HIRA) is a collective term that

encompasses all activities involved in identifying hazards and evaluating risk at
facilities, throughout their life cycle, to make certain that risks to employees, the
public, or the environment are consistently controlled within the organization’s risk
tolerance. These studies typically address three main risk questions to a level of
detail commensurate with analysis objectives, life cycle stage, available
information, and resources.

The three main risk questions are:

Hazard – What can go wrong?

Consequences – How bad could it be?

Likelihood – How often might it happen?

When answering these questions, the objective is to perform only the level of
analysis necessary to reach a decision, because insufficient analysis may lead to
poor decisions and excessive analysis wastes resources. A suite of tools is available
to accommodate varying analysis needs: (1) tools for simple hazard identification
or qualitative risk analysis include hazard and operability analysis (HAZOP), what-
if/checklist analysis, and failure modes and effects analysis (FMEA), (2) tools for
simple risk analysis include failure modes, effects, and criticality analysis (FMECA)
and layer of protection analysis (LOPA), and (3) tools for detailed quantitative risk

16
analysis include fault trees and event trees (Refs. 9.2, 9.3, 9.4). For example, some
companies may judge the mere existence of an explosion hazard to be an
unacceptable risk, regardless of its likelihood. Others may be willing to tolerate an
explosion risk if proper codes and standards are followed. Still others may be
unwilling to accept an explosion risk unless it can be shown that the expected
frequency of explosions is less than 10-6/y. HIRA encompasses the entire
spectrum of risk analyses, from qualitative to quantitative. A process
hazard analysis (PHA) is a HIRA that meets specific regulatory requirements in the
U.S. Figure 9.1 illustrates the increasing rigor of risk analyses possible as the scope
of the study becomes more focused on specific accident scenarios. Note that as
risk studies become more focused and detailed, the cost per scenario
analyzed increases, but the overall cost may decrease if only a few representative
or bounding scenarios are analyzed.

17
 CHAPTER – 3

REVIEW OF LITERATURE

18
 CHAPTER 3.0 REVIEW OF LITERATURE

3.1 About the factory:

3.1.1 Introduction about the factory:

Maha Hydraulics Private Limited is a drive system solution company with complete
manufacturing of Cam Curve Radial Piston Hydraulic Motor up to 150Lts/rev
capacity & Power units up to 1600KW capacity. The hydraulic motors are designed
and manufactured by Maha Hydraulics under brand name "MASCOT". The motors
& power units are extensively used in various industries.

Maha Hydraulics Private Limited was established in the year 2000 with a team of
qualified Engineers from reputed Institute. The Directors of the company have
done specialization in Hydraulics for nearly 20 years before starting this
organization. We have recently shifted our manufacturing activity to our new
premises at Irungattukottai near Chennai with a modern manufacturing facility and
high-quality Test facilities.

Our organization is concentrating mainly on Direct Gearless Hydraulic Drive

systems & Hydraulic Power Units along with Automation for new equipment and
also for replacement of Electro Mechanical Systems to Hydraulic systems.

We have been manufacturing Hydraulic systems for various equipment like Stacker
Reclaimer, Wagon Tippler, Conveyors, Ball Mills, Bowl Mills and Apron Feeders for
material handling applications. We also manufacture systems for Sugar Industries,
Paper & Pulp, Cement and Steel Industries.

We undertake design and manufacture of custom built Hydraulic equipment as per

customer's requirement. We also offer consultancy services for upgrading and
modification of existing hydraulic systems.
19
In Recent years the application of Hydraulic drives for Bulk material handling
equipment has been increasing at a rapid phase compared to Electro mechanical
drives. In fact, many customers whose machines are with Gear Box drive are
converting their machines with Hydrostatic drives for higher productivity.

3.1.2 Products:

We have been manufacturing Hydraulic systems for various equipments like

Stacker Reclaimer, Wagon Tippler, Conveyors, Ball Mills, Bowl Mills and Apron
Feeders for material handling applications. We also manufacture systems for Sugar
Industries, Paper & Pulp, Cement and Steel Industries.

20
3.1.2.1 Hydraulic Power Packs:

Maha hydraulics can provide hydraulic systems for Industrial and Marine
application to any part of the world. Typical Hydraulic drive applications include
Stalker Reclaimer, Wagon tippler, Paddle Feeder, Apron Feeder, Side Arm Charger,
Boom luffing, Conveyors and as well as other varieties of industrial machinery. We
offer our distributors reliable products through design and manufacturing
expertise. Each power pack is designed and manufactured in our Factory premises
(Chennai) using latest technologies and that makes us one of the top competent
in the world market.

Some of our Hydraulic Power Packs are:

• Bucket Wheel Reclaimer and Slew Drive

• Wagon Tipplers
• Conveyors
• Apron feeders

21
• Side arm chargers
• Boom Luffing
• Paddle Feeders

22
23
3.1.2.2 Hydraulic Motor:

LD SERIES – Description:

MASCOT MDS Series hydraulic motors are designed for high power and high-speed
applications. The compact size, light weight and ease of installation make these
motors highly suited also for mobile applications. Several mounting options are
available for high radial load applications. The axial load capacity of LD series
motors is high. This makes them very suitable for use in Paddle Feeder Wheel
Drive and other applications where axial forces are more. Parking brake at the
front side of the motor ensures high holding torque.

24
OPTIONS FEATURES

Customized shaft. Long Life

Integral multi plate disc brake High Mechanical Efficiency

(Static / Parking). Constant torque output
High speed versions. Smooth low speed performance
Double shaft. <1rpm

Super low noise. Resistance to thermal shock

Corrosion resistant material. Double shaft sealing

Through hole shaft of various Shrink disc coupling

sizes. Shaft or Flange mounting
Custom finish. Shock Resistance
Deep water submersible. Low noise
Non magnetic material.

Dual Displacement.

25
MD SERIES – Description:

MD Series Hydraulic Motors are designed for high power and high-speed
applications. Most of the Wagon Tippler, slew drive are driven by MD Series
motors. In addition, these motors are most suited for use in Feeder Breaker, Ball
Mills and Bowl Mills. Optionally, a brake can be fitted in the front end of the motor.

26
The motor displacements available range from 12 lit/rev. to 15 lit/rev. They aim
to provide a wide variety of precise hydraulic motor and pump combinations. These
motors can take heavy shock loads due to the incorporation of a robust front
bearing arrangement.

27
MDS SERIES – Description:

MDS Series hydraulic motors are designed for high power and high speed
applications. These motors are exclusively developed for Wagon Tippler, Side Arm
Charger & Paddle Feeder Hydraulic Drive Application due to high radial & Axial
Load capacity. In addition, these motors are also most suited for use in Feeder
Breaker, Ball Mills and Bowl Mills. Optionally, a brake can be fitted in the rear end
of the motor. The motor displacements available range from 9 lit/rev. to 15 lit/rev.

28
They aim to provide a wide variety of precise hydraulic motor and pump
combinations. These motors can take heavy shock loads due to the incorporation
of a robust front bearing arrangement.

29
HD series – description:

HD Series Hydraulic Motors aim to provide high torque for low speed applications.
On specific request, the motors can also be custom-made to suit high speed
requirements. These motors incorporate the “high-flow” distribution system. The
HD Series motors are always torque arm mounted, making them the ideal choice
for applications such as Bucket Wheel Drive, Apron Feeder, Kiln Drive etc., to
eliminate misalignment.

The motors run with high efficiency and the power output from the motor is as
high as 1000 KW. The Mascot HD Series motors ensure trouble free operation even
in dusty environmental conditions.

30
31
32
820 series – Description:

820 Series Hydraulic Motors aim to provide high torque for high speed applications.
These motors incorporate the “high-flow” distribution system. These motors are
extensively used for Wagon tippler and high inclination conveyors where high
brake torque is required. Hydraulic brake (static) up to 16000 kgm are used in
these motors which made these motors an ideal choice for high braking torque
application.

The motor displacements available range from 15 lit/rev. to 30 lit/rev. These

motors can take heavy shock load due to incorporation of robust front bearing
arrangement.

33
34
CR series – Description:

The Hydraulic Motor CR Series is designed and manufactured considering the

provisions of directives, standards and specifications relating to this technology.
There is however still a risk of personal injury or damage to property if the
following safety instructions and warnings contained in this document are not
observed.

User should read these instructions completely and thoroughly before working with
the hydraulic power unit/hydraulic drive assembly, using our mascot hydraulic
motors.

• When reading these instructions, user should always have the product-
specified documentation on hand.
• These instructions, together with the relevant product-specified
documentation, should be kept so as to be readily accessible to all users.
• Always include the operating instructions and the product specified
documentation when passing the hydraulic power unit/hydraulic
assembly/Hydraulic Motor to a third party.

35
Due to the interaction between the hydraulic power unit/Hydraulic Motor and the
complete machine, the installation of the hydraulic power unit into the machinery
will result in additional potential hazards. This applies in particular to the influence
of hydraulic and electric controls on hydraulic drives generating mechanical
movements. It is therefore essential for the manufacturer of the complete machine
to have undertaken an independent risk assessment. Furthermore, the
manufacturer must on this basis have prepared operating instructions for the
complete machine.

3.1.2.3 Electronics:

Each and every hydraulic drive is controlled and regulated by a specific set of
Controller systems. The entire algorithm of starting and running a hydraulic drive

36
shall be automated through electronics. Using our electronic sector, we shall
ensure our hydraulic system is totally a user friendly one with all safety interlocks.

Our electronic products include

• Microprocessor
• PLC
• PAM controllers

Hydraulic Drive Controllers – Microprocessor:

Digital I/O's* 24 - 100 I/O

Analog I/O's* 4 I/O

Make Schroder

37
Pump Controllers – Microprocessor:

Range* 18mA to 3000mA

Ramp* 10sec to 100sec
Input type 4-20mA, 0-5Vdc, 0-10Vdc
Make Schroder

38
Hydraulic Drive Controllers - PLC base

Digital I/O's* 24 to 256 I/O

Analog, I/O's* 4 I/O
Make Siemens / GE

3.1.2.4 Static / Parking Hydraulic Brakes:

Our spearhead and reliable hydraulic brake system is designed in such a way to
meet your specific requirements. Every braking solution we manufacture is
extensively tested under tough conditions and can be customized to suit with your
required operational needs and environment.

39
Key benefits of our brakes are:

• Easy maintenance and reduced costs

• Short response time and fast braking
• Reduces loss of force and provides high level of safety
• preventing the presence of oil on brake discs, increasing safety levels
• Tested down to - 40 degrees C

Brake torque* 800 - 16000Kgm

Release Pressure* upto 50Bar

Type Multi Spline Disc Dry Brake

40
3.1.2.5 Services:

Maha Hydraulics is always ready to provide service during and after maintenance
period of our system. Our service team is usually ready on war foot basis to report
to our customers to satisfy their needs for which a separate set of Service
engineers and technicians are available who have a well-versed knowledge in
trouble shooting the systems.

Motor Endurance Test Bench:

Installed 250 KW motor back to back test facility for Hydraulic motor calibration.
All Hydraulic motors up to 100 lit/rev can be tested for 300 bar maximum operating
pressure. This is the first of its kind in India to test Radial Piston Hydraulic motors
for torque up to 60,000 Kgm.

41
3.1.3 Manufacturing process:

The manufacturing and assembly of power packs and motors includes a various
safe procedures as described in below flow chart;

42
3.1.3.1 Power pack flow chart:

43
3.1.3.2 Motor process flow chart:

44
3.1.4 Operation of motors in various location:

Operation of boom hydraulic cylinder:

As soon as electric motor is switched on, Hydraulic Pump shall start delivering the
flow in the system. Hydraulic Oil shall get unloaded to tank through Pressure Relief
Valve For Cylinder extension, Solenoid S2 of DC Valve is energized along with S1
of Unloading Valve, the hydraulic oil pushes the boom luff cylinder. Accordingly for
retraction, Solenoid S3 and S1 is energized and the hydraulic oil pulls boom luff
cylinder. Hydraulic cylinder speed can be varied by Flow Control valve.

Bucket Wheel hydraulic system description:

The above system is equipped with closed loop axial piston Hydraulic pumps. The
pump is with through shaft for mounting additional control pumps on it. The
additional control pump is of vane pump for boost and cooling purpose. A Small
vane pump (servo pump) mounted in Main Pump supplies oil to Servo control unit
through a servo filter.

Boost pump Supplies oil to main pump. Boost pump oil is blow through relief valve
in main pump which is normally set at 25 bar at Main Pump. The Boost pressure
value is monitored in Hydraulic drive controller panel.

The main pump pressure at port A, B is monitored in Hydraulic drive controller

panel. The system having a external control valve block with Proportional pressure
control valve and DC Valve to control the pump displacement to deliver desirable
flow

45
Slew Drive hydraulic system description:

The above system is equipped with closed loop axial piston Hydraulic pump with
inbuilt small gear pump to supply boost and servo oil. A tandem Gear pump
attached to shaft of Main pump for supply of oil for Brake release and line filling.

The Gear pump in Hydraulic Pump Supplies oil to main pump through Filter. The
boost oil shall be used for filling up the system lines and for control of main pump
swash plate / Servo piston.

The boost pressure value is monitored in Hydraulic drive controller panel. The main
pump pressure at port A,B is monitored in Hydraulic drive controller panel. The
Gear pump supplies oil to brake control manifold block and it is used for release
of Hydraulic motor parking.

Operation of Operator cabin hydraulic cylinder:

As soon as electric motor is switched on, Hydraulic Pump shall start delivering the
flow in the system. Hydraulic Oil shall get unloaded to tank through Pressure Relief
Valve.

For Cylinder extension, Solenoid S1 of DC Valve is energized, the hydraulic oil

pushes the Cabin cylinder. Accordingly, for retraction, Solenoid S3 is energized and
the hydraulic oil pulls Cabin cylinder. Hydraulic cylinder speed can be varied by
Throttle Check Valve.

Interlocks of hydraulic system:

• In case of low oil level in the reservoir, complete system should be switched
off through level sensor.

46
 • Temperatures switch with two set points. One set at 55 deg. C to alarm and
other one set at 65 deg. C to switch off the complete system.
• Main electric motor of bucket wheel & slew drive should not be switched on
in case of the following.
(a) Low oil level.
(b) High oil temperature.
(c) In case if air oil cooler, electric motor is not switched on.
(d) if suction valve is closed.

Connection between amplifier card in and (Proportional control valve) should be

with shielded wires. In case, if any one of return line filter is clogged electrical
signal will be available showing clogging of the filter and same should be used to
switch off the complete system.

3.1.5 Safety for handling (on-site):

• Observe the transport instructions, e.g. on the packing

• The package can be opened for inspection purposes, package. It should not
be removed before assembling the unit.

Lifting methods:

One of the methods shown here must be used when handling the motor. Before
lifting, check the lifting eyes are screwed tools can handle the weight. Always make
sure where the center of gravity is before any lifting. Never stand below a hanging

47
motor.

Standing the motor on flat surface:

When the motor is placed on a flat surface such as floor it must stand either on its
outer diameter or on the suitably protected end face of the hollow shaft.

Note: When in storage the motors must always be placed on the end face to the
hollow shaft. It is also advisable to provide supports at the mounting surface of
the motor.

48
49
3.2 Standard:

3.2.1 International Standards:

3.2.1.1 OHSAS 18001-2007

As per OHSAS 18001-2007, following are listed related to hazard identification

and risk assessment

Planning: Hazard Identification, Risk Assessment and Determining

Controls

The organization shall establish, implement and maintain a procedure(s) for the

ongoing hazard identification, risk assessment, and determination of necessary

controls.

The procedure(s) for hazard identification and risk assessment shall take into

account:

a) Routine and non-routine activities;

b) Activities of all persons having access to workplace (including contractors and

visitors);

c) Human behavior, capabilities and other human factors;

d) Identified hazards originating outside the workplace capable of adversely

affecting the health and safety of persons under the control of the organization

within the workplace;

50
e) Hazards created in the vicinity of the workplace by work-related activities

under the control of the organization;

Note: It may be more appropriate for such hazards to be assessed as an

environmental aspect.

f) Infrastructure, equipment and materials at the workplace, whether provided

by the organization or others;

g) Changes or proposed changes in the organization, its activities, or materials;

h) Modifications to the OH&S management system, including temporary

changes, and their impacts on operations, processes, and activities;

I) any applicable legal obligations relating to risk assessment and

implementation of necessary controls;

j) The design of work area processes. Installations, machinery / equipment,

operating procedures and work organization, including their adaptation to

human capabilities.

The organization’s methodology for hazard identification and risk assessment

shall

a) Be defined with respect to its scope, nature and timing to ensure it is

proactive rather than reactive; and

b) Provide for the identification, priorization and documentation of risks, and

the application of controls, as appropriate. For the management of change, the

organization shall identify the OH&S hazards and OH&S risks associated with

51
changes in the organization, the OH&S management system, or its activities,

prior to the introduction of such changes.

The organization shall ensure that results of these assessments are considered

when determining controls.

When determining controls, or considering changes to existing controls,

consideration shall be given to reducing the risks according to the following

hierarchy

a) Elimination;

b) Substitution;

c) Engineering controls;

d) Signage / warnings and / or administrative controls;

e) Personal protective equipment.

The organization shall document and keep the results of identification of

hazards, risk assessment and determined control up-to-date.

The organization shall ensure that OH&S risks and determined controls are

taken into account when establishing, implementing and maintaining its OH&S

management system.

Legal and Other Requirements

The organization shall establish, implement and maintain a procedure(s) for

identifying and accessing the legal and other OH&S requirements that are

applicable to it.

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The organization shall ensure that these applicable legal requirements and other

requirements to which the organization subscribes are taken into account in

establishing, implementing and maintaining its OH&S management system. The

organization shall keep this information up-to-date. The organization shall

communicate relevant information on legal and other requirements to persons

working under the control of the organization, and other relevant interested

parties.

Objectives and Programme(s)

The organization shall establish, implement and maintain documented OH&S

objectives, at relevant functions and level within the organization.

The objectives shall be measurable, where practicable, and consistent with the

OH&S policy, including the commitments to the prevention of injury and ill

health, to compliance with applicable legal requirements and with other

requirements to which the organization subscribes and to continual

improvement.

When establishing and reviewing its objectives, an organization shall take into

account the legal requirements and other requirements to which the

organization subscribes, and its OH&S risks. It shall also consider its

technological options, its financial, operational and business requirements, and

the views of relevant interested parties.

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The organization shall establish, implement and maintain a programme(s) for

achieving its objectives. Programme(s) shall include as a minimum:

a) Designation of responsibility and authority for achieving objectives at relevant

functions and levels of the organization; and

b) The means and time-frame by which the objectives are to be achieved.

The programme(s) shall be reviewed at regular and planned intervals, and

adjusted as necessary, to ensure that the objectives are achieved.

3.2.1.2 OHSAS 18002 -2006

As per OHSAS 18002 -2006, following are listed related to hazard identification

and risk assessment;

Planning: Hazard Identification and Risk assessment

The organization shall establish, implement and maintain a procedure(s) for the

ongoing hazard identification, risk assessment, and determination of necessary

controls.

The procedure(s) for hazard identification and risk assessment shall take into

account:

a) Routine and non-routine activities;

b) Activities of all persons having access to the workplace (including contractors

and visitors);

c) Human behavior, capabilities and other human factors;

54
d) Identified hazards originating outside the workplace capable of adversely

affecting the health and safety of persons under the control of the organization

within the workplace

e) Hazards created in the vicinity of the workplace by work-related activities

under the control of the organization;

NOTE 1 it may be more appropriate for such hazards to be assessed as an

environmental aspect.

f) Infrastructure, equipment and materials at the workplace, whether provided

by the organization or others;

g) Changes or proposed changes in the organization, its activities, or materials;

h) Modifications to the OH&S management system, including temporary

changes, and their impacts on operations, processes, and activities.

i) any applicable legal obligations relating to risk assessment and

implementation of necessary controls.

j) The design of work areas, processes, installations, machinery/equipment,

operating procedures and work organization, including their adaptation to

human capabilities

55
The organization’s methodology for hazard identification and risk

assessment shall:

a) Be defined with respect to its scope, nature and timing to ensure it is

proactive rather than reactive; and

b) Provide for the identification, prioritization and documentation of risks, and

the application of controls, as appropriate.

c) For the management of change, the organization shall identify the OH&S

hazards and OH&S risks associated with changes in the organization, the OH&S

management system, or its activities, prior to the introduction of such changes.

d) The organization shall ensure that the results of these assessments are

considered when determining controls.

e) When determining controls, or considering changes to existing controls,

consideration shall be given to reducing the risks according to the following

hierarchy:

a) Elimination;

b) Substitution;

c) Engineering controls;

d) signage/warnings and/or administrative controls;

e) Personal protective equipment.

The organization shall document and keep the results of identification of

hazards, risk assessments and determined controls up-to-date.

56
The organization shall ensure that the OH&S risks and determined controls are

taken into account when establishing, implementing and maintaining its OH&S

management system.

General

Hazards have the potential to cause human injury or ill health. Hazards therefore

need to be identified before the risks associated with these hazards can be

assessed and, if no controls exist or existing controls are inadequate, effective

controls should be implemented according to the hierarchy of controls. An

organization will need to apply the process of hazard identification and risk

assessment to determine the controls that are necessary to reduce the risks of

incidents. The overall purpose of the risk assessment process is to recognize

and understand the hazards that might arise in the course of the organization’s

activities and ensure that the risks to people arising from these hazards are

assessed, prioritized and controlled to a level that is acceptable.

This is achieved by:

⎯ developing a methodology for hazard identification and risk assessment

⎯ identifying hazards

⎯ estimating the associated risk levels, taking into account the adequacy of any

existing controls (it may be necessary to obtain additional data and perform

further analysis in order to achieve a reasonable estimation of the risk level)

⎯ determining whether these risks are acceptable, and

57
⎯ determining the appropriate risk controls, where these are found to be

necessary (workplace hazards and the way they are to be controlled are often

defined in regulations, codes of practice, guidance published by regulators, and

industry guidance documents).

The results of risk assessments enable the organization to compare risk

reduction options and prioritize resources for effective risk management.

The outputs from the hazard identification, risk assessment and determining

control processes should also be used throughout the development and

implementation of the OH&S management system.

Methods adopted to collect information and data for this report are studying the

various statutory requirements related to hazard identification and risk assessment

and analyze the existing hazards in our sugar plant.

• Discussion with all categories of workmen, supervisory staff and

management.

• Study of available accident records.

• Study of safety manuals, books, journals, magazines, website etc.,

• Discussing with maintenance wing, line managers and engineers in the plant.

• Conducting safety survey in the plant and studying the previous safety audit

reports.

• By discussing with the guide

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A hazard is anything that has the potential to cause harm when combined with

some initiating stimulus. Many system safety techniques have been pioneered to

aid in the identification of potential system hazards. None is more basic than

“energy analysis.” Here, potential hazards associated with various physical

systems and their associated operation, including common industrial and

consumer related activities, can be identified (for later evaluation and control) by

first recognizing that system and product “hazards” are directly related to various

common forms of “energy.” That is, system component or operator “damage” or

“injury” cannot occur without the presence of some form of hazardous “energy.”

Hazard identification and risk assessment is based upon fundamental principles

and rules of practice. It involves the (a) identification, (b) evaluation, and (c)

control of hazards in man-machine systems (products, machines, equipment, or

facilities) that contain a potential to cause injury to people or damage to property.

HAZARD IDENTIFICATION

“Hazard identification” in reality can be viewed as “energy identification,”

recognizing that an unanticipated undesirable release or exchange of energy in a

system is absolutely necessary to cause an “accident” and subsequent system

damage or operator injury. Therefore, an” accident” can now be seen as “an

undesired and unexpected, or at least untimely release, exchange, or action of

energy, resulting, or having the potential to result in damage or injury.” This

approach simplifies the task of hazard identification as it allows the identification

59
of hazards by means of a finite set of search paths, recognizing that the common

forms of energy that produce the vast majority of accidents can be placed into

only ten descriptive categories.

The following hazards present in the sugar industry.

• General hazards

• Mechanical Energy Hazards

• Electrical Energy Hazards

• Chemical Hazards

• Kinetic (Impact) Energy Hazards

• Potential (Stored) Energy Hazards

• Thermal Energy Hazards

• Acoustic Energy Hazards

• Biological Hazards

Findings

After collection of the data and interaction with plant people, all the hazards in the

industry identified as following.

General hazards

As part of bearing and bushings manufacturing and maintenance of the plant, it is

required to working at machinery, scaffolding and platforms, and work on roofs.

It also covers the use of ladders, the erection and dismantling of scaffolding.

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Slips trips and falls

Slips trips and falls are a cause of injury in most large workplaces and can be

caused by poor design, damage and in particular, poor levels of, or incorrectly

placed lighting.

Sugar manufacturing has some particular processes which may affect the risk of

slips trips and falls for example, reactions between concrete and sugar products

(sugar dust, molasses, or massecuite) which can damage floors and walkways.

Varying weather conditions can also create slippery conditions in sugar plant.

• No ergonomic design of stair cases, platforms and ladders etc.

• Plane MS sheets are using for platforms instead of chequred sheets at various

sctions

• Usage of wooden platforms at certain sections like evaporator station etc

Working at height

• No strict implementation of work permit system

• Lack of awareness on work permit system

• No emergency rescue mechanism for workers working at height.

• Special training programmess for working at fragile roofs.

Falling objects

Our Sugar plant was constructed in multi-level installations and has some

structures which can be higher than 40 meters like chimney stacks. Operators

61
should consider a range of issues when assessing the risk of injury from falling

objects, including:

• The type of work being conducted

• What equipment is being used

• The number of people using the area below

• Whether special provisions are required for specific work (e.g. hot work)

• How far an object might fall and what the object might be

• The consequences of being struck.

• Toe board system should be improved

• Personal protection equipment usage is to be improved

Hitting and being hit by moving objects

Hitting and being hit by moving objects is a major hazard at sugar plants.

• Cluttered workplace, due expansion of the plant from 500tcd to 5000 tcd in

long run

• Workers colliding with moving plant or equipment

• Lack of warning signs fitted at intersections

• Poor personal protection equipment usage.

• Lack of warning devices on moving plant and vehicles such as forklifts.

Mechanical Energy Hazards

Mechanical energy hazards involve system hardware components that cut, crush,

bend, shear, pinch, wrap, pull, and puncture. Such hazards are associated with

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components that move in circular, transverse (single direction), or reciprocating

(“back and forth”) motion.

• No Standard operating procedures for operation and maintenance of various

critical machineries like fibrizers, cutters, mill drives and compressors etc.

• No risk assessment of machinery for hazard control.

• No availability of Instruction Manuals at operator and supervisor level to ready

reference.

• Lack of awareness on guarding system among workers

• Poor Hand railing system at bagasse carrying slot conveyors at boilers.

• No standard system for machine guard design

• Hand railing system is to be improved at bagasse carrying conveyors

• Lac of frequent training programmes related to machine operation, cleaning,

maintenance and repair and about hazards associated with the machines.

• Poor incident reporting

• Various equipment machine guards are not designed as per standards.

• Poor periodical maintenance of existing guarding systems.

• Lack of awareness among guarding system.

• No standard training modules for Machine guard training

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Electrical Energy Hazards

Electrical energy hazards have traditionally been divided into the categories of low

voltage electrical hazards (below 440 volts) and high voltage electrical hazards

(greater than 440 volts).

Typical electrical risks within a sugar plant include:

• Operation of plant around electrical lines and parts

• Electrical work

• Use electrical equipment

• Failure of electrical equipment

Chemical Energy Hazards

Chemical energy hazards involve substances that are corrosive, toxic, flammable,

or reactive, to include chemical explosives.

In our plant, we are using sulphur, Cao, phosphoric acid, flocculants and acid and

alkali cleaning chemicals etc.

• Workers may be exposed to chemical by following means.

• While start up of sulphur burner.

• Preparation of chemical solution for chemical boiling.

• Internal painting of vessels.

• While doing insulation work.

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Kinetic (Impact) Energy Hazards

Kinetic energy hazards involve “things in motion” and “impact,” and are associated

with the collision of objects in relative motion to each other.

Potentially hazardous items of plant that are likely to be found at a plant

workplace and can be a risk to anyone near the plant include:

• Abrasive wheels

• Belts and pulleys

• Chain and sprocket gears and drives

• Circular saws

• Conveyors (belt, screw and bucket)

• Cutter grinders

• Disintegrators

• drills and chucks

• Fans

• Flywheels and gear wheels

• milling train carriers and rolls

• Shafts and spindles

Potential (Stored) Energy Hazards

Potential energy hazards involve “stored energy.” This includes things that are

under pressure, tension, or compression; or things that attract or repulse one

another.
65
 • Use of air blower to clean the dust on electrical equipment

• Improper addressing of potential hazards.

Thermal Energy Hazards

Thermal energy hazards involve things that are associated with extreme or

excessive heat, extreme cold, sources of flame ignition, flame propagation, and

heat related explosions.

In sugar plant the following thermal hazards are there,

• Live and exhaust steam

• Hot juice

• Hot condensate

• Back fire at sulphur burners

• Boiler black fires

• Bagasse fires

• Coal fires

• Sulphur fires

• No identification of fire crew members.

• Insufficient training programs and fire drills

• The is no reliable fire hydrant system to cope up needs of fire fighting

• In sufficient fire extinguishers

• No designated locations for fire extinguishers

66
• Sugar cane handling and grading operations cause accumulation of the trash

in the cane yard

• Bagasse fibre dust accumulated on the floor and electrical cable trays to be

cleaned regularly.

• Raw sulphur bags are keeping near to sulphur mealting tank.

• Lack of respiratory protective equipments for the operating personnel.

• Centrifugal machinery, sugar handling equipment can be arranged electrical

earthing for static electricity discharge.

• Emergency system such as fire alarm fire bell or PA system can be installed

for evacuation of personnel and early response of the fire crew.

• Sugar dust accumulated on the floor, top of the bins, electrical cable trays,

motors to be cleaned regularly.

• Care must be taken while attending any hot works in drying hall.

• Bigger sign boards “No smoking” should be provided in the vicinity of the

warehouse and stores.

• In sufficient emergency exits fire extinguishers and fire buckets at stores

• Improper Material segregation at stores

• Lack of bagasse storage area.

• No strict implementation of hot work permits system near bagasse handling

area.

• Present Fire hydrant system is not sufficient for mazor fire accidents.

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 • No Emergency fire response system.

• No specific training module to combat sulphur fires.

• No Respiratory protective equipment like SCBA, canister masks to use in case

of emergency.

Acoustic Energy Hazards

Acoustic energy hazards involve excessive noise and vibrations.

• Personal protective equipment utilization is poor.

• Cleaning of evaporators, juice heater with mechanical cleaners is high decibel

job.

• Use of hydraulic breakers by civil workers.

• Juice heater bolting work with pneumatic wrench.

• Steam blow off of boilers and turbines.

• Diesel Gen set operation..

• ID fan of fluidized bed drier.

• Ball mill for rust removal.

• Bodies shell cleaning.

Biological Hazards

These hazards are associated with poisonous plants, dangerous animals, biting or

poisonous insects, and disease carrying bacteria, etc.

• No awareness on Legionella bacteria.

• No specific pest control programme in the plant.

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Assessment of hazards:

After all related hazards identified, assessment was done as per procedure given

in the literature.

3.2.2 National standards:

3.2.2.1 IS 15656-2006:

This Code describes specific techniques to prevent human and property losses

in the operation and management of process plant. The overall methodology

presented in this Code allows systematic identification of hazards as well as

quantification of the risks associated with the operation of process plants.

Applied with due expertise and rigor the prescribed methodology can help the

user understand the relative levels of hazards and risk potential in an

installation. This aids the selection and prioritization of necessary strategies for

Incident prevention and limiting their consequences. Therefore, the Code can

be used for improving plant safety performance as well as to reduce human and

property losses. Risk analysis is a process that consists of a number of sequential

steps as follows:

a) Hazard Identification — identifying sources of process Incidents involving

release of hazardous material in the atmosphere and the various –ways (that is

scenarios) they could occur.

69
b) Consequence Assessment — estimating the probable zone of impact of

Incidents as well as the scale and/or probability of damages with respect to

human beings and plant equipment and other structures.

c) Incident Frequency Assessment — Computation of the average likelihood of

Incidents.

d) Risk Estimation — Combining Incident consequence and frequency to obtain

risk distribution within and beyond a process plant.

This Code describes the essential nature of each of the above sequence of steps

and describes a variety of techniques for identifying hazards and the

quantification of Incident consequence and the frequency towards the final risk

estimation.

The Quantitative Risk Analysis (QRA) is most applicable and provides meaningful

results when a plant is built, operated and maintained as per design intent and

good engineering practices.

Terminologies:

For the purpose of this Code, the following technical terms used are interpreted

and understood as given below.

Incident — A specific unplanned event or sequence of events that has

undesirable consequences.

Basic Event — A fault tree event that is sufficiently basic that no “further

development is necessary.

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Consequence — A measures of the expected effects of an incident.

Explosion —A sudden release of energy characterized by accompaniment of a

blast wave.

External Event — an event caused by a natural hazard (earthquake, flood, etc.)

or man-induced events (aircraft crash, -sabotage, etc.).

Fire — A process of combustion characterized by heat or smoke or flame or any

combination of these.

Frequency — the number of occurrences of an event per unit of time.

Hazard — A characteristic of the system/plant process that represents a

potential for an Incident causing damage to people, property or the

environment.

Initiating Event — the first event in an event sequence

Mitigation System — Equipment and/or procedures designed to respond to an

incident event sequence by interfering with incident propagation and/or

reducing the incident consequence.

Probability — An expression for the likelihood of occurrence of an event or an

event sequence during an interval of time or the likelihood of the success or

failure of an event on test or on demand.

Risk — A measure of potential economic loss or human injury in terms of the

probability of the loss or injury occurring and the magnitude of the loss or injury

if it occurs.

71
Top Event — the unwanted event or incident at the top of a fault tree that is

traced downward to more basic failures using logic gates to determine its causes

and likelihood

Worst Case Consequence — a conservative (high) estimate of the consequences

of the most severe incident identified.

3 RISK ANALYSIS METHODOLOGY

The flow chart for risk analysis is given in Fig.l 3.1 The terms in Fig. 1 are

explained as follows.

3.1.1 Goal:

Goal for carrying out risk analysis is required as a part of statutory requirement,

emergency planning, etc. depending on the nature of industry.

72
Flow chart of risk assessment:

3.1.2 Location, Layout, Process Parameters

The information on plant location, the layout of equipment,

the process conditions, etc, is required for the risk analysis.

73
3.1.3 Hazard Identification

Hazard identification is done by comparative and/or fundamental methods

leading to qualitative or quantitative results.

3.1.4 Quantification of Hazards

The indices method for hazard identification can assess the hazard potential for

the identified scenarios and can be used as a tool for screening.

3.1.5 Select Most Credible Scenario

The credible scenarios which can culminate into an accident out of several major

and minor scenarios, possible for the release of material and energy.

3.1.6 Select Worst-Case Scenario

The incident, which has the highest potential to cause an accident of maximum

damage, is selected for further analysis.

3.1.7 Estimate Consequences

The consequences of scenarios in the plant in the form of fire, explosion and

toxic effects have to be estimated and presented.

3.1.8 Estimate Frequency of Occurrence

The probability or frequency of its occurrence of any incident is to be found out

by reliability analysis, which includes fault tree/event tree, etc.

74
3.1.9 Estimate the Risk

Risk is expressed as the product of frequency of an event and the magnitude of

the consequences that result each time the event occurs. The calculated risk can

be compared with national or international values.

3.1.10 Prioritize and Reduce Risk

Based on the estimated risk the contributing factors leading to events/accidents

are analysed and prioritized in the risk analysis.

5 HAZARD IDENTIFICATION AND HAZARD

ANALYSIS

A hazard is generally realised as a loss of containment of a hazardous material.

The routes for such loss of containment can include release from pipe fittings

containing liquid or gas, releases from vents/relief and releases from vessel

rupture. Adhering to good engineering practices alone may not be adequate for

controlling plant hazards thus, a variety of techniques of hazard identification

and probability of their occurrence have been developed for analysis of

processes, systems and operations.

The objective of hazard identification is to identify and evaluate the hazards and

the unintended events, which could cause an accident. The first task usually is

to identify the hazards that are inherent to the process and/or plant and then

75
focus on the evaluation of the events, which could be associated with hazards.

In hazard identification and quantification of probability of occurrence it is

assumed that the plant will perform as designed in the absence of unintended

events (component and material failures, human errors, external event, process

unknown), which may affect the plant/process behaviour.

5.1 Hazard Identification

Formal hazard identification studies generate a list of failure cases. The list can

usually be derived reliably by considering: (a) fonn in which chemicals are stored

or processed, (b) nature of hazard it poses, and (c) quantity of the material

contained. The hazard identification methods may be categorized as comparative

methods and fundamental methods. These techniques are also described

inA-2.

5.1.1 Comparative Method')

These techniques are based on hazard identification by comparing with

standards. The various methods are checklist, safety audit, hazard indices and

preliminary hazard analysis.

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5.1.1.1 Checklist

Purpose Applicability Data required Results For quick identification of hazards. In

all phases - design construction, commissioning, operation and shutdown.

Checklist is prepared from prior experience/standard procedure/ manual!

knowledge of system or plant. Essentially qualitative in nature and leads to "yes-

or-no" decision with respect to compliance with the standard procedure set forth.

5.1.1.2 Safety audit

Purpose Applicability Data required Results For ensuring that procedures match

design intent. In all phases of the plant and periodicity of review depending on

the level of hazard. Applicable codes and guides, plant flow sheet, P & I

diagrams, start-up/ shutdown procedure, emergency control, injury report,

testing and inspection report, material properties. Qualitative in nature - the

inspection teams report deviation from design and planned procedures and

recommends additional safety features.

5.1.1.3 Hazard indices

Purpose Applicability Data required For identifying relative hazards. In design

and operation phase used as an early screening technique for fire/ explosion

potential.

77
Plot plan of a plant, process flow condition, Fire and Explosion Index Form, Risk

Analysis Form, Worksheets. Results Relative quantitative ranking of plant process

units based on degree of risk.

5.1.1.4 Preliminary hazard analysis

Purpose For early identification of hazards. Applicability In preliminary design

phase to provide guidance for final design. Data required Results Plant design

criteria, hazardous materials involved and major plant equipment. List of hazards

(related to available design details) with recommendation to designers to aid

hazard reduction.

5.1.2 Fundamental Methods

These techniques are a structured way of stimulating a group of people to apply

foresight along with their knowledge to the task of identifying the hazards mainly

by raising a series of questions. These methods have the advantage that they

can be used whether or not the Codes of practice are available for a particular

process. Three main techniques are available in this family of methods that is

What-if Analysis, Failure Modes and Etfects Analysis, (FMEA) and Hazard and

Operability Study (HAZOP).

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5.1.2.1 What-if analysis

Purpose Applicability Data required Results Identifying possible event sequences

related to hazards. During plant changes, development stage or at pre start-up

stage. Detailed documentation ofthe plant, the process and the operating

procedure. Tabular listing of accident scenarios, their consequences and possible

risk reduction methods.

5.1.2.2 Failure modes and effects analysis

Purpose Applicability Data required Results Identifying equipment failure modes

and their effects In design, construction and operation phases, useful for plant

modification. Knowledge of equipment/system/plant functions. Qualitative in

nature and includes worstcase estimate of consequence resulting from failure of

equipment.

5.1.2.3 Hazard and operability study

Purpose Identifying hazard and operability problem. Application Optimal when

applied to a new/ modified plant where the design is nearly firm. Data required

Detailed process description, detailed P&I drawing and operating procedure for

batch process. Identification of hazards and operating problems, recommends

change in design, procedure and further study.

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5.2 Hazard Analysis

The principle techniques are fault tree analysis (FTA) and event tree analysis

(ETA). These techniques are also described in A-3.

5.2.1 Fault Tree Analysis

Purpose Identifying how basic events lead to an accident event. Applicability

Data required Results In design and operation phases of the plant to uncover

the failure modes. Knowledge of plant/system function, plant/system failure

modes and effects on plant/system. Listing of set of equipment or operator

failures that can result in specific accidents.

5.2.2 Event Tree Analysis

Purpose Identifying the event sequences from initiating event to accident

scenarios. Applicability In design/operating plants to assess adequacy of existing

safety features. Data required Results Knowledge of initiating events and safety

system/emergency procedure. Provides the event sequence that result in an

accident following the occurrence of an initiating event.

7 RISK CALCULATION

7.1 Risk can be defined as a measure of economic loss, human injury or

environmental damage both in terms of likelihood and magnitude of loss, injury

80
or damage. In this document only the property damage, that is, economic loss

and human loss have been considered. Risk is expressed as the product of

frequency of an event and the magnitude of the consequences that result each

time the event occurs. The mathematical expression for risk is:

R =FC

where

R = risk (1oss or injury per year);

F = frequency (event per year); and

C = consequence (loss or injury per event).

7.2 In many cases the hazard cannot be completely eliminated though the

probability of occurrence can be reduced with addition of safety measures and

at a fmancial cost.

7.3 The basic approach for estimating frequency has been discussed in 5.2.

7.4 The consequence in terms of deaths/year or in terms of monetary loss per

year can be estimated by the methods of consequence analysis described in 6.

7.5 Risk Criteria

Risk criteria are the acceptable levels of risk that can be tolerated under a

particular situation. In many countries the acceptable risk criteria has been

81
defined for industrial installations and are shown in Annex E. These criteria are

yet to be defined in the Indian context, but values employed in other countries

can be used for comparison.

3.3 STATUES:

3.3.1. The Factories Act 1948

Section 7. Notice by occupier:

(1) The occupier shall, at least fifteen days before he begins to occupy or, use any

Premises as a factory, send to the Chief Inspector a written notice containing-

(a) The name and situation of the factory;

(b) The name and address of the occupier;

(c) The name and address of the owner of the premises or building (including the
Precincts thereof) referred to in section 93;

(c) The address io which communication relating to the factory may be sent;

(d) The nature of the manufacturing process

(i) Carried on in the factory during the last twelve months in the case of factories

In existence on the date of the commencement of this Act, and

(ii) To be carried on in the factory during the next twelve months in the case of
all factories;

82
(e) The total rated horse power installed or to be installed in the factory, which
Shall not include the rated horse power of any separate standby plant;

(f) The name of the manager of the factory for the purposes of this Act;

(g) The number of workers likely to be employed in the factory:

(h) The average number of workers per day employed during the last twelve

Months in the case of a factory in existence on the date of the commencement

of this Act;

(i) Such other particulars as may be prescribed.

(2) In respect of all establishments, which come within the scope of the Act for
the first time the occupier shall send a written notice to the Chief Inspector
Containing the particulars specified in sub-section (1) within thirty days from the
date of the commencement of this Act.

(3) Before a factory engaged in a manufacturing process which is ordinarily carried

out for less than one hundred and eighty working days in the year, resumes
working, the occupier shall send a written notice to the Chief Inspector containing
the particulars specified in sub-section (1) that least thirty days before the date of
the commencement of work.

(4) Whenever a new manager is appointed, the cccupies shall send to the
Inspector a written notice and to the Chief Inspector a copy thereof within seven
days from the date on which such person takes over charge.

(5) During a period for which no person has been designated as manager of a
factory or during which the person designated does not manage the factory, any
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person found acting as manager, or if no such person is found, the occupier
himself, shall be deemed to be the manager of the factory for the purposes of this
Act.

Section 7A. General duties of the occupier

(1) Every occupier shall ensure, so far as is reasonably practicable, the health,
safety and welfare of all workers while they are at work in the factory.

(2) Without prejudice to the generality of the provisions of sub-section (1), the
matters to which such duty extends, shall include-

(a) The provision and maintenance of plant and systems of work in the factory
that are safe and without risks to health;

(b) The arrangement in the factory for ensuring safety and absence of risks to
health in connection with the use, handling, storage and transport of articles and
substances;

(c) The provision of such information, instruction, training and supervisions as are
necessary to ensure the health and safety of all workers at work;

(d) the maintenance of all places of work in the factory in a condition that is safe
and without risks to health and the provision and maintenance of such means of
access to, and egress from, such place as are safe and without such risks;

(e) the provision, maintenance or monitoring of such working environment in the

factory for the workers that is safe, without risks to health and adequate as regards
facilities and arrangements for their welfare at work.

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(3) Except in such cases as may be prescribed, every occupier shall prepare, and,
as often as may be appropriate, revise, a written statement of his general policy
with respect to the health and safety of the workers at work and the organization
and arrangements for the time being in force for carrying out that policy, and to
bring the statement and any revision thereof to the notice of all the workers in
such manner as may be prescribed.

Section 11. cleanliness:

(1) Every factory shall be kept clean and free from effluvia arising from any
drain, privy or other nuisance, and in particular-

(a) accumulation of dirt and refuse shall be removed daily by sweeping or

by any other effective method from the floors and benches of workrooms
and from staircases and passages, and disposed of in a suitable manner;
(b) the floor of every workroom shall be cleaned at least once in every
week by washing, using disinfectant, where necessary, or by some
other effective method;
(c) where a floor is liable to become wet in the course of any manufacturing
process to such extent as is capable of being drained, effective means of
drainage shall be provided and maintained;
(d) all inside walls and partitions, all ceilings or tops of rooms and all walls, sides
and tops of passages and staircases shall
(i) where they are 1*[painted otherwise than with washable water-paint] or
varnished, be repainted or varnished at least once in every period of five years;

2*[(ia) where they are painted with washable water paint, be repainted with at
least one coat of such paint at least once in every period of three years and
washed at least once in every period of six months;]
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(ii) where they are painted or varnished or where they have smooth impervious
surfaces, be cleaned at least once in every period of fourteen months by such
method as may be prescribed;
(iii) in any other case, be kept whitewashed or color washed, and the
whitewashing or colour washing shall be carried out at least once in every
period of fourteen months;

2*[(dd) all doors and window frames and other wooden or metallic framework
and shutters shall be kept painted or varnished and the painting or varnishing
shall be carried out at least once in every period of five years;]
(2) If, in view of the nature of the operations carried on 1*[in a factory or class
or description of factories or any part of a factory or class or description of
factories], it is not possible for the occupier to comply with all or any of the
provisions of sub- section (1), the State Government may be order exempt such
factory or class or description of factories 2* [or part] from any of the provisions
of that sub-section and specify alternative methods for keeping the factory in a
clean state.

Section 12. Disposal of wastes and effluents.-

(1) Effective arrangements shall be made in every factory for the treatment of
wastes and effluents due to the manufacturing process carried on therein, so as
to render them innocuous, and for their disposal.

(2) The State Government may make rules prescribing the arrangements to be
made under sub-section (1) or requiring that the arrangements made in
accordance with sub-section (1) shall be approved by such authority as may be
prescribed.

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Section 13. Ventilation and temperature

(1) Effect and suitable provisions shall be made in every factory for securing and
maintaining in every workroom-

(a) Adequate ventilation by the circulation of fresh air, and

(b) Such a temperature as will secure to workers therein reasonable conditions of

comfort and prevent injury to health; and in particular,

(i) Walls and roofs shall be of such material and so designed that such
temperature shall not be exceeded but kept as low as practicable;

(ii) Where the nature of the work carried on in the factories involves, or is likely to
involve, the production of excessively high temperature, such adequate measures
as are practicable shall be taken to protect the workers there from, by separating
the process, which produces such temperature from the workroom, by insulating
the hot parts or by other effective means.

(2) The State Government may prescribe a standard of adequate ventilation and
reasonable temperature for any factory or class or description of factories or parts
thereof and direct that proper measuring instruments, at such places and in such
position as may be specified, shall be provided and such records, as maybe
prescribed, shall be maintained.

(3) If it appears to the Chief Inspector that excessively high temperature in any
factory can be reduced by the adoption of suitable measures, he may, without
prejudice to the rules made under sub-section (2), serve on the occupier, an order
in writing specifying the measures which, in his opinion should be adopted, and
requiring them to be carried out before a specified date.

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Section 14. Dust and fume

• In every factory in which, by reason of the manufacturing process carried on,

there is given off any dust or fume or other impurity of such a nature and to
such an extent as is likely to be injurious or offensive to the workers employed
therein, or any dust in substantial quantities, effective measures shall be taken
to prevent its inhalation and accumulation in any workroom, and if any exhaust
appliance is necessary for this purpose, it shall be applied as near as possible
to the point of
1. origin of the dust, fume or other impurity, and such point shall be enclosed so
far as possible.
2. In any factory no stationary internal combustion engine shall be operated
unless the exhaust is conducted into the open air, and no other internal
combustion engine shall be operated in any room unless effective measures
have been taken to prevent such accumulation of fumes there from as are likely
to be injurious to workers employed in the room.

Section 15. Artificial humidification

(1) In respect of all factories in which the humidity of the air is artificially increased,
the State Government may make rules

(a) prescribing standards of humidification;

(b) Regulating the methods used for artificially increasing the humidity of the air;

(c) Directing prescribed tests for determining the humidity of the air to be correctly
carried out and recorded;

(d) Prescribing methods to be adopted for securing adequate ventilation and

cooling of the air in the workrooms.
88
(2) In any factory in which the humidity of the air is artificially increased, the water
used for the purpose shall be taken from a public supply, or other source of
drinking water, or shall he effectively have purified before it is so used.

(3) If it appears to an Inspector that the water used in a factory for increasing
humidity which is required to be effectively purified under sub-section

(2) Is not effectively purified he may serve on the manager of the factory an order
in Writing, specifying the measures which in his opinion should be adopted, and
requiring them to be carried out before specified date.

Section 16. overcrowding:

(1) No room in any factory shall be overcrowded to an extent injurious to the

health of the workers employed therein.

(2) Without prejudice to the generality of sub-section (1), there shall be in every
workroom of factory in existence on the date of the commencement of this Act at
least 1*[9.9 cubic metres] and of a factory built after the commencement of this
Act at least 1*[14.2 cubic meters] of space for every worker employed therein,
and for the purposes

of this sub-section no account shall be taken of any space which is more than
1*[4.2 meters] above the level of the floor of the room.

(3) If the Chief Inspector by order in writing so requires, there shall be posted in
each workroom of a factory a notice specifying the maximum number of workers
who may, in compliance with the provisions of this section, be employed in the
room.

89
(4) The chief Inspector may by order in writing exempt, subject to such conditions,
if any, as he may think fit to impose, any workroom from the provisions of this
section, if he is satisfied that compliance therewith in respect of the rooms is
unnecessary in the interest of the health of the workers employed therein.

Section 17. Lighting

(1) In every part of a factory where workers are working or passing, there shall
be provided and maintained sufficient and suitable lighting, natural or artificial, or
Both.

(2) In every factory all glazed windows and skylights used for the lighting of the
workroom shall be kept clean on both the inner and outer surfaces and, so far as
compliance with the provisions of any rules made under sub-section (3) of section
13 will allow, free from obstruction.

(3) In every factory effective provision shall, so far as is practicable, be made for
the Prevention of-

(a) Glare, either directly from a source of light or by reflection from a smooth or
polished surface;

(b) The formation of shadows to such an extent as to cause eye-strain or the risk
of accident to any worker.

(4) The State Government may prescribe standards of sufficient and suitable
lighting For factories or for any class or description of factories or for any
manufacturing process.

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Section 18. Drinking water

(1) In every factory effective arrangements shall be made to provide and maintain
at Suitable points conveniently situated for all workers employed therein a
sufficient supply of wholesome drinking water.

(2) All such points shall be legibly marked "drinking water" in a language
understood by a majority of the workers employed in the factory and no such
points shall be situated within 1[six meters of any washing place, urinal, latrine,
spittoon, open drain carrying spillage or effluent or any other source of
contamination unless a shorter distance is approved in writing by the Chief
Inspector.

(3) In every factory wherein more than two hundred and fifty workers are
ordinarily employed, provisions shall be made for cooling drinking water during hot
weather by effective means and for distribution thereof.

(4) In respect of all factories or any class or description of factories the State
Government may make rules for securing compliance with the provisions of
subsections

(1), (2) and (3) and for the examination by prescribed authorities of the Supply
and distribution of drinking water in factories.

Section 19. latrines and urinals:

(1) In every factory—

(a) sufficient latrine and urinal accommodation oaf prescribed types shall be
providing conveniently situated and accessible to workers at all times while they
at the factory;

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(b) separate enclosed accommodation shall be provided for male and female
workers;

(c) such accommodation shall be adequately lighted and ventilated, and no latrine
or urinal shall, unless specially exempted in writing by the Chief Inspector,
communicate with any workroom except through an intervening open space or
ventilated passage;

(d) all such accommodation shall be maintained in a clean and sanitary condition
at all times;

(e) sweepers shall be employed whose primary duty it would be to keep clean
latrines, urinals and washing places.

(2) In every factory wherein more than two hundred and fifty workers are
ordinarily employed-

(a) all latrine and urinal accommodation shall be of prescribed sanitary types;

(b) the floors and internal walls, up to a height of 2* [ninety continents] of the
latrines and urinals and the sanitary blocks shall be laid in glazed tiles or otherwise
finished to provide a smooth polished impervious surface;

Section 21. Fencing of machinery:

(1) In every factory the following, namely,--

(i) every moving part of a prime mover and every flywheel connected to a prime
mover whether the prime mover or flywheel is in the engine house or not;

(ii) the headrace and tailrace of every water-wheel and water turbine;

92
(iii)any part of a stock-bar which projects beyond the head stock of a lathe; and

(iv) unless they are in such position or of such construction as to be safe to

every person employed in the factory as they would be if they were securely
fenced, the following, namely,--

(a) every part of an electric generator, a motor or rotary convertor;

(b) every part of transmission machinery; and

(c) every dangerous part of any other machinery,

shall be securely fenced by safeguards of substantial construction which 3[shall be

constantly maintained and kept in position] while the parts of machinery they are
fencing are in motion or in use:

1[Provided that for the purpose of determining whether any part of machinery is
in such position or is of such construction as to be safe as aforesaid, account shall
not be taken of any occasion when-

(i) it is necessary to make an examination of any part of the

machinery aforesaid while it is in motion or, as a result of such
examination, to carry out lubrication or other adjusting operation
while the machinery is in motion, being an examination or
operation which it is necessary to be carried out while that part
of the machinery is in motion, or
• in the case of any part of a transmission machinery used in such process as
may be prescribed (being a process of a continuous nature the carrying on
of which shall be, or is likely to be, substantially interfered with by the
stoppage of that part of the machinery), it is necessary to make an
examination of such part of the machinery while it is in motion or, as a
result of such examination, to carry out any mounting or shipping of belts
93
 or lubrication or other adjusting operation while the machinery is in motion,
and such examination or operation is made or carried out in accordance
with the provisions of sub-section (1) of section 22.]

(2) The 2[State] Government may by rules prescribe such further precautions as
it may consider necessary in respect of any particular machinery or part thereof,
or exempt, subject to such condition as may be prescribed, for securing the safety
of the workers any particular machinery or part thereof from the provisions of this
section.

Section 22. Work on or near machinery in motion.-

(1) Where in any factory it becomes necessary to examine any part of machinery
referred to in section 21, while the machinery is in motion, or as a result of such
examination, to carry out-

(a) in a case referred to in clause (i) of the proviso to sub-section (1) of section
21, lubrication or other adjusting operation; or

(b) in a case referred to in clause (ii) of the proviso aforesaid, any mounting or
shipping of belts or lubrication or other adjusting operation,

while the machinery is in motion, such examination or operation shall be made or

carried out only by a specially trained adult male worker wearing tight fitting
clothing (which shall be supplied by the occupier) whose name has been recorded
in the register prescribed in this behalf and who has been furnished with a
certificate of his appointment, and while he is so engaged:-

(a) such worker shall not handle a belt at a moving pulley unless-

(i) the belt is not more than fifteen centimetres in width;

94
(ii) the pulley is normally for the purpose of drive and not merely a fly-wheel or
balance wheel (in which case a belt is not permissible);

(iii) the belt joint is either laced or flush with the belt;

(iv) the belt, including the joint and the pulley rim, are in good repair,

(v) there is reasonable clearance between the pulley and any fixed plant or
structure;

(vi) secure foothold and, where necessary, secure handhold, are provided for the
operator; and

(vii) any ladder in use for carrying out any examination or operation aforesaid is
securely fixed or lashed or is firmly held by a second person

without prejudice to any other provision of this Act relating to the fencing of
machinery, every set screw, bolt and key on any revolving shaft, spindle, wheel or
pinion, and all spur, worm and other toothed or friction gearing in motion with
which such worker otherwise be liable to come into contact, shall be securely
fenced to prevent such contact.

1[(2) No woman or young person shall be allowed to clean, lubricate or adjust any
part of a prime mover or of any transmission machinery while the prime mover or
transmission machinery is in motion, or to clean, lubricate or adjust any part of
any machine if the cleaning, lubrication or adjustment thereof would expose the
woman or young person to risk of injury from any moving part either of that
machine or of any adjacent machinery.]

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 (1) The 2[State] Government may, by notification in the Official
Gazette, prohibit, in any specified factory or class or description
of factories, the cleaning, lubricating or adjusting by any person
of specified parts of machinery when those parts are in motion
Section 23. Employment of young persons on dangerous machines.-

(1) No young person 3[shall be required or allowed to work] at any machine to

which this section applies, unless he has been fully instructed as to the dangers
arising in connection with the machine and the precautions to be observed and-

(a) has received sufficient training in work at the machine, or

(b) is under adequate supervision by a person who has a thorough knowledge and
experience of the machine.

(2) Sub-section (1) shall apply to such machines as may be prescribed by the
4[State] Government, being machines which in its opinion are of such a dangerous
character that young persons ought not to work at them unless the foregoing
requirements are complied with.

(2) In every factory suitable devices for cutting off power in emergencies from
running machinery shall be provided and maintained in every workroom: Provided
that in respect of factories in operation before the commencement of this Act, the
provisions of this sub-section shall apply only to workrooms in which electricity is
used as power.

1[(3) When a device, which can inadvertently shift from “off” to “on” position, is
provided in a factory to cut-off power, arrangements shall be provided for locking
the device in safe position to prevent accidental starting of the transmission
machinery or other machines to which the device is fitted.]

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Section 24. Striking gear and devices for cutting off power.-

(1) In every factory-

(a) suitable striking gear or other efficient mechanical appliance shall be provided
and maintained and used to move driving belts to and from fast and loose pulleys
which form part of the transmission machinery, and such gear or appliances shall
be so constructed, placed and maintained as to prevent the belt from creeping
back on to the fast pulley;

(b) driving belts when not in use shall not be allowed to rest or ride upon shafting
in motion.

Section 25. Self-acting machines.-

No traversing part of a self-acting machine in any factory and no material carried

thereon shall, if the space over which it runs is a space over which any person is
liable to pass, whether in the course of his employment or otherwise, be allowed
to run on its outward or inward traverse within a distance of 2[forty-five
centimetres] from any fixed structure which is not part of the machine:

Provided that the Chief Inspector may permit the continued use of a machine
installed before the commencement of this Act, which does not comply with the
requirements of this section on such conditions for ensuring safety as he may think
fit to impose.

Section 26. Casing of new machinery.-

(1) In all machinery driven by power and installed in any factory after the
commencement of this Act,-

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(a) every set screw, bolt or key on any revolving shaft, spindle, wheel or pinion
shall be so sunk, encased or otherwise effectively guarded as to prevent danger;

(b) all spur, worm and other toothed or friction gearing which does not require
frequent adjustment while in motion shall be completely encased, unless it is so
situated as to be as safe as it would be if it were completely encased.

(2) Whoever sells or lets on hire or, as agent of a seller or hirer, causes or procures
to be sold or let or hire, for use in a factory any machinery driven by power which
does not comply with the provisions of 3[sub-section (1) or any rules made under
sub-section (3)], shall be punishable with imprisonment for a term which may
extend to three months or with fine which may extend to five hundred rupees or
with both.

4[(3) The State Government may make rules specifying further safeguards to be
provided in respect of any other dangerous part of any particular machine or class
or description of machines

Section 28. Hoists and lifts.-

(1) In every factory- (a) every hoist and lift shall be-

(i) of good mechanical construction, sound material and adequate strength;

(ii) properly maintained, and shall be thoroughly examined by a competent person

at least once in every period of six months and a register shall be kept containing
the prescribed particulars of every such examination.

(b) every hoist way and lift way shall be sufficiently protected by an enclosure
fitted with gates, and the hoist or lift and every such enclosure shall be so

98
constructed as to prevent any person or thing from being trapped between any
part of the hoist or lift and any fixed structure or moving part;

(c) the maximum safe working load shall be plainly marked on every hoist or lift,
and no load greater than such load shall be carried thereon;

(d) the cage of every hoist or lift used for carrying persons shall be fitted with a
gate on each side from which access is afforded to a landing;

(e) every gate referred to in clause (b) or clause (d) shall be fitted with inter-
locking or other efficient device to secure that the gate cannot be opened except
when the cage is at the landing and that the cage cannot be moved unless the
gate is closed.

(2) The following additional requirements shall apply to hoists and lifts used for
carrying persons and installed or reconstructed in a factory after the
commencement of this Act, namely:-

(a) where the cage is supported by rope or chain, there shall be at least two ropes
or chains separately connected with the cage and balance weight, and each rope
or chain with its attachments shall be capable of carrying the whole weight of the
cage together with its maximum load;

(b) efficient devices shall be provided and maintained capable of supporting the
cage together with its maximum load in the event of breakage of the ropes, chains
or attachments;

(c) an efficient automatic device shall be provided and maintained to prevent the
cage from over-running.

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(3) The Chief Inspector may permit the continued use of a hoist or lift installed in
a factory before the commencement of this Act which does not fully comply with
the provisions of sub-section (1) upon such conditions for ensuring safety as he
may think fit to impose.

(4) The 1[State] Government may, if in respect of any class or description of hoist
or lift, it is of opinion that it would be unreasonable to enforce any requirement of
sub-sections (1) and (2), by order direct that such requirement shall not apply to
such class or description of hoist or lift.

Explanation.- For the purposes of this section, no lifting machine. or appliance shall
be deemed to be a hoist or lift unless it has a platform or cage, the direction or
movement of which is restricted by a guide or guides

Section 29. Lifting machines, chains, ropes and lifting tackles.-

(1) In any factory the following provisions shall be complied with in respect of
every lifting machine other than a hoist and lift and every chain, rope and lifting
tackle for the purpose of raising or lowering persons, goods or materials:-

(a) all parts, including the working gear, whether fixed or moveable, of every lifting
machine and every chain, rope or lifting tackle shall be-

(i) of good construction, sound material and adequate strength and free from
defects;

(ii) properly maintained; and

(iii) thoroughly examined by a competent person at least once in every period of

twelve months, or at such intervals as the Chief Inspector may specify in writing;

100
and a register shall be kept containing the prescribed particulars of every such
examination;

(b) no lifting machine and no claim, rope or lifting tackle shall, except for the
purpose of test, be loaded beyond the safe working load which shall be plainly
marked thereon together with an identification mark and duly entered in the
prescribed register; and where this is not practicable, a table showing the safe
working loads of every kind and size of lifting machine or, chain, rope or lifting
tackle in use shall be displayed in prominent positions on the premises;

(c) while any person is employed or working on or near the wheel track of a
travelling crane in any place where he would be liable to be struck by the crane,
effective measures shall be taken to ensure that the crane does not approach
within 2[six metres] of that place.

(2) The State Government may make rules in respect of any lifting machine or any
chain, rope of lifting tackle used in factories-

(a) prescribing further requirements to be complied with in addition to those set

out in this section;

(b) providing for exemption from compliance with all or any of the requirements
of this section, where in its opinion, such compliance is unnecessary or
impracticable.

(3) For the purposes of this section a lifting machine or a chain, rope or lifting
tackle shall be deemed to have been thoroughly examined if a visual examination
supplemented, if necessary, by other means and by the dismantling of parts of the
gear, has been carried out as carefully as the conditions permit in order to arrive
at a reliable conclusion as to the safety of the parts examined.

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Explanation.-In this section-

(a) “lifting machine” means (a) “lifting machine” means a crane, crab, winch,
teagle, pulley block, gin wheel, transporter or runway.

3[(b) “lifting tackle” means any chain, sling, rope sling, hook, shackle, swivel,
coupling, socket, clamp, tray or similar appliance, whether fixed or movable, used
in connection with the raising or lowering of persons, or loads by use of lifting
machines.

32. Floors, stairs and means of access.-

In every factory-

(a) all floors, steps, stairs, passages and gangways shall be of sound construction
and properly maintained 5[and shall be kept free from obstructions and substances
likely to cause persons to slip],and where it is necessary to ensure safety, steps,
stairs, passages and gangways shall be provided with substantial hand-rails;

(b) there shall, so far as is reasonably practicable, be provided and maintained

safe means of access to every place at which any person is at any time required
to work.

(c) When any person has to work at a height from where he is likely to fall,
provision shall be made, so far as is reasonably practicable, by fencing or
otherwise, to ensure the safety of the person so working.]

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Section 33. Pits, sumps, openings in floors, etc.-

(1) In every factory fixed vessel, sump, tank, pit or opening in the ground or in a
floor which, by reasons of its depth, situation, construction or contents, is or may
be a source of danger, shall be either securely covered or securely fenced.

(2) The 1[State] Government may, by order in writing, exempt, subject to such

conditions as may be prescribed, any factory or class or description of factories in

respect of any vessel, sump, tank, pit or opening from compliance with the
provisions of this section.

Section 34. Excessive weights.-

(1) No person shall be employed in any factory to lift, carry or move any load so
heavy as to be likely to cause him injury.

(2) The 2[State] Government may make rules prescribing the maximum weights
which may be lifted, carried or moved by adult men, adult women, adolescents
and children employed in factories or in any class or description of factories or in
carrying on any specified process.

Section 35. Protection of eyes.-

In respect of any such manufacturing process carried on in any factory as may be

prescribed, being a process which involves-

(a) risk of injury to the eyes from particles or fragments thrown off in the course
of the process, or

(b) risk to the eyes by reason of exposure to excessive light, the 3[State]
Government may by rules require that effective screens or suitable goggles shall

103
be provided for the protection of persons employed on, or in the immediate vicinity
of the process

Section 36. Precautions against dangerous fumes, gases, etc.-

(1) No person shall be required or allowed to enter any chamber, tank, vat, pit,
pipe, flue or other confined space in any factory in which any gas, fume, vapour
or dust is likely to be present to such an extent as to involve risk to persons being

Overcome thereby, unless it is provided with a manhole of adequate size or other

effective means of egress.

(2) No person shall be required or allowed to enter any confined space as is

referred to in sub-section (1), until all practicable measures have been taken to
remove any gas, fume, vapour or dust, which may be present so as to bring its
level within the permissible limits and to prevent any ingress of such gas, fume,
vapour or dust and unless-

(a) a certificate in writing has been given by a competent person, based on a test
carried out by himself that the space is reasonably free from dangerous gas, fume,
vapour or dust: or

(b) Such person is wearing suitable breathing apparatus and a belt securely
attached to a rope the free end of which is held by a person outside the confined
space.

Section 36A. Precautions regarding the use of portable electric

Light - In any factory- (a) No portable electric light or any other electric appliance
of voltage exceeding twenty-four volts shall be permitted for use inside any

104
chamber, tank, vat, pit, pipe, flue or other confined space unless adequate safety
devices are provided.

(b) If any inflammable gas, fume or dust is likely to be present in such chambers
tank, vat, pipe, flue or other confined space, no lamp or light other than that of
flame-proof construction shall be permitted to be used therein.

Section 38. Precautions in case of fire.-

(1) In every factory, all practicable measures shall be taken to prevent outbreak
of fire and its spread, both internally and externally, and to provide and maintain-

(a) safe means of escape for all persons in the event of a fire, and

(b) the necessary equipment and facilities for extinguishing fire.

(2) Effective measures shall be taken to ensure that in every factory all the workers
are familiar with the means of escape in case of fire and have been adequately
trained in the routine to be followed in such cases.

(3) The State Government may make rules, in respect of any factory or class or
description of factories, requiring the measures to be adopted to give effect to the
provisions of sub- sections (1) and (2).

(4) Notwithstanding anything contained in clause (a) of sub- section (1) or sub-
section (2), if the Chief Inspector, having regard to the nature of the work carried
on in any factory, the construction of such factory, special risk to life or safety, or
any other circumstances, is of the opinion that the measures provided in the
factory, whether as

105
prescribed or not, for the purposes of clause (a) of sub-section (1) or sub-section
(2), are inadequate, he may, by order in writing, require that such additional
measures as he may consider reasonable and necessary, be provided in the factory
before such date as is specified in the order.]

Section 39. Power to require specifications of defective parts or test of

stability.-

If it appears to the Inspector that any building or part of a building or any part of
the ways, machinery or plant in a factory is in such a condition that it may be
dangerous to human life or safety, he may serve on 3[the occupier or manager or
both] of the factory an order in writing requiring him before a specified date-

(a) to furnish such drawings, specifications and other particulars as may be

necessary to determine whether such building, ways, machinery or plant can be
used with safety, or (b) to carry out such test in such manner as may be specified
in the order, and to inform the Inspector of the results thereof.

Section 40B. Safety Officers

(1) In every factory-

(i) Wherein one thousand or more workers are ordinarily employed, or

(ii) wherein, in the opinion of the State Government, any manufacturing processor
operation is carried on, which process, or operation involves any risk of bodily
injury, poisoning or disease or any other hazard to health, to the person employed
in the factory, the occupier shall, if so required by the State Government by
notification in Official Gazette, employ such number of Safety Officers as may be
specified in that notification.

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(2) The duties, qualifications and conditions of service of Safety Officers shall
Section 41C. Specific responsibility of the occupier in relation to hazardous
processes.-

Every occupier of a factory involving any hazardous process shall-

(a) maintain accurate and up-to-date health records or, as the case may be,
medical records, of the workers in the factory who are exposed to any chemical,
toxic or any other harmful substances which are manufactured, stored, handled or
transported and such records shall be accessible to the workers subject to such
conditions as may be prescribed;

(b) Appoint persons who possess qualifications and experience in handling

hazardous substances and are competent to supervise such handling within the
factory and to provide at the working place all the necessary facilities for protecting
the workers in the manner prescribed:

Provided that where any question arises as to the qualifications and experience of
a person so appointed, the decision of the Chief Inspector shall be final;

(c) Provide for medical examination of every worker

(i) Before such worker is assigned to a job involving the handling of, or working
with, a hazardous substance, and

(ii) While continuing in such job, and after he has ceased to work in such job, at
intervals not exceeding twelve months in such manner as may be prescribed

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Section 42. Washing facilities.-

(1) In every factory-

(a) adequate and suitable facilities for washing shall be provided and maintained
for the use of the workers therein;

(b) separate and adequately screened facilities shall be provided for the use of
male and female workers;

(c) such facilities shall be conveniently accessible and shall be kept clean.

(2) The 1[State] Government may, in respect of any factory or class or description
of factories or of any manufacturing process, prescribe standards of adequate and
suitable facilities for washing.

Section 45. First aid appliances.-

(1) There shall in every factory be provided and maintained so as to be readily

accessible during all working hours first-aid boxes or cupboards equipped with the
prescribed contents, and the number of such boxes or cupboard to be provided
and maintained shall not be less than one for every one hundred and fifty workers
ordinarily employed 3[at any one time] in the factory.

(2) Nothing except the prescribed contents shall be kept in a first-aid box or
cupboard.

(3) Each first-aid box or cupboard shall be kept in the charge of a separate
responsible person 2[who holds a certificate in first-aid treatment recognised by
State Government] and who shall always be readily available during the working
hours of the factory.]

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(4) In every factory wherein more than five hundred workers are 4[ordinarily
employed] there shall be provided and maintained an ambulance room of the
prescribed size,

containing the prescribed equipment and in the charge of such medical and nursing
staff as may be prescribed 5[and those facilities shall always be made readily
available during the working hours of the factory.

Section 47. Shelters, rest rooms and lunch rooms.-

(1) In every factory, wherein more than one hundred and fifty workers are
ordinarily employed, adequate and suitable shelters or rest rooms and a suitable
lunch room, with provision for drinking water, where workers can eat meals
brought by them, shall be provided and maintained for the use of the workers:
Provided that any canteen maintained in accordance with the provisions of section
46 shall be regarded as part of the requirements of this sub-section: Provided
further that where a lunch room exists no worker shall eat any food in the
workroom.

(2) The shelters or rest rooms or lunch rooms to be provided under sub-section
(1) shall be sufficiently lighted and ventilated and shall be maintained in a cool and
clean condition.

(3) The 1[State] Government may-

(a) prescribe the standards in respect of construction, accommodation, furniture

and other equipment of shelters, rest rooms and lunch rooms to be provided,
under this section;

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(b) by notification in the Official Gazette, exempt any factory or class or description
of factories from the requirements of this section.

Section 51. Weekly hours.-

No adult worker shall be required or allowed to work in a factory for more than
forty-eight hours in any week.

Section 52. Weekly holidays.-

(1) No adult worker shall be required or allowed to work in a factory on the first
day of the week (hereinafter referred to as the said day), unless-

(a) he has or will have a holiday for a whole day on one of the three days
immediately before or after the said day, and

(b) the manager of the factory has, before the said day or the substituted day
under clause (a), whichever is earlier,-

(i) delivered a notice at the office of the Inspector of his intention to require
the worker to work on the said day and of the day which is to be substituted,
and

(ii) displayed a notice to that effect in the factory: Provided that no

substitution shall be made which will result in any worker working for more than
ten days consecutively without a holiday for a whole day.

(2) Notices given under sub-section (1) may be cancelled by a notice delivered at
the office of the Inspector and a notice displayed in the factory not later than the
day before the said day or the holiday to be cancelled, whichever is earlier.

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(3) Where, in accordance with the provisions of sub-section (1), any worker works
on the said day and has had a holiday on one of the three days immediately before
it, that said day shall, for the purpose of calculating his weekly hours of work, be
included in the preceding week

Section 54. Daily hours.-

Subject to the provisions of section 51, no adult worker shall be required or allowed
to work in a factory for more than nine hours in any day:

1[Provided that, subject to the previous approval of the Chief Inspector, the daily
maximum hours specified in this section may be exceeded in order to facilitate the
change of shifts.]

Section 55. Intervals for rest.-

2[(1) 3[The periods of work] of adult workers in a factory each day shall be so
fixed that no period shall exceed five hours and that no worker shall work for more
than five hours before he has had an interval for rest of at half an hour.

The State Government or, subject to the control of the State Government, the
Chief Inspector, may, by written order and for the reasons specified therein,
exempt any factory from the provisions of sub- section (1) so however that the
total number of hours worked by a worker without an interval does not exceed six.

Section 57. Night shifts.-

Where a worker in a factory works on a shift which extends beyond midnight-

a) for the purposes of sections 52 and 53, a holiday for a whole day shall mean in
his case a period of twenty-four consecutive hours beginning when his shift ends;

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(b) the following day for him shall be deemed to be the period of twenty-four
hours beginning when such shift ends, and the hours he has worked after midnight
shall be counted in the previous day.

Section 58. Prohibition of overlapping shifts.-

(1) Work shall not be carried on in any factory by means of a system of shifts so
arranged that emore than one relay of workers is engaged in work of the same
kind at the same time.

3[(2) The State Government or, subject to the control of the State Government,
the Chief Inspector, may, by written order and for the reasons specified therein,
exempt on such conditions as may be deemed expedient, any factory or class or
description of factories or any department or section of a factory or any category
or description of workers therein from the provisions of sub-section (1).]

Section 59. Extra wages for overtime.- (1) Where a worker works in a factory
for more than nine hours in any day or for more than forty-eight hours in any
week, he shall, in respect to overtime work, be entitled to wages at the rate of
twice his ordinary rate of wages.

4[(2) For the purposes of sub-section (1), “ordinary rate of wages” means the
basic wages plus such allowances, including the cash equivalent of the advantage
accruing through the concessional sale to workers of foodgrains and other articles,
as the worker is for the time being entitled to, but does not include a bonus and
wages for overtime work

(3) Where any workers in a factory are paid on a piece-rate basis, the time rate
shall be deemed to be equivalent to the daily average of their full-time earnings
for the days on which they actually worked on the same or identical job during the

112
month immediately preceding the calendar month during which the overtime work
was done, and such time rates shall be deemed to be the ordinary rates of wages
of those

Provided that in the case of a worker who has not worked in the immediately
preceding calendar month on the same or identical job, the time rate shall be
deemed to be equivalent to the daily average of the earning of the worker for the
days on which he actually worked in the week in which the overtime work was
done.

Explanation.-For the purposes of this sub-section, in computing the earnings for

the days on which the worker actually worked such allowances, including the cash
equivalent of the advantage accruing through the concessional sale to workers of
foodgrains and other articles, as the worker is for the time being entitled to, shall
be included but any bonus or wages for overtime work payable in relation to the
period with reference to which the earnings are being computed shall be
excluded.]

1[(4) The cash equivalent of the advantage accruing through the concessional sale
to a worker of foodgrains and other articles shall be computed as often as may be
prescribed on the basis of the maximum quantity of foodgrains and other articles
admissible to a standard family.

Explanation

1.-”Standard family” means a family consisting of the worker, his or

her spouse and two children below the age of fourteen years requiring in
all three adult consumption units. Explanation

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 2.-”Adult consumption unit” means the consumption unit of a male
above the age of fourteen years; and the consumption unit of a female
above the age of fourteen years and that of a child below the age of
fourteen years shall be calculated at the rates of 0.8 and 0.6 respectively
of one adult consumption unit.

(5) The State Government may make rules prescribing-

(a) the manner in which the cash equivalent of the advantage accruing through
the concessional sale to a worker of foodgrains and other articles shall be
computed; and

(b) the registers that shall be maintained in a factory for the purpose of securing
compliance with the provisions of this section.

Section 60. Restriction on double employment.-

No adult worker shall be required or allowed to work in any factory on any day on
which he has already been working in any other factory, save in such
circumstances as may be prescribed.

Section 61. Notice of periods of work for adults.-

(1) There shall be displayed and correctly maintained in every factory in

accordance with the provisions of sub-section (2) of section 108, a notice of
periods of work for adults, showing clearly for every day the periods during which
adult workers may be required to work.

(2) The periods shown in the notice required by sub-section (1) shall be fixed
beforehand in accordance with the following provisions of this section, and shall
be such that workers working for those periods would not be working in
contravention of any of the provisions of sections 51, 52, 54 2[55, 56 and 58].

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(3) Where all the adult workers in a factory are required to work during the same
periods, the manager of the factory shall fix those period for such workers
generally.

(4) Where all the adult workers in a factory are not required to work during the
same periods, the manager of the factory shall classify them into groups according
to the nature of their work indicating the number of workers in each group.

(5) For each group which is not required to work on a system of shifts, the manager
of the factory shall fix the period during which the group may be required to work.

(6) Where any group is required to work on a system of shifts and the relays are
not to be subject to predetermined periodical changes of shifts, the manager of
the factory shall fix the periods during which each relay of the group may be
required to work.

(7) Where any group is to work on a system of shifts and the relays are to be
subject to predetermined periodical changes of shifts, the manager of the factory
shall draw up a scheme of shifts where under the periods during which any relay
of the group may be required to work and the relay which will be working at any
time of the day shall be known for any day.

(8) The 1[State] Government may prescribe forms of the notice required by sub-
section (1) and the manner in which it shall be maintained.

(9) In the case of a factory beginning work after the commencement of this Act,
a copy of the notice referred to in sub-section (1) shall be sent in duplicate to the
Inspector before the day on which work is begun in the factory.

(10) Any proposed change in the system of work in any factory which will
necessitate a change in the notice referred to in sub- section (1) shall be notified
115
to the inspector in duplicate before the change is made, and except with the
previous sanction of the Inspector, no such change shall be made until one week
has elapsed since the last change.

Section 62. Register of adult workers.-

(1) The manager of every factory shall maintain a register of adult workers, to be
available to the Inspector at all times during working hours, or when any work is
being carried on in the factory, showing-

(a) the name of each adult worker in the factory;

(b) the nature of his work;

(c) the group, if any, in which he is included;

(d) where his group works on shifts, the relay to which he is allotted; and

(e) such other particulars as may be prescribed: Provided that, if the Inspector is
of opinion that any muster roll or register maintained as a part of the routine of a
factory gives in respect of any or all the workers in the factory the particulars
required under this section, he may, by order in writing direct that such muster
roll or register shall to the corresponding extent be maintained in place of, and be
treated as, the register of adult workers in that factory.

[(1A) No adult worker shall be required or allowed to work in any factory unless
his name and other particulars have been entered in the register of adult workers.]

(2) The 3[State] Government may prescribe the form of the register of adult
workers, the manner in which it shall be maintained and the period for which it
shall be preserved.

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Section 63. Hours of work to correspond with notice under section 61
and register under section 62.-

No adult worker shall be required or allowed to work in any factory otherwise than
in accordance with the notice of periods of work for adults displayed in the factory
and the entries made before hand against his name in the register of adult workers
of the factory.

Section 66. Further restrictions on employment of women.-

(1) The provisions of this Chapter shall, in their application to women in factories,
be supplemented by the following further restrictions, namely:-

(a) no exemption from the provisions of section 54 may be granted in respect of

any woman;

(b) no woman shall be 8[required or allowed to work in any factory] except

between the hours of 6 a.m. and 7 p.m.

Provided that the 1[State] Government may, by notification in the Official Gazette
in respect of 2[any factory or group or class or description of factories], vary the
limits laid down in clause (b), but so that no such variation shall authorise the
employment of any woman between the hours of 10 p.m. and 5 a.m.;

3[(c) there shall be no change of shifts except after a weekly holiday or any other
holiday.]

(2) The 4[State] Government may make rules providing for the exemption from
the restrictions set out in sub-section (1), to such extent and subject to such
conditions as it may prescribe, of women working in fish curing or fish canning
factories, where the employment of women beyond the hours specified in the said

117
restrictions is necessary to prevent damage to, or deterioration in, any raw
material.

(3) The rules made under sub-section (2) shall remain in force for not more than
three years at a time.

Section 67. Prohibition of employment of young children.-

No child who has not completed his fourteenth year shall be required or allowed
to work in any factory. 68. Non-adult workers to carry tokens.-

A child who has completed his fourteenth year or an adolescent shall not be
required or allowed to work in any factory unless-

(a) a certificate of fitness granted with reference to him under section 69 is in the
custody of the manager of the factory, and

(b) such child or adolescent carries while he is at work a token giving a reference
to such certificate. 69. Certificates of fitness.-

(1) A certifying surgeon shall, on the application of any young person or his parent
or guardian accompanied by a document signed by a manager of a factory that
such person will be employed therein if certified to be fit for work in a factory, or
on the application of the manager of the factory in which any young person wishes
to work, examine such person and ascertain his fitness for work in a factory.

(2) The certifying surgeon, after examination, may grant to such young person, in
the prescribed form, or may renew-

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 (a) a certificate of fitness to work in a factory as a child, if he is satisfied
that the young person has completed his fourteenth year, that he has attained the
prescribed physical standards and that he is fit for such work;

(b) a certificate of fitness to work in a factory as an adult, if he is satisfied

that the young person has completed his fifteenth year, and is fit for full day's
work in a factory:

Provided that unless the certifying surgeon has personal knowledge of the place
where the young person proposes to work and of the manufacturing process in
which he will be employed, he shall not grant or renew a certificate under this sub-
section until he has examined such place.

(3) A certificate of fitness granted or renewed under sub-section (2)-

(a) shall be valid only for a period of twelve months from the date thereof;

(b) may be made subject to conditions in regard to the nature of the work
in which the young person may be employed, or requiring re-examination of the
young person before the expiry of the period of twelve months.

(4) A certifying surgeon shall revoke any certificate granted or renewed under sub-
section (2) if in his opinion the holder of it is no longer fit to work in the capacity
stated therein in a factory.

(5) Where a certifying surgeon refuses to grant or renew a certificate or a

certificate of the kind requested or revokes a certificate, he shall, if so requested
by any person who could have applied for the certificate, or the renewal thereof,
state his reasons in writing for so doing.

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(6) Where a certificate under this section, with reference to any young person is
granted or renewed subject to such conditions as are referred to in clause (b) of
sub-section (3), the young person shall not be required or allowed to work in any
factory except in accordance with those conditions.

(7) Any fee payable for a certificate under this section shall be paid by the occupier
and shall not be recoverable from the young person, his parents or guardian. 70.
Effect of certificate of fitness granted to adolescent.-

(1) An adolescent who has been granted a certificate of fitness to work in

a factory as an adult under clause (b) of sub-section (2) of section 69 and who
while at work in a factory carries a token giving reference to the certificate, shall
be deemed to be an adult for all the purposes of Chapters VI and VII;

1[***]

[(1A) No female adolescent or male adolescent who has attained the age of
seventeen years but who has been granted a certificate of fitness to work in a
factory as an adult,

shall be required or allowed to work in any factory except between 6 a.m. and 7
p.m.: Provided that the State Government may, by notification in the Official
Gazette, in respect of any factory or group or class or description of factories,-

(i) vary the limits laid down in this sub-section so, however, that
no such section shall authorise the employment of any female
adolescent between 10 p.m. and 5 a.m.;
(ii) (ii) grant exemption from the provisions of this sub- section
in case of serious emergency where national interest is
involved.

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(2) An adolescent who has not been granted a certificate of fitness to work in a
factory as an adult under the aforesaid clause (b) shall, notwithstanding his age,
be deemed to be a child for all the purposes of this Act.

3.3.2 TamilNadu Factories Rules 1950:

Rule 2-A. 4[Competent person]

(1) The Chief Inspector may recognize any person as a 'Competent person' within
such area and for such period as may he specified for the purposes of carrying out
tests, examinations, inspections and certification for such buildings, dangerous
machinery, hoists and lifts, lifting machines and lifting tackles, confined space
ventilation system and such other process or plant and equipment as stipulated in
the Act and the rules made thereunder located in a factory, if such a person
possesses the qualifications, experience and other requirements asset out in the
Schedule annexed to this rule:

Provided that the Chief Inspector may relax the requirements of qualifications in
respect of a `competent person' if such a person is exceptionally experienced and
knowledgeable, but not the requirements in respect of the facilities at his
command.

Provided further that where it is proposed to recognize a person employed under

the Chief Inspector as a 'Competent person' concurrence of the State Government
shall be taken and such a person after being so recognised shall not have powers
of an ‘Inspector’:

Provided also that the 'Competent person' recognised under this provision shall
not be above the age of sixty-two and shall be physically fit for the purpose of
carrying out the tests, examinations and inspections.

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(2) The Chief Inspector may recognize an institution of repute having persons
possessing qualifications and experience as set out in the Schedule annexed to
this rule for the purpose of carrying out tests, examination, inspections, and
certification for building, dangerous machinery, hoists and lifts, lifting machines
and lifting tackles, confined space ventilation system and such other process or
plant and equipment as stipulated in the Act and the rules made there under ,asa
'Competent person' within such area and for such period as may be specified.

(3) The Chief Inspector on receipt of an application in the prescribed form from a
person or an institution intending to be recognised as a 'Competent person' for the
purposes of this Act and the rules made thereunder shall register such application
and within a period of sixty days of the date of receipt of application either after
having satisfied himself as regards competence and facilities available at the
disposal of the applicant, recognize the applicant as a 'Competent person' and
issue a certificate of competency in the prescribed form or reject the application
specifying the reasons therefor.

(4) The Chief Inspector may after giving an opportunity to the competent person
of being heard, revoke the certificate of competency, (i) if he has reason to believe
that a competent person

(a) has violated any condition stipulated in the certificate of competency;

(or)

(b) has carried out a test examination and inspection or

(c) has acted in a manner inconsistent with the intent or the purpose of this Act
or the rules made there under; or

(d) has omitted to act as required under the Act and rules made there under
122
(ii) for any other reason to be recorded in writing

Explanation: For the purpose of this rule, an institution includes an organization.

(5) The Chief Inspector may, for reasons to be recorded in writing, require
certification of lifting machines, lifting tackles, or ventilation system, as the case
may be which has been certified by a competent person outside the State.

Rule 15. Cleanliness of walls and ceilings

(1) The provision of clause (d) of sub-section (I) of section I of the Act
shall not apply to the classes of factories or descriptions of factories
or parts thereof specified in the Schedule below: Provided that they
are kept in a clean state by washing, sweeping, brushing, dusting,
vacuum-cleaning or other effective means:

Provided further that the said clause (d) shall continue to apply

(i) in respect of factories or parts of factories specified in Part A of the schedule,

to workrooms in which the amount of cubic space allowed for every person
employed in the room is less than 500 cubic feet;

(ii) in respect of factories or parts of factories specified in Part B of the schedule,

to workrooms in which the amount of cubic space allowed for every person
employed in the room is less than 2,500 cubic feet;

(iii) to engine houses, fitting shops, lunch rooms, canteens, shelters, crèches, cloak
rooms, rest rooms, and wash places; and

(iv) to such parts of walls, sides and tops of passages and staircases as are less
than 20 feet above the floor or stair.]

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(2) If it appears to the Chief Inspector that any part of a factory, to which by virtue
of sub-rule(I) any of the provisions of the said clause (d)do not apply, is not being
kept in a clean state, he may by written notice require the occupier to whitewash
or colour wash, wash, paint or varnish the same, and in the event of the occupier
failing to comply with such requisition within two months from the date of the
notice, sub-rule (I) shall cease to apply to such part of a factory, unless the Chief
Inspector otherwise determines.

Rule 17. Disposal of trade wastes and effluents

In every factory, effective arrangements shall be made for the treatment of wastes
and effluents due to the manufacturing processes carried on therein and the
arrangements so made shall be in accordance with those approved by the relevant
authorities of Tamil Nadu Pollution Control Board appointed under the Water
(Prevention and Control of Pollution) Act, 1974 and the Air (Prevention and Control
of Pollution) Act, 1981 and the authorities of Department of Environment.)

Rule 17A Ventilation and temperature

1. Limits of temperature and air movement

In any factory the maximum wet bulb temperature of air in a workroom at a height
of 1.5 meters (5 feet) above the floor level shall not exceed 30°C (86F) and
adequate air movement of at least 30 meters per minute (100 feet per minute)
shall be provided ; and in relation to dry bulb temperature the wet bulb
temperature in the workroom at the said height shall not exceed that shown in the
Schedule, or as regards a dry bulb reading intermediate between the two dry bulb
readings that specified in relation to the higher of these two dry bulb readings.

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Provided that if the temperature measured with a thermometer inserted in a hollow
globe of 15 c.m. (6 inches) dia, coated mat black outside and kept in the
environment for not less than 20 minutes exceeds the dry bulb temperature of air,
the temperature so

Recorded by the globe thermometer shall be taken in place of the dry bulb
temperature: Provided further that when the reading of the wet bulb temperature
outside in the shade exceeds 27°C (80.6°F) the value of the wet bulb temperature
allowed in the Schedule for a given dry bulb temperature may be correspondingly
exceeded to the same extent: Provided also that this requirement shall not apply
in respect of factories covered by section 15 and in respect of factories where the
nature of work carried on involves production of excessively high temperatures
referred to in clause (ii) of sub-section (I) to which workers are exposed for short
periods of time not exceeding one hour followed by an interval of sufficient
duration in thermal environments not exceeding those otherwise laid down in this
rule:

Provided also that, the Chief Inspector having due regard to the health of the
worker may in special and exceptional circum-stances, by an order in writing,
exempt any factory or part of a factory from the foregoing requirement, in so far
as restricting the thermal conditions within the limits laid down in the Schedule are
concerned, to the extent that he may consider necessary, subject to such
conditions as he may specify.

2. Provision of Thermometers

(1) If it appears to the Inspector that in any factory, the temperature of air in a
workroom is sufficiently high and is likely to exceed the limits prescribed in rule
(1) he may serve on the manager of the factory an order requiring him to provide

125
sufficient number of whirling hygrometers or any other type of hygrometers and
direct that the dry bulb and wet bulb readings in each such workroom shall be

recorded at such positions as approved by the Inspector twice during each working
shift by a person especially nominated for the purpose by the manager and
approved by the Inspector.

(2) If the Inspector has reason to believe that a substantial amount of heat is
added inside the environment of a workroom by radiation from walls, roof or other
solid surroundings, he may serve on the manager of the factory an order requiring
him to provide one or more globe thermometers referred to in the first proviso in
rule (I) and further requiring him to place the globe thermometers at places
specified by him and keen a record of the temperatures in a suitable register.

3. Ventilation

(1) In every factory the amount of ventilating openings in a workroom below the
caves shall, except where mechanical means of ventilation as required by sub rule

(2) are provided, be of as aggregate area of not less than 15 per cent of the floor
area and so located as to afford a continued supply of fresh air:

Provided that the Chief Inspector may relax the requirements regarding the
amount of ventilating openings if he is satisfied that having regard to the location
of the factory, orientation of the workroom, prevailing winds, roofs height and the
nature of manufacturing process carried on, sufficient supply of fresh air into the
workroom is afforded during most part of the working time: Provided further that
these requirements shall not apply in respect of workrooms of factories

(i) Covered by section 15; or

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(ii) in which temperature and humidity are controlled by refrigeration.

(2) Where in any factory owing to special circumstances such a situation with
respect to adjacent buildings and height of the building with respect to floorspace,
the requirements of ventilation openings under sub-rule (1) cannot be complied
with or in the opinion of the Inspector the temperature of air in a workroom is
sufficiently high and is likely to exceed the limits prescribed in sub-rule (I), he may
serve on the manager of the factory an order requiring him to provide additional
ventilation either by means of roof ventilators or by mechanical means.

(3) The amount of fresh air supplied by mechanical means of ventilation in an hour
shall be equivalent to at least six times the cubic capacity of the workroom and
shall be distributed evenly throughout the workroom without dead air pockets or
undue draughts caused by high inlet velocities.

(4) In regions where in summer (15th March-15th July) dry bulb temperatures of
outside air in the shade during most part of the day exceed 35°C (95°F) and
simultaneous wet bulb temperatures are 25°C (67°F) or below and in the opinion
of the Inspector the manufacturing process carried on in the workroom of a factory
permits thermal environments with relative humidity of 50 per cent or more, the
Inspector may serve on the manager of the factory an order to have sufficient
supply of outside air for ventilation cooled by passing it through water sprays either
by means of unit type of evaporative air coolers (desert coolers) or, where supply
of outside air is provided by mechanical means through ducts in a plenum system,
by means of central air washing plants.

Rule 18. When artificial humidification not allowed

There shall be no artificial humidification in any room of a cotton spinning or

weaving factory

127
(a) By the use of steam during any period, when the dry bulb temperature of that
room exceeds [85oFor29.5o C]69

(b) At any time when the wet bulb reading of the hygrometer in higher than that
specified in the following schedule in relation to the dry bulb reading of the
hygrometer at the time; or as regards a dry bulb reading intermediate between
any two dry bulb reading indicated consecutively in the schedule, when the wet
bulb reading is higher than that specified in relation to the higher of these two dry
bulb readings:

Rule 29. Lighting Application and commencement

(1) Subject as in these rules provided, rules 29 to 33 shall apply to factories in

which persons are being regularly employed in a manufacturing process or
processes for more than 48 hours a week, or in shifts, provided that nothing in
these rules shall be deemed to require the provision of lighting of a specified
standard in any building or structure so constructed that, in the opinion of the
Chief Inspector, it would not be reasonably practicable to comply with such
requirement.

(2) Rules 29 to 33 shall come into force, in respect of any class or description of
factories, on such dates as the State Government may, by notification in the Official
Gazette, appoint in this behalf.

Rule 30. Lighting of interior parts

(1) The general illumination over those interior parts of a factory where persons
are regularly employed shall he not less than 73[65 lux] measured in the horizontal
plane at a level of 91.4 centimeters above the floor:

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Provided that in any such parts in which the mounting height of the light source
for general illumination necessarily exceeds 7.6 meters measured from the floor
or where the structure of the room or the position or construction of the fixed
machinery or plant prevents the uniform attainment of this standard, the general
illumination at the said level shall be not less than 74[22 lux] and where work is
actually being done the illumination shall be not less than 75[65 lux).

(2) The illumination over all other interior parts of the factory over which persons
employed pass, shall, when and where a person is passing, be not less
than76[5.5lux] at floor level.

(3) The standard specified in this rule shall be without prejudice to the provision
of any additional illumination required to render the lighting sufficient and suitable
for the nature of the work.

Rule 31. Prevention of glare

(1) Where any source of artificial light in the factor is less than 4.9 meters above
floor level, no part of the light source or of the lighting fitting having a brightness
greater than 15 candles per square centimeters shall be visible to persons whilst
normally employed within 30.5 meters of the source except where the angle of
elevation from the eye to the source or part of the fitting exceeds 200

(2) Any local light. an artificial light designed to illuminate particularly the area or
part of the area of work of a single operative or small group of operatives working
near each other, shall be provided with a suitable shade of opaque material to
prevent glare or with other effective means by which the tight source is completely
screened from the eyes of every person employed at a normal working place, or
shall be so placed that no such person is exposed to glare there from.

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Rule 32. Power of Chief Inspector to exempt

Where the Chief Inspector is satisfied in respect of any particular factory or part
there of or in respect of any description of workroom or process that any
requirement of rules 29 o 31 is inappropriate or is not reason-ably practicable, he
may, by order in writing, exempt the factory or part thereof, or description of
workroom or process from such requirement to such extent and subject to such
conditions as he may specify.

Rule 39. Cooling of water

In every factory wherein more than two hundred and fifty workers are ordinarily
employed

(a) the drinking water supplied to the workers shall, during hot weather, be cooled
by Ice or other effective method:

Provided that, if ice is placed in the drinking water, the ice shall be clean and
wholesome and shall be obtained only from a source approved in writing by the
Health Officer;

(b) the cooled drinking water shall be supplied in every canteen, lunch-room and
restroom and also at conveniently accessible points throughout the factory which
fur the purpose of these rules shall be called "Water Centers";

(c) the water centers shall be sheltered from the weather and adequately drained;

(d) the number of water centers to be provided shall be one "centre" for every
150 persons employed at any one lime in the factory.

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Provided that in the case of a factory where the number of persons employed
exceeds 500, it shall be sufficient if there is one such "centre" as aforesaid for
every 150 persons up to the first 500 and one for every 500 persons thereafter.;

77[Provided further that the distance between the places of work of any worker
shall not be more than fifty meters from the nearest water centre or any distance
as may be specified by the Inspector.]

(e) every water centre shall be maintained in a clean and orderly condition;

(f) every water centre shall be in charge of a suitable person who shall distribute
the water. Such person shall be provided with clean clothes while on duty:
Provided that, the Chief Inspector may exempt any" water centre "from the
requirements of this clause.

Clause (f) shall not apply to any factory in which suitable mechanically operated
drinking water refrigerating units are installed to the satisfaction of the Chief
Inspector.

Rule 40. Latrine Accommodation

Latrine accommodation shall be provided in every factory on the following scale:

(a) Where women are employed, there shall be at least one latrine seat for every
20 women;

(b) Where males are employed, there shall be at least one latrine scat for every
20 males:

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Provided that, where the number of males employed exceeds 100, it shall be
sufficient if there is one latrine scat for every 20 males up to the first 100, and one
for every 50 thereafter.

In calculating the number of seats required under this rule, any odd number of
workers less than 20 or 50, as the case may be, shall be reckoned as 20 or 50 and
the maximum number of persons working in the factory at any time and not the
total number of persons employed in the factory, shall be taken into account

Rule 41. Latrines to conform to public health requirements

Latrines other than those connected with an efficient water-home sewage system,
shall comply with the requirements of the Public Health authorities.

Rule 42. Privacy of latrines

Every latrine shall be under cover and every seat in the latrine shall be so
partitioned off as to secure privacy and each partition shall have a proper door and
fastenings.

Rule 43. Signboards to be displayed

Where workers of both sexes are employed there shall be displayed outside each
latrine block a notice in the language understood by the majority of the workers
"For Men only— or "For Women only", as the case may be. The notice shall also
bear the figure of "a man "or of" a woman", as the case maybe.

Rule 44. Urinal accommodation

(1) Urinal accommodation shall be provided for the use of worker sand shall not
be less than 61 centimeters in length for every 50 workers: provided that, where

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the number of workers employed exceeds 500, it shall be sufficient if there is one
urinal for every 50 workers up to the first 50X) employed and one for every 100
thereafter.

Where women are employed, separate urinal accommodation shall he provided for
them on the same scale as mentioned above:

Provided further that the Chief Inspector of Factories may by order in writing
exempt. subject to such conditions as he may think fit to impose, small factories
employing less than 20 'workers from the provision of separate urinal
accommodation if he is satisfied that the latrine accommodation in such factories
is sufficient and suitable.

(2) In calculating the urinal accommodation required under sub-rule (1), any odd
number of workers less than 50 or 100, as the case may be, shall be reckoned as
50 or100, and the maximum number of persons working in the factory, at any time
and not the total number of persons employed in the factory, shall be taken into
account.

Rule 45. Urinals to conform to public health requirements

Urinals other than those connected with efficient water borne sewage system, and
urinals

in a factory wherein more than two hundred and fifty workers are ordinarily
employed shall comply with the requirements of the Public Health authorities.

Rule 46. Certain latrines and urinals to be connected to sewage system

When any general system of underground sewerage with an assured water-supply

for any particular locality is provided in a municipality all latrines and urinals other

133
than septic tank latrines and any other type of latrines and urinals to be approved
for this purpose by the Public Health authority, of a factory situated in such locality
shall, if the factory is situated within 30.5 meters of an existing sewer, be
connected with that sewage system.

Rule 47. White washing and colour washing of latrines and urinals

The walls, ceilings and partitions of every latrine and urinal shall be white-washed
or colour washed and the whitewashing or colour washing shall be repeated at
least once in every period of four months. The dates on which the whitewashing
or colour washing is carried out shall be entered in the prescribed register (Form
No. 7):

Provided that this rule shall not apply to latrines and urinals, the walls, ceiling, or
partitions of which are laid in glazed tiles or otherwise finished to provide a smooth
polished impervious surface and that they are washed with suitable detergents
and disinfectants at least once in every period of four months.

Rule 48. Construction and maintenance of drains

All drains carrying waste or spoilage water shall be constructed in masonry or other
impermeable materials and shall be regularly flushed and effluent disposed of by
connecting such drains with a suitable drainage line:

Provided that, where there is no such drainage line, the effluent shall be
deodorized and rendered innocuous and then disposed off in suitable manner to
the satisfaction of the Health Officer.

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Rule 49. Water taps in latrines

Where piped water-supply is available a sufficient number of water taps,

conveniently access shall be provided in or near such latrine accommodation.
Where there is no continuous supply of water, water cisterns with cans should be
provided for washing purposes.

Rule 52-A Planting of trees

The occupier of every factory employing one hundred or more workers shall plant
and maintain trees within the premises of the factory. The number, type and layout
of trees shall be approved by the District Agricultural Officer concerned:

Provided that if it is not possible to plant trees due to non-availability of space in

any factory or class of factories, the District Agricultural Officer may recommend
to the Government for grant of exemption to such factory or class of factories from
the provisions of this rule

Rule 53. other safety precautions:

SCHEDULE VI

ALL FACTORIES

(a) Wherever practicable and considered necessary by the Inspector, service

platforms and gangways shall be provided for overhead shafting and when
required by him these shall be securely fenced with guards, rails and toe boards.

(b) Safe access shall be provided to all hearing clutches, belt shifting levers and
all such other appliances which are required to be handled or operated while the
machinery is at work.

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(c) All ladders used in replacing belts or in attending similar overhead machinery
shall be specially made for that work and provided with books or an effective
nonskid device.

(d) No transmission machinery in motion shall be cleaned with cotton waste, rags
or similar materials held in hand.

(e) All belts shall be regularly examined to ensure that the joints are safe and the
belts are kept in proper tension.

(f) Each water gauge glass of a boiler shall be fitted with an efficient guard.

(g) All condenser pipes of steam engines and exhaust pipes of oil engine; shall be
adequately guarded.

SCHEDULE VII

SAFELY OF CENTRIFUGAL MACHINES

1. Centrifugal machine shall be provided with sufficient inter-locking devices that

will physically prevent the lids from being opened whilst the rotating drums or
baskets are in motion under power or due to power derived earlier and by then
switched off and also prevent the starling of the drums or baskets under power
while the lids are open.

2. The above requirements shall not apply while charging, ploughing and
discharging operations are carried out when the drums or the baskets are rotated
at lower speed.

3. Centrifugal machines shall not be operated at a speed in excess of the

manufacturer's rating which shall be legibly stamped by the manufacturers both

136
on the inside of the basket and on the outside of the machine casing at easily
visible places.

4. All centrifugal machines shall be provided with effective breaking arrangements

85[for bringing the] cage, drum or basket to rest within a seasonable short period
of time after the power to drive the motor is cut off.

5. The cages, drums or baskets shall be thoroughly examined by a competent

person once in envy twelve months to check their balance and in case balance at
high speed is not observed, effective steps shall be taken to restore their balance
before recommissioning the machines.]

SCHEDULE VIII

POWER PRESSES

1. Application

The schedule shall apply to all types of power presses including press brakes,
except when Used for working hot metal.

2. Definition

For the purpose of this Schedule,

(a) "approved" means approved by the Chief Inspector;

(b) "fixed fencing" means fencing provided for the tools of a power press being
fencing which has no moving part associated with or dependent upon the
mechanism of a power press and includes that part of a closed tool which acts as
a guard;

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(c) "power press" means a machine used in metal or other industries for molding,
pressing, blanking, raising drawing and similar purposes;

(d) "safety device" means the fencing and any other safeguard provided for the
tools of a power press.

3. Starting and stopping mechanism

The starting and stopping mechanism shall be provided with a safety stop so as to
prevent over running of the press or descent of the ram during tool setting, etc.

4. Protection of tool and disc

(1) Each press shall be provided with a fixed guard with a slip plate on the
underside enclosing the front and all sides of the tool.

(2) Each disc shall be provided with a (heed guard surrounding its front and sides
and extending to the back in the form of a tunnel through which the pressed article
falls to the rear of the press.

(3) The design, construction and mutual position of the guards referred to in
subparagraphs (1) and (2) shall be such as to preclude the possibility of the
workers hand or fingers reaching the danger zone.

(4) The machine shall be fed through a small aperture at the bottom of the guard
but a wider aperture may be permitted for a second or subsequent operation if
feeding is done through a chute.

(5) Not withstanding anything contained in sub-paragraphs (1) and (2) an

automatic or an inter-locked guard may he used in place of a fixed guard, but
where such guards are used they shall be maintained in an efficient working

138
condition and if any guard develops a defect, the power press shall not be operated
unless the defect of the guard is removed.

5. Appointment of persons to prepare power presses for use

(1) Except as provided in paragraph 6, no person shall set, re-set, adjust or try
out the tools on a power press or install or adjust any safety device thereon, being
installation or adjustment preparatory to production of (to proving, or carry out an
inspection and test of any safety device thereon required by paragraph 8 unless
he –

(a) has attained the age eighteen;

(b) has been trained in accordance with the sub-paragraph (2) ; and

(c) has been appointed by the Occupier of the Factory to carry out those duties in
respect of the class or description of power pressor the class or description of
safety device to which the power press or the safety device (as the case may be)
belongs; and the name of every such person shall be entered in a Register in
Form35.

(2) The training shall include suitable and sufficient practical instruction in the
matters in relation to cash type of power press and safety device in respect of
which it is proposed to appoint the person being trained.

6. Examination and testing of power-presses and safety devices

(1) No power press or safety device shall he taken into use in any Factory for the
first time in that factory or in case of a safety device for the first time on any power
press, unless it has been thoroughly examined and tested, in the case of a power

139
press, after installation in the factory, or in the ease of a safety device, when in
position on the power press in connection with which it is to be used.

(2) No power press shall be used unless it has been thoroughly examined and
tested by a competent person, within the immediately preceding period of twelve
months.

(3) No power press shall be used unless every safety device (other than fixed
fencing) there on has within the immediately preceding six months when in
position on that power press been thoroughly examined and tested by a competent
person.

(4) The competent person carrying out an examination and test under the
foregoing provisions shall make a report of the examination and test containing
the following particulars and every such report shall be kept readily available for
inspection, namely:

(a) name of the occupier of the Factory;

(b) address of the Factory;

(c) identification number or mark sufficient to identify the power press or the safety
device;

(d) date on which the power press or the safe device was first taken into use in
the Factory;

(e) the date of each periodical thorough examination carried out as per
requirements of sub-paragraph (2) above;

140
(f) particulars of any defects affecting the safe working of the power press or the
safety device found at any such thorough examination and steps taken to remedy
such defects.

7. Defects disclosed during a thorough examination and tests

(1) Where any defect is disclosed in any power press or in any safety device by
any examination and test under paragraph 6 and in the opinion of the competent
person carrying out the examination and test, either

(a) the said defect is a cause of danger to workers and in consequence the power
press or safely device (as the case may be) ought not to be used until the said
defect has been remedied; or

(b) the said defect may become a cause of danger to workers and in consequence
the power press or the safety device (as the case maybe) ought not to be used
after the expiration of a specified period unless the said defect has been remedied;
such defect shall, as soon as possible after the completion of the examination and
test, be notified in writing by the competent person to the Occupier of the Factory
and, in the case of a defect falling within clause (b) of this paragraph such
notification shall include the period within which, in the opinion of the competent
person, the defect ought to be remedied.

(2) In every case where notification has been given under this paragraph, a copy
of the report made under sub-paragraph (4) of paragraph 6 shall be sent by the
competent person to the Inspector for the area within fourteen days of the
completion of the examination and test.

141
(3) Where any such defect is notified to the Occupier in accordance with the
foregoing provisions of this paragraph the power press or safety device ( as the
case may be ) having the said defect shall not be used

(a) In the case of a defect falling within clause (a) of sub-paragraph (1) until the
said defect has been remedied; and

(b) In the case of defect falling within clause (b) of sub-paragraph (1), after the
expiration of the said defect has been remedied.

(4) As soon as is practicable after any defect of which notification has been given
under sub-paragraph (1) has been remedied, are cord shall be made by or on
behalf of the Occupier stating the measures by which and the date on which the
defect was remedied.

8. Inspection and test of safety devices

(1) No power press shall be used after the setting, resetting or adjustment of the
tools thereon unless a person appointed or authorized for the purpose under
paragraph 5 has inspected and tested every safety device thereon whack is in
position on the said power press;

Provided that an inspection, test and certificate as aforesaid shall not be required
where any adjustment of the tools has not caused or resulted in any alteration to
or disturbance of any safety device on the power press and if, after the adjustment
of the tools, the safety devices remain, in the opinion of such a person as aforesaid,
in efficient working order.

(2) Every power press and every safety device thereon while it is in position on
the said power press shall be inspected and tested by a trained person every day.

142
9. Defects disclosed during an inspection and test

(1) Where it appears to any person as a result of any inspection and test carried
out by him under paragraph 8 that any necessary safety device is not in position
or is not properly in position on a power press or that any safety device which is
in position on a power press is not in his opinion suitable, he shall notify the
manager forthwith.

(2) Except as provided in sub-paragraph (3) of this paragraph where any defect is
disclosed in a safety device by any inspection and test under paragraph 8, the
person carrying out the inspection and test shall notify the manager forthwith.

(3) Where any defect in a safety device is the subject of a notification in writing
under paragraph7 by virtue of which the use of the safety device may be continued
during a specified period without the said defect having been remedied, the
requirement in sub-paragraph (2) of this paragraph shall not apply to the said
defect until the said period has expired.

10. Identification of power presses and safety devices

For the purpose of identification every power press and every safety device
provided for the same shall be distinctively and plainly marked.

11. Training and Instructions to operators

The operators shall be trained and instructed in the safe method of work before
starting work on any power press.

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12. Exemptions

(1) If in respect of any factory, the Chief Inspector is satisfied that owing to the
circumstances or infrequency of the processes or for any other reason, all or any
of the provisions of this Schedule are not necessary for the protection of the
workers employed

on any power press or any class or description of power press in the factory, the
Chief Inspector may by a certificate in writing (which he may in his discretion
revoke at any time), exempt such factory from all or any of such provisions subject
to such conditions, if any, as he may specify therein.

(2) Where such exemption is granted a legible copy of the certificate, showing the
conditions (if any) subject to which it has been granted, shall be kept posted in
the factory in a position where it may be conveniently read by the persons
employed.

Rule 55. Hoists and lifts

(1) A Register shall be maintained to record particulars of examination of hoists

and lifts and shall give particulars as shown in Form No. 36.]

(2) Exemption of certain hoists and lifts: In pursuance of the provisions of sub-
section (4) of section 28. in respect of any class or description of hoist or lift
specified in the first column of the following schedule, the requirements of section
28 specified in the second column of the said schedule and set opposite to that
class or description of hoist or lift shall not apply.

144
SCHEDULE-

Class or description of hoist or lift Class or description of hoist or lift

(1) (2)
Hoists or lifts mainly used for raising Sub-section (1) (b) in so far as it
materials for charging blast furnaces or requires a gate at the bottom landing:
lime kilns. sub-section (1) (d); sub-section (1) (e)
Hoists not connected with mechanical Sub-section (1) (b) in so far as it
power and which are not used for requires the hoist-way or lift-way
carrying persons enclosure to be so constructed as to
prevent any person or thing from being
trapped between any pans of the hoist
or lift and any fixed structure or moving
part; sub-section (1)(e).

Rule 55A. Lifting machines, chains, ropes and lifting tackles

(1) No lifting machine and no chain, rope or lifting tackle, except a fiber rope or
fiber rope sling, shall be taken into use in any factory for the first time in that
factory unless it has been tested and all parts have been thoroughly examined by
a competent person and a certificate of such a test and examination specifying the
safe working load or loads and signed by the person making the test and the
examination, has been obtained and is kept available for inspection.

(2) Every jib crane so constructed that the safe working load may be varied by the
raising or lowering of the jib. shall have attached thereto either an automatic
indicator of safe working loads or an automatic jib angle indicator and a table
indicating the safe working loads at corresponding inclinations of the jib or
corresponding radii of the load.

145
(3) A table showing the safe working loads of every kind and size of chain, rope
or lifting tackle in use, and in the case of a multiple sling, the safe working load at
different angles of the legs, shall be posted in the store in which the chains, ropes
or lifting tackles are kept, and in prominent positions on the premises, and no
chain, rope or lifting tackle not shown in the table shall be used. This sub-rule shall
not apply in respect of any lifting tackle if the safe working loads thereof or in the
case of a multiple sling, the safe working load at different angles of the legs is
plainly marked upon it.

(4) The register to be maintained under clause (a)(iii) of sub-section (1) of section
29 of the Act shall contain the following particulars and shall be kept readily
available for inspection:

(i) Name of occupier of factory.

(ii) Address of the factory.

(iii) Distinguishing number or mark, if any and description sufficient to identify the
lifting machine, chain, rope or the lifting tackle.

(iv) Date when the lifting machine, chain, rope or lifting tackle was first taken into
use in the factory

(v) Date and number of the certificate relating to any test and examination made
under sub-rules (I) and (8) together with the name and address of the person who
issued the certificate.

(vi) Date of each periodical thorough examination made under clause (a) (iii) of
sub-section (I) of section 29 of the Act and sub-rule (7) and by whom it was carried
out.

146
(vii) Date of annealing or other heat treatment of the chain and other lifting tackle
made under sub-rule (6) and by whom it was carried out.

(viii) Particulars of any defects found at any such thorough examination or after
annealing and affecting the safe working load, and of the steps taken to remedy
such defects.

(4A) Passage ways for cranes

(i) To provide access to mil tracks of overhead travelling cranes suitable

passageways of at least 50cm. (20 inches) width with toe boards and double
handrails 90 cm. (3 feet) high shall be provided alongside, and clear of the rail
tracks of overhead travelling cranes, such that no moving part of the crane can
strike persons on the ways, and the passage-way shall be at a lower level than the
crane can strike persons on the ways, and the passage-way shall be at a lower
level than the crane track itself. Safe access ladders shall be provided at suitable
intervals to afford access to these passage-ways, and from passage ways to the
rail tracks.

(ii) 92[The Chief Inspector may, for reasons to be specified in writing, exempt any
factory in respect of any overhead travelling crane from the operation of any
provisions of clause (i) subject to such conditions as he may specify.]

(5) All rails on which a travelling crane moves and every track on which the carriage
of a transporter or runway moves shall be of proper size and adequate strength
and have an even running surface and every such rail or track shall be properly
laid, adequately supported and properly maintained.

(6) All chains, and lifting tackle, except a rope sling shall, unless they have been
subjected to such other heat treatment as may be approved by the Chief Inspector,

147
be effectively annealed under the supervision of a competent person at the
following intervals:

(i) All chains, slings, rings, hooks, shackles and swivels used in connection with
molten metal or molten slag or when they are made of 12.7 millimeters bar or
smaller, once at least in every six months.

(ii) All other chains, rings, hooks, shackles and swivels in general use, once at least
in every twelve months:

Provided that chains and lifting tackle not in frequent use shall, subject to the Chief
Inspector's approval, be annealed only when necessary. Particulars of such
annealing shall be entered in a register prescribed under sub-rule (4) which shall
be kept available for inspection.

(7) Nothing in the foregoing sub-rule (6) shall apply to the following classes of
chains and lifting tackle:

(i) Chains made of malleable cast iron.

(ii) Plate link chains.

(iii) Chains, rings, hooks, shackles and swivels made of steel or of any non-ferrous
metals.

(iv) Pitched chains, working on sprocket or pocketed wheels.

(v) Rings, hooks, shackles and swivels permanently attached to pitched chains,
pulley blocks or weighing machines.

(vi) Hooks and swivels having screw threaded parts or ball-bearing or other
casehardened parts.
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(vii) Socket shackles secured to wire ropes by white metal capping.

(viii) Bordeaux connections. Such chains and lifting tackles shall be thoroughly
examined by a competent person once at least in every twelve months and
particulars entered in the register kept in accordance with sub-rule (4).

(8) All lifting machines, chains, ropes and lifting tackle, except a fiber rope or fiber
rope sling, which have been lengthened, altered or repaired by welding or
otherwise shall, before being again taken into use, be adequately i.e., tested and
re-examined by a competent person and a certificate of such test and examination
be obtained and particulars entered in the register kept in accordance with sub-
rule (4).

(9) No person under 18 years of age and no person who is not sufficiently
competent and reliable shall be employed as driver of a lifting machine whether
driven by mechanical power or otherwise, or to give signals to a driver

Rule 57. Excessive weights

(1) No man, woman or young person shall, unaided by another person, lift, carry
or move by hand or head, any material, article, tool or appliance exceeding the
Maximum limiting weight set out in the following schedule:

SCHEDULE

Persons Maximum weight of material, article, tool

or appliance K.Grams

A Adult male 50
B Adult female 30
C Adolescent male 30

149
 D Adolescent female 20
E Male child 16
F Female child 13

(2) No man, woman or young person shall engage in conjunction with others, in
lifting, carrying or moving by hand or on head, any material, ankle, tool, or
appliance, if the weight thereof exceeds the lowest weight fixed by the schedule
to sub-rule (1) for any of the persons engaged, multiplied by the number of the
persons engaged.

Rule 58. Protection of eyes

Effective screens or suitable goggles shall be provided for the protection of persons
employed in or in the immediate vicinity of the following processes.

(a) The processes specified in Schedule I annexed hereto, being processes which
involve risk of injury to the eyes from particles or fragments thrown off in the
course of the process.

(b) The processes specified in Schedule 11 annexed hereto, being processes which
involve risk of injury to the eyes by reason of exposure to excessive light 113[or
infrared or ultra-violet radiations

SCHEDULE I

1. The breaking, cutting, dressing or carving of bricks, stone, concrete, slag or

similar materials by means of a hammer, a chisel, pick or similar hand tool. Or by
means of a portable tool driven by mechanical power, and the dry grinding of
surfaces of any such materials by means of a wheel or disc driven by mechanical
power, wherein any of the fore going cases particles or fragments am liable to be
thrown off towards the face of the operator in the course of the process.

150
2. The dry grinding of surfaces of metal by supplying them by hand to a wheel,
disc or hand driven by mechanical power and of surfaces of metal by means of a
portable tool driven by mechanical power.

3. The dividing into separate parts of metal, bricks, stone, concrete or similar
materials by means of high speed of saw driven by mechanical power or by means
of an abrasive cutting off wheel or disc driven by mechanical power.

4. The turning of metals, or articles of metal, where particles or fragments are

liable to the thrown off towards the fact of the operator in the course of the
process.

5. Drilling by means of portable tools, where particles or fragments are liable to

bethrown off towards the face of the operator in the course of the process.

6. The welding and cutting of metals by means of an electric, oxy-acetylene or

similar process.

7. The hot fettling of steel castings by means of a flux injected burner or air-torch,
and the dc-seaming of metal.

8. The fettling metal castings, involving the removal of metal, including runners,
gates and riser sand the removal of any other material during the course of such
fettling.

9. The chipping of metal, and the chipping knocking out, cutting out or cutting off
cold rivets, bolts, nuts, lugs, pins, collars, or similar articles from any structure or
plant, or from part of any structure or plant, by means of a hammer, chisel, punch
or similar hand tool, or by means of a portable tool driven by mechanical power.

151
10. The chipping or sculling of paint, scale, slag rust or other corrosion from the
surface of metal and other hard materials by means of a hand tool or by a portable
tool driven by mechanical power.

11. The breaking of scrap metal by means of a hammer or by means of a tool

driven by mechanical power.

12. The routing of metal, where particles or fragments are liable to be thrown off
Towards the face of the operator in the course of the process.

13. Work with drop hammers and power hammers, used in either case for the
manufacture of forgings. and work by any person not working with such hammers
whose work is carried on in such circumstances and in such a position that particles
or fragments arc liable to be thrown off towards his face during work with drop
hammers or power hammers.

14. Work at a furnace where there is risk to the eyes from molten metal.

15. Pouring or skimming of molten metal.

16. Work involving risk to the eyes from hot sand being thrown off.

17. Turning or dressing of an abrasive wheel.

18. The handling in open vessels or manipulation of strong acids or dangerous

corrosive liquids or materials, and the operation, maintenance or dismantling of
plant or any

Part of plant, being plant or part of plant, which contains or has contained such
acids liquids or materials, unless the plant or part of plant has been so prepared

152
(by isolation, reduction of pressure, or otherwise) treated or designed and
constructed as to prevent risk of injury

19. Any other process wherein there is a risk of injury to eyes from particles or
fragments thrown off during the course of the process.

114[SCHEDULE

(1) Welding or cutting of metals by means of an electrical, oxy-acetylene or similar

process.

(2) All work on furnaces where there is risk of exposure to excessive light or infra-
red radiations.

(3) Process such as rolling, casting or forging of metals where there is risk of
exposure to excessive light or infra-red radiations.

(4) Any other process wherein there is a risk of injury to eyes from exposure to
excessive light or ultra-violet or infra-red radiations.]

SCHEDULE I

MANUFACTURE OF AERATED WATERS AND PROCESSES INCIDENTAL THERETO

1. Fencing of machines

All machines for filling bottles or syphons shall be so constructed, placed or fenced
as to prevent at far as may be practicable, a fragment of a bursting bottle or
syphon from striking any person employed in the factory.

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2. Face-guards and gauntlets

(1) The occupier shall provide and maintain in good condition for the use of all
persons engaged in filling bottles or siphons

(a) suitable face-guards to protect the face, neck and throat, and

(b) suitable gauntlets for both arm stop protects the whole hands and arms:

Provided that--

(i) paragraph 2 (1) shall not apply where bottles are filled by means of an
automatic machine so constructed that no fragment of a bursting bottle can
escape, and (ii) where a machine is so constructed that only one arm of the bottle
at work upon it is exposed to danger, a gauntlet need not be provided for the arm
which is not exposed to danger.

(2) The occupier shall provide and maintain in good condition for the use of all
persons engaged in corking, crowning, screwing, wiring, foiling capsuling, sighting

192[handling] or labeling bottles or syphons –

(a) suitable face-guards to protect the fact, neck and throat, and

(b) suitable gauntlets for both arms to protect the arm and at least half of the
palm and the space between the thumb and forefinger.

3. Wearing of face-guards and gauntlets

All persons engaged in any of the processes specified in paragraph (2) shall, while
at work in such processes, wear the faceguards and gauntlets provided under the
provisions of the said paragraph

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257[SCHEDULE XXXII

OPERATIONSINFOUNDARIES ANDFURNACES

1. Application

Provisions of this schedule shall apply to all parts of factories where any of the
following

operations or process are carried on:

(a) The production of iron casting or, as the case may be, steel castings by casting
in moulds made of sand, loam, moulding composition or other mixture of materials,
or by shell moulding or by centrifugal casting and any process incidental to such
production;

(b) the production of non-ferrous castings by casting metal in moulds made of

sand, loam, metal, moulding composition or other material or mixture or materials,

or by shell mouldings, die-casting (including pressure die-casting), centrifugal

casting or continuous casting and any process incidental to such production;

(c) the melting and casting of non-ferrous metal land/or ferrous metal) for the
production of ingots, billets, slabs or other similar products and the stripping
thereof; but shall not apply with respect to

(i) any process with respect to the smelting and manufacture of lead and the
Electric Accumulators;

(ii) any process for the purposes of a printing we; or

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(iii) any smelting process in which metal is obtained by a reducing operation or
any process incidental to such operation; or

(iv) the production of steel in the form of ingots; or

(v) any process in the course of the manufacture of solder or any process incidental
to such manufacture; or

(vi) the melting and casting of lead or any lead-based alloy for the production of
ingots, billets, slabs or other similar products or the stripping thereof, or any
process incidental to such melting, casting or stripping.

2. Definition

For the purpose of this Schedule

(a) "approved respirator” means a respirator of a type approved by the Chief

Inspector;

(b) " Cupola or furnace " includes a receiver associated there with;

(c) "dressing or fettling operations "includes stripping and other removal of

adherent sand, corers, runners, risers, flash and other surplus metal from a casting
and the production of reasonably clean and smooth surface, but does not include
(i) the removal of metal from a casting when performed incidentally in connection
with the machining or assembling of castings after they have been dressed or
fettled ,or (ii) any operation which is a knockout operation within the meaning of
this Schedule ;

(d) "foundry" means those parts of a factory in which the production of iron or
steel or non-ferrous castings (not being the production of pig iron or the production

156
of steel in the form of ingots) is carried on by casting in moulds made of sand,
loam, moulding composition or other mixture of materials, or by steel moulding or
by centrifugal casting in metal moulds lined with sand, or die casting including
pressure die castings, together with any part of the factory in which any of the
following processes arc carried on as incidental processes in connection with and
in the course of, such production, namely, the preparation and mixing of materials
used in foundry process, the preparation of moulds and cores, knock-out
operations and dressing or fettling operations ;

(e) "knock-out operations" means all methods of removing castings from moulds
and the following operations, when done in connection therewith, namely, striping,
coring out and the removal of runners and risers;

(f) "pouring aisle" means an aisle leading from a main gangway or directly from a
cupola or furnace to where metal is poured in to moulds.

(g) “qualified supervisors” means a person possessing a Bachelor’s Degree in

Science or Diploma or Degree in Engineering with Certificate in ferrous/non-ferrous
technology from any institution recognized by the Chief Inspector.

3. Prohibition of use of certain materials as parting materials

(1) A material shall not be used as a parting material if it is a material containing

compounds of silica calculated as silica to the extent more than five per cent, by
weight of the dry material:

Provided that this prohibition shall not prevent the following being used as a
parting material if the material does not contain an admixture of any other silica:

(a) Zirconium silicate (zircon).

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(b) Calcined china clay.

(c) Calcined aluminious fireclay.

(d) Sillimanite.

(e) Calcined or fused alumina.

(f) Olivine.

(g) Natural sand.

(2) Dust or other matter deposited from a fettling or blasting process shall not be
used as a parting material or as a constituent in a parting material.

4. Arrangement and storage

For the purposes of promoting safety and cleanliness in workrooms, the following
requirements shall be observed:

(a) moulding boxes, loam plates, ladles, patterns, pattern plates, frames, boards,
box weights, and other heavy articles shall be so arranged and placed as to enable
work to be carried on without unnecessary risk;

(b) suitable and conveniently accessible racks, bins or other receptacles shall be
Provided and used for the storage of other gear and tools;

(c) where there is bulk storage of sand, fuel, metal scrap or other materials or
residues, suitable bins, bunkers or other receptacles shall be provided for the
purpose of such storage.

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5. Construction, Installation and Operation

(1) The precinct in which induction furnace is installed shall be of adequate

strength and shall be segregated from the other parts of the factory in such a way
so that minimum number of workers is exposed to the risk of any fire or explosion
at any time;

(2) Furnace shed shall be well ventilated

(3) All the fitting and attachment of Induction furnace shall be of good
construction, sound material and adequate strength;

(4) Adequate arrangements shall be made to avoid tilting of the ladles while
transportation

(5) Ladle shall not be filled with molten metal more than 3/4th of its volume to
avoid spillage of molten metal while being carried by the crane;

(6) The refractory material of the induction furnace shall be strong at high
temperature, resistant to thermal shock, chemically inert, low thermal conductivity
and coefficient of expansion and of adequate uniform thickness.

(7) The lining of the induction furnace shall be checked by qualified supervisor
every week for any wear and tear and damage as per relevant Bureau of Indian
Standards.

(8) Adequate precautions shall be taken during repair of induction furnace as per
relevant bureau of Indian Standards.

159
6. Construction of floors

(1) Floors or indoor work places in which the processes are carried on, other than
parts which are of sand, shall have an even surface of hard material.

(2) No part of the floor of any such indoor work place shall be of sand except,
where this is necessary by reason of the work done.

(3) All parts of the surface of the floor of any such indoor workplace which are of
sand shall, so far as practicable, be maintained in an even and firm condition.

7. Means of escape

There shall be at least two ways of escape with adequate width at opposite ends
of the furnace platforms.

8. Display of Notice

Notice regarding non-use of water, etc. near induction furnace shall be displayed

9. Charging of scrap in Induction Furnace

(1) No scrap material with close cavities shall be charged in the induction furnace.
Scrap to be charged shall be dry and shall not contain oil or any other liquid or
moisture.

(2) No scrap material shall be fed into induction furnace unless it is thoroughly
checked in the presence of qualified Supervisor.

(3) No closed container scrap shall be fed into the furnace unless it is cut into
pieces. Such container shall be rendered safe by suitable means.

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(4) No wet scrap material shall be charged into the induction furnace.

(5) Scrap received in the form of pressed bundle should be opened, sorted and
only then fed into furnace.

10. Cleanliness of Indoor workplaces

(1) All accessible parts of the walls of every indoor workplace in which the
processes are carried on and of everything affixed to those wall shall be effectively
cleaned by a suitable method to a height of not less than 4.2 meters from the floor
at least once in every period of fourteen months. A record of the carrying out of
every such effective cleaning in pursuance of this paragraph including the date
(which shall be not less than five months nor more than nine months after the last
immediately preceding washing, cleaning or other treatment).

(2) Effective cleaning by a suitable method shall be carried out at least once every
working day of all accessible parts of the floor of every indoor workplace in which
the processes arc carried on, other than pans which are of sand; and the parts
which are of sand shall be kept in good order.

11. Manual operations Involving molten metal

(1) There shall be provided and properly maintained for all persons employed on
manual operations involving molten metal with which they are liable to be
splashed, a working space for that operation

(a) which is adequate for the safe performance of the work and

(b) which, so far as reasonably practicable, is kept free from obstruction.

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(2) Any operation involving the carrying by hand of a container holding molten
metal shall be performed on a floor all parts of which were any person walks while
engaged in the operation shall be on the same level:

Provided that, where necessary to enable the operation to be per-formed without

undue risk, nothing in this paragraph shall prevent the occasional or exceptional
use of a working space on a different level from the floor, being a space provided
with a safe means of access from the floor for any person while engaged in the
operation.

12. Gangways and pouring aisles

(1) In every workroom to which this paragraph applies constructed, reconstructed

or converted for use as such after the making of this schedule and, so far as
reasonably practicable, in every other workroom to which this paragraph applies,
sufficient and dearly defined main gangways shall be provided and properly
maintained which

(a) shall have an even surface of hard material and shall, in particular, not be of
sand or have on them more sand than is necessary to avoid risk of flying metal
from accidental spillage;

(b) shall be kept, so far as reasonably practicable, free from obstruction;

(c) if not used for carrying molten metal, shall be at least 920 millimeters in width;

(d) if used for carrying molten metal shall be

(i) Where truck ladles are used exclusively, at least 600 millimeters wider than the
overall width of the ladle;

162
(ii) Where hand shanks are carried by not more than two men, at least 920
millimeters in width;

(iii) Where hand shanks are carried by more than two men, at least 1.2 meters in
width; and

(iv) Where used for simultaneous travel in both directions by men carrying hand
shanks, at least 1.8 meters in width.

(2) In workroom to which this paragraph applies constructed, reconstructed or

converted for use as such after the making of this Schedule, sufficient and clearly
defined pouring aisles shall be provided and properly maintained which

(a) shall have an even surface of hard material and shall, in particular, not be of
sand or have on them more sand than is necessary to avoid risk of flying metal
from accidental spillage;

(b) shall be kept so far as reasonably practicable free from obstruction;

(c) if molten metal is carried in hand ladles or bull ladles by not more than two
men per ladle, shall be at least 460 millimeters wide, but where any moulds
alongside the aisle arc more than 510 millimeters above the floor of the aisle, the
aisle shall be not less than 600 millimeters wide;

(d) if molten metal is carried in hand ladles or bull ladles by more than two men
per ladle, shall be at least 760 millimeters wide;

(e) if molten metal is carried in crane, trolley or truck ladles, shall be of a width
adequate for the safe performance of the work.

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(3) Requirements of sub-paragraphs (1) and (2) shall not apply to any workroom
or part of a workroom if, by reason of the nature of the work done therein, the
floor of that workroom or, as the case maybe, that part of a work room has to be
of sand.

(4) In this paragraph "workroom to which this paragraph applies" means a part of
a ferrous or non-ferrous foundry in which molten metal is transported or used, and
a workroom to which this paragraph applies shall be deemed for the purposes of
this paragraph to have been constructed, reconstructed or converted for use as
such after the making of this schedule if the construction, reconstruction or
conversion thereof was begun after the making of this Schedule.

13. Work near cupola sand furnaces

No person shall carry out any work within a distance of four meters from a vertical
line passing through the delivery and of any spout of a cupola or furnace, being a
spout used for delivering molten metal, or within a distance of 2.4 meters from a
vertical line passing through the nearest part of any ladle which is in position at
the end of such a spout, except in either case where it is necessary for the proper
use or maintenance of a cupola or furnace that work should be carried out within
that distance of that work is being carried out at such a time and under such

conditions that there is no danger to the person carrying it out from molten metal
which is being obtained from the cupola or furnace or is in a ladle in position at
the end of the spout.

14. Dust and fumes

(1) Open coal, coke or wood fires shall not be used for heating or drying ladles
inside a workroom unless adequate measures are taken to prevent, so far as

164
practicable, fumes or other impurities from entering into or remaining in the
atmosphere of the workroom.

(2) No open coal, coke or wood fires shall be used for drying moulds except in
circumstances in which the use of such fires is un-avoidable.

(3) Mould stoves, core stoves and annealing furnaces shall be so designed,
constructed, maintained and worked as to prevent, so far as practicable, offensive
or injurious fumes from entering into any workroom during any period when a
person is employed therein

(4) All knock-out operations shall be carried out

(a) In a separate part of the foundry suitably partitioned off, being a room or part
in which, so far as reasonably practicable, effective and suitable local exhaust
ventilation and a high standard of general ventilation are provided; or

(b) In an area of the foundry in which, so far as reasonably practicable, effective

and suitable local exhaust ventilation is provided, or where compliance with this
requirement is not reasonably practicable, a high standard of general ventilation
is provided.

(5) All dressing or fettling operations shall be carried out

(a) in a separate room or in a separate part of the foundry suitably partitioned off;
or

(b) in an area of the foundry set apart for the purpose; and shall, so far as
reasonably practicable, be carried out with effective and suitable local exhaust
ventilation or other equally effective means of suppressing dust, operating as near
as possible to the point of origin of the dust.

165
15. Maintenance and examination of exhaust plant

(1) All ventilating plant used for the purpose of extracting, suppressing or
controlling dust or fumes shall be properly maintained.

(2) All ventilation plant used for the purpose of extracting, suppressing or
controlling dust or fumes shall be examined and inspected once every week by a
responsible person. This shall be thoroughly examined and tested by a competent
person at least once in every period of twelve months; and particulars of the results
of every such examination and test shall be entered in a register approved by the
Chief Inspector of Factories which shall be kept readily available for inspection by
an inspector. Any defect found on any such examination and test shall be
immediately reported in writing by the person carrying out the examination and
test to the Occupier or Manager of the Factory.

16. Protective equipment

(1) The occupier shall provide and maintain suitable protective equipment specified
for the protection of workers,

(a) suitable gloves or other protection for the hands for workers engaged in

handling any hot material likely to cause damage to the hands by burn, scald or
scar, or in handling pig iron, rough castings or other articles likely to cause damage
to the hands by cut or abrasion;

(b) approved respirators for workers carrying out any operations creating a heavy
dust concentration which cannot be dispelled quickly and effectively by the existing
ventilation arrangements.

166
(2) No respirator provided for the purposes of sub-paragraph (1) (b) has been
worn by a person shall be worn by another person if it has not since been
thoroughly cleaned and disinfected.

(3) Persons who for any of their time

(a) work at a spout of or attend to, a cupola or furnace in such circumstances that
material there from may come into contact with the body, being material at such
a temperature that its contact with the body would cause a burn; or

(b) are engaged in, or in assisting with, the pouring of molten metal; or

(c) carry by hand or move by manual power any ladle or mould containing molten

metal; or

(d) are engaged in knocking-out operations involving material at such a

temperature that its contact with the body would cause a burn; shall be provided
with suitable footwear and gaiters which worn by them prevent, so far as
reasonably practicable, risk of burns to his feet and ankles.

(4) Where appropriate, suitable screens shall be provided for protection against
flying materials (including splashes of molten metal and sparks and chips thrown
off in the course of any process).

(5) The occupier shall provide and maintain suitable accommodation for the
storage and make adequate arrangements for cleaning and maintaining of the
protective equipment supplied in pursuance of this paragraph.

(6) Every person shall make full and proper use of the equipment provided for his
protection in pursuance of sub-paragraphs (1) and (4) and shall without delay

167
report to the Occupier, Manager or other appropriate person any defect in, or loss
of, the same.

(7) Workers working in the furnace/casting pit area shall be provided with cotton
clothes. Safety shoes, leg guards, apron, face shield, hand gloves and safety
helmet.

(8) Workers employed for segregation of scrap shall be provided with safety shoes
and hand gloves

(9) Five retardant and heat retardant clothing shall be provided to all the workers
Working on platform of induction furnace

17. Training and Supervision

(1) All operations under this Schedule shall be carried out under the supervision
of qualified supervisors at all times.

(2) Workers carrying out operations and maintenance activities in foundries and
furnaces shall be adequately trained

18. Washing and bathing facilities

(1) There shall be provided and maintained in clean state and good repair for the
use of all workers employed in the foundry,

(a) a wash place under cover with either

(i) a trough with impervious surface fitted with a waste pipe without plug, and of
sufficient length to allow at least sixty centimeters for every 10 such persons
employed at any one time and having a constant supply of dean water from taps
or jets above the trough at intervals of not more than sixty centimeters; or
168
(ii) at least one taper stand pipe for every ten such persons employed at any one
time, and having a constant supply of dean water, the tap or stand pipe being
spaced not less than 1.2 meters apart; and

(b) not less than one-half of the total number of washing places provided under
clause(a) shall be in the form of bathrooms;

(c) a sufficient supply of clean towels made of suitable material changed daily,
with sufficient supply of nail brushes and soap.

(2) The facilities provided for the purposes of sub-paragraph (1) shall be placed in
charge of a responsible person or persons and maintained in a clean and orderly
condition.

19. Disposal of dross and skimming

Dross and skimming’s removed from molten metal or taken from a furnace shall
be placed forthwith in suitable receptacles.

20. Disposal of waste

Appropriate measures shall be taken for the disposal of all waste products from
shell moulding (including waste burnt sand) as soon as reasonably practicable after
the castings have been knocked-out.

21. Material and equipment left out of doors

All material and equipment left out of doors (including material and equipment so
left only temporarily or occasionally) shall be so arranged and placed as to avoid
unnecessary risk. There shall be safe means of access to all such material and
equipment and, so far reasonably practicable, such access shall be by roadways

169
or pathways or which shall be properly maintained. Such roadways or pathways
shall have a firm and even surface and shall, so far as reasonably practicable be
kept free from obstruction.

22. Medical facilities and records of examination sand tests

(1) The occupier of every factory to which the schedule applies, shall

(a) employ a qualified medical practitioner for medical surveillance of the workers
employed therein whose employment shall be subject to the approval of the

Chief Inspector of Factories; and

(b) Provide to the said medical practitioner all the necessary facilities for the
purpose referred to in sub-paragraph (a);

(2) The record of medical examinations and appropriate tests carried out by the
said medical practitioner shall be maintained in a separate register approved by
the Chief Inspector of Factories, which shall be kept readily available for inspection
by the Inspector

23. Medical Examination by Certifying Surgeon

(1) Every worker employed in a foundry shall be examined by a Certifying Surgeon

within fifteen days of his first employment. Such medical examination shall include
pulmonary function tests and chest X- ray. No worker shall be allowed to work
after fifteen days of his first employment in the factory, unless certified fit for such
employment by the Certifying Surgeon.

(2) Every worker employed in the said processes shall be re- examined by a
Certifying Surgeon at least once in every 12 months. Such examination shall,

170
wherever the Certifying Surgeon considers appropriate, include all the tests as
specified in subparagraph (1) except chest X-ray which will be once in three years.

(3) The Certifying Surgeon after examining a worker, shall issue a certificate of
fitness in Form 27. The record of examination and re-examinations carried out
shall be entered in the Certificate and the Certificate shall be kept in the custody
of the Manager of the Factory. There cord of each examination carried out under
subparagraphs (1) and (2) including the nature and the results of the tests, shall
also be entered by the Certifying Surgeon in a Health Register in Form 17.

(4) The certificate of fitness and the health register shall be kept readily available
for inspection by the Inspector.

(5) If at any time the Certifying Surgeon is of the opinion that a worker is no longer
fit for employment in the said processes on the ground that continuance therein
would involve special danger to the health of the worker, he shall make a record

of his findings in the said certificate and the health register. The entry of his
findings in those documents should also include the period for which he considers
that the said person is unfit for work in the said processes. The person so
suspended from the process, shall be provided with alternate placement facilities
unless he is fully incapacitated in the opinion of the Certifying Surgeon, in which
case the person affected shall be suitably rehabilitated.

(6) No person who has been found unfit to work as said in sub-paragraph (5)
above shall be re-employed or permitted to work in the said processes unless the

Certifying Surgeon, after further examination, again certifies him fit for
employment in those processes.

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24. Exemption

If in respect of any factory, the Chief Inspector is satisfied that owing to the
exceptional circumstances or infrequency of the processes or for any other reason,
all or any of the provisions of this schedule is not necessary for protection of the
workers in the factory, the Chief Inspector may by a Certificate in writing, which
he may at his discretion revoke at any time, exempt such factory from all or any
of such provisions subject to such conditions, if any, as he may specify therein.]

Rule 96. Notification of accidents

(1) When any accident or dangerous occurrence specified in the Schedule occurs
in a factory the manager of factory shall forthwith send notice thereof by
telephone, special messenger or telegram to the Inspector and the Chief
Inspector:

Provided that in respect of any accident or dangerous occurrence specified in sub-

item (a) of item 1 and item 2 of the Schedule, notice as a foresaid shall also be
sent to:

(a) The District Magistrate or Sub-Divisional Officer; and

(b) The Officer-in-charge of the Police Station having jurisdiction over the area:

Provided further that in respect of any accident specified in item t of the Schedule,
notice as a foresaid shall also be sent to the next of kin of the injured or deceased
person.

(2) The notice so given under sub-rule (1) in respect of an accident shall be
confirmed by the manager of the factory by sending to the above-mentioned

172
authorities within 12 hours of the accident, a separate written report in respect of
each person killed or injured in the prescribed Form No. 18.

(3) The notice so given under sub-rule (1) in respect of a dangerous occurrence
specified in paragraph 2 of the Schedule shall be confirmed by the manager of the
factory by sending to the above-mentioned authorities within 12 hours of the
dangerous occurrence a written report in the prescribed 258[Form No. 18- A]

(4) When any accident occurs in a factory which causes such bodily injury as
prevents the person injured from working for a period of 48 hours immediately
following the accident, the Manager of the factory shall send to the Inspector,
within 24 hours of the expiry of 48 hours after the occurrence of the accident, a
separate report thereof in respect of each person injured, in the prescribed Form
No.18:

Provided that it shall be open to the Chief Inspector of Factories to accept a report
in any other form if he is satisfied that the form contains all the particulars specified
in Form No. 18 aforesaid.

(5) Wherever the person injured returns to work in the factory without any
disablement before the expiry of 21 days after the occurrence of the accident, the
Manager of the factory shall send to the Inspector within 7 days of the return to
work of the person injured a written report giving the particulars of

(a) the Registration Number of the factory;

(b) the relevant serial running number of the accident in the factory for the
calendar year and calendar year as reported against item 2 in the report in
FormNo.18;

(c) the name of the person injured;

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(d) the date of accident;

(e) the date of return to work; and

(f) the number of days the person injured was away from work.

Such reports may also be sent in convenient batches for a number of accidents
together at a time within the time prescribed.

(6) Wherever the person injured does not return to work in the factory before the
expiry of 21 days after the occurrence of the accident with or without disablement
and wherever the person injured returns to work in the factory after sustaining
compensable disablement as a result of the accident, the Manager of the factory
shall send to the Inspector within 28 days of the occurrence of the accident, a

written report in the prescribed Form No. 18-B and follow it up as necessary with
further reports in the same Form No. 18-B once every fortnight thereafter, until
the final report on the date of return to work of the person injured is made. In the
event of the person injured not returning to work of his own accord or otherwise
the full circumstances of the same should also be reported to the Inspector by the
Manager of the factory within seven days of his name being removed from muster
roll of the factory.

Even if the person injured were to be covered by the Employees' State Insurance
Scheme it shall be the responsibility of the Manager of the factory to obtain the
relevant information for the purpose of this rule and Form No. 18-B and report the
same to the Inspector as prescribed.

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THE SCHEDULE

1.

(a) An accident which causes death to any person or is of such a serious nature
that it is Likely to prove fatal.

(b) An accident of a serious nature which is likely to result in loss of limbs or vision
or permanent disablement to any person.

2. The following classes of dangerous occurrence whether or not they are attended
by personal injury or disablement

(a) Bursting of a plant used for containing or supplying steam under pressure
greater than atmospheric pressure.

(b) Collapses or failure of a crane, derrick, winch, hoist or other appliance used in
raising or lowering persons or goods, or any part thereof, or the overturning of a
crane.

(c) Explosion or fire or bursting out, leakage or escape of any hot (molten) metal,
liquid or gas causing damage to any person or any room or place in which persons
are employed, or fire in rooms of cotton pressing factories when a cotton opener
is in use.

(d) Explosion of a receiver or container used for the storage at a pressure greater
than atmospheric pressure of any gas or gases (including air) or any liquid or solid
resulting from the compression of gas.

(e) collapse or subsidence of any floor, gallery, roof, bridge, tunnel, chimney, wall,
building or any other structure (f) Bursting of centrifugal machines.

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3.4 CODES OF PRACTICES:

3.4.1 ILO Conventions

C155 - Occupational Safety and Health Convention, 1981 (No. 155)

Part I. Scope And Definitions

Article 1

1. This Convention applies to all branches of economic activity.

2. A Member ratifying this Convention may, after consultation at the earliest

possible stage with the representative organisations of employers and workers

concerned, exclude from its application, in part or in whole, particular branches

of economic activity, such as maritime shipping or fishing, in respect of which

special problems of a substantial nature arise.

3. Each Member which ratifies this Convention shall list, in the first report on

the application of the Convention submitted under Article 22 of the Constitution

of the International Labor Organisation, any branches which may have been

excluded in pursuance of paragraph 2 of this Article, giving the reasons for such

exclusion and describing the measures taken to give adequate protection to

176
workers in excluded branches, and shall indicate in subsequent reports any

progress towards wider application.

Article 2

1. This Convention applies to all workers in the branches of economic activity

covered.

2. A Member ratifying this Convention may, after consultation at the earliest

possible stage with the representative organisations of employers and workers

concerned, exclude from its application, in part or in whole, limited categories

of workers in respect of which there are particular difficulties.

3. Each Member which ratifies this Convention shall list, in the first report on

the application of the Convention submitted under Article 22 of the Constitution

of the International Labour Organisation, any limited categories of workers

which may have been excluded in pursuance of paragraph 2 of this Article,

giving the reasons for such exclusion, and shall indicate in subsequent reports

any progress towards wider application.

Article 3

For the purpose of this Convention

(a) the term branches of economic activity covers all branches in which workers

are employed, including the public service;

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(b) the term workers covers all employed persons, including public employees;

(c) the term workplace covers all places where workers need to be or to go by

reason of their work and which are under the direct or indirect control of the

employer;

(d) the term regulations covers all provisions given force of law by the

competent authority or authorities;

(e) the term health , in relation to work, indicates not merely the absence of

disease or infirmity; it also includes the physical and mental elements affecting

health which are directly related to safety and hygiene at work.

Part II. Principles of National Policy

Article 4

1. Each Member shall, in the light of national conditions and practice, and in

consultation with the most representative organisations of employers and

workers, formulate, implement and periodically review a coherent national

policy on occupational safety, occupational health and the working environment.

2. The aim of the policy shall be to prevent accidents and injury to health arising

out of, linked with or occurring in the course of work, by minimising, so far as

is reasonably practicable, the causes of hazards inherent in the working

environment.

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Article 5

The policy referred to in Article 4 of this Convention shall take account of the

following main spheres of action in so far as they affect occupational safety and

health and the working environment:

(a) design, testing, choice, substitution, installation, arrangement, use and

maintenance of the material elements of work (workplaces,working

environment, tools, machinery and equipment, chemical, physical and biological

substances and agents, work processes);

(b) relationships between the material elements of work and the persons who

carry out or supervise the work, and adaptation of machinery, equipment,

working time, organization of work and work processes to the physical and

mental capacities of the workers;

(c) training, including necessary further training, qualifications and motivations

of persons involved, in one capacity or another, in the achievement of adequate

levels of safety and health;

(d) communication and co-operation at the levels of the working group and the

undertaking and at all other appropriate levels up to and including the national

level;

(e) the protection of workers and their representatives from disciplinary

measures as a result of actions properly taken by them in conformity with the

policy referred to in Article 4 of this Convention;

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Article 6

The formulation of the policy referred to in Article 4 of this Convention shall

indicate the respective functions and responsibilities in respect of occupational

safety and health and the working environment of public authorities, employers,

workers and others, taking account both of the complementary character of

such responsibilities and of national conditions and practice.

Article 7

The situation regarding occupational safety and health and the working

environment shall be reviewed at appropriate intervals, either over-all or in

respect of particular areas, with a view to identifying major problems, evolving

effective methods for dealing with them and priorities of action, and evaluating

results.

Article 9

1. The enforcement of laws and regulations concerning occupational safety and

health and the working environment shall be secured by an adequate and

appropriate system of inspection.

2. The enforcement system shall provide for adequate penalties for violations

of the laws and regulations.

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Article 10

Measures shall be taken to provide guidance to employers and workers so as to

help them to comply with legal obligations.

Article 11

To give effect to the policy referred to in Article 4 of this Convention, the

competent authority or authorities shall ensure that the following functions are

progressively carried out:

(a) the determination, where the nature and degree of hazards so require, of

conditions governing the design, construction and layout of undertakings, the

commencement of their operations, major alterations affecting them and

changes in their purposes, the safety of technical equipment used at work, as

well as the application of procedures defined by the competent authorities;

(b) the determination of work processes and of substances and agents the

exposure to which is to be prohibited, limited or made subject to authorisation

or control by the competent authority or authorities; health hazards due to the

simultaneous exposure to several substances or agents shall be taken into

consideration;

the establishment and application of procedures for the notification of

occupational accidents and diseases, by employers and, when appropriate,

insurance institutions and

181
(c) others directly concerned, and the production of annual statistics on

occupational accidents and diseases;

(d) the holding of inquiries, where cases of occupational accidents, occupational

diseases or any other injuries to health which arise in the course of or in

connection with work appear to reflect situations which are serious;

(e) the publication, annually, of information on measures taken in pursuance of

the policy referred to in Article 4 of this Convention and on occupational

accidents, occupational diseases and other injuries to health which arise in the

course of or in connection with work;

(f) the introduction or extension of systems, taking into account national

conditions and possibilities, to examine chemical, physical and biological agents

in respect of the risk to the health of workers.

Article 12

Measures shall be taken, in accordance with national law and practice, with a

view to ensuring that those who design, manufacture, import, provide or

transfer machinery, equipment or substances for occupational use,

(a) satisfy themselves that, so far as is reasonably practicable, the machinery,

equipment or substance does not entail dangers for the safety and health of

those using it correctly;

(b) make available information concerning the correct installation and use of

machinery and equipment and the correct use of substances, and information
182
on hazards of machinery and equipment and dangerous properties of chemical

substances and physical and biological agents or products, as well as

instructions on how known hazards are to be avoided;

(g) others directly concerned, and the production of annual statistics on

occupational accidents and diseases;

(h) the holding of inquiries, where cases of occupational accidents, occupational

diseases or any other injuries to health which arise in the course of or in

connection with work appear to reflect situations which are serious;

(i) the publication, annually, of information on measures taken in pursuance of

the policy referred to in Article 4 of this Convention and on occupational

accidents, occupational diseases and other injuries to health which arise in the

course of or in connection with work;

(j) the introduction or extension of systems, taking into account national

conditions and possibilities, to examine chemical, physical and biological agents

in respect of the risk to the health of workers.

Article 12

Measures shall be taken, in accordance with national law and practice, with a

view to ensuring that those who design, manufacture, import, provide or

transfer machinery, equipment or substances for occupational use,

183
(c) satisfy themselves that, so far as is reasonably practicable, the machinery,

equipment or substance does not entail dangers for the safety and health of

those using it correctly;

(d) make available information concerning the correct installation and use of

machinery and equipment and the correct use of substances, and information

on hazards of machinery and equipment and dangerous properties of chemical

substances and physical and biological agents or products, as well as

instructions on how known hazards are to be avoided;

(e) undertake studies and research or otherwise keep abreast of the scientific

and technical knowledge necessary to comply with subparagraphs (a) and (b)

of this Article.

Article 13

A worker who has removed himself from a work situation which he has

reasonable justification to believe presents an imminent and serious danger to

his life or health shall be protected from undue consequences in accordance

with national conditions and practice.

Article 14

Measures shall be taken with a view to promoting in a manner appropriate to

national conditions and practice, the inclusion of questions of occupational

safety and health and the working environment at all levels of education and

184
training, including higher technical, medical and professional education, in a

manner meeting the training needs of all workers.

Article 15

1. With a view to ensuring the coherence of the policy referred to in Article 4 of

this Convention and of measures for its application, each Member shall, after

consultation at the earliest possible stage with the most representative

organisations of employers and workers, and with other bodies as appropriate,

make arrangements appropriate to national conditions and practice to ensure

the necessary co-ordination between various authorities and bodies called upon

to give effect to Parts II and III of this Convention.

2. Whenever circumstances so require and national conditions and practice

permit, these arrangements shall include the establishment of a central body.

Part IV. Action at the Level of the Undertaking

Article 16

1. Employers shall be required to ensure that, so far as is reasonably practicable,

the workplaces, machinery, equipment and processes under their control are

safe and without risk to health.

2. Employers shall be required to ensure that, so far as is reasonably practicable,

the chemical, physical and biological substances and agents under their control

185
are without risk to health when the appropriate measures of protection are

taken.

3. Employers shall be required to provide, where necessary, adequate protective

clothing and protective equipment to prevent, so far as is reasonably

practicable, risk of accidents or of adverse effects on health.

Article 17

Whenever two or more undertakings engage in activities simultaneously at one

workplace, they shall collaborate in applying the requirements of this

Convention.

Article 18

Employers shall be required to provide, where necessary, for measures to deal

with emergencies and accidents, including adequate first-aid arrangements.

Article 19

There shall be arrangements at the level of the undertaking under which

(a) workers, in the course of performing their work, co-operate in the fulfilment

by their employer of the obligations placed upon him;

(b) representatives of workers in the undertaking co-operate with the employer

in the field of occupational safety and health; representatives of workers in an

186
undertaking are given adequate information on measures taken by the employer

to secure occupational safety and health and may consult

(c) their representative organisations about such information provided they do

not disclose commercial secrets;

(d) workers and their representatives in the undertaking are given appropriate

training in occupational safety and health;

(e) workers or their representatives and, as the case may be, their

representative organisations in an undertaking, in accordance with national law

and practice, are enabled to enquire into, and are consulted by the employer

on, all aspects of occupational safety and health associated with their work; for

this purpose technical advisers may, by mutual agreement, be brought in from

outside the undertaking;

(f) a worker reports forthwith to his immediate supervisor any situation which

he has reasonable justification to believe presents an imminent and serious

danger to his life or health; until the employer has taken remedial action, if

necessary, the employer cannot require workers to return to a work situation

where there is continuing imminent and serious danger to life or health.

Article 20

Co-operation between management and workers and/or their representatives

within the undertaking shall be an essential element of organisational and other

measures taken in pursuance of Articles 16 to 19 of this Convention.

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Article 21

Occupational safety and health measures shall not involve any expenditure for

the workers.

Part V. Final Provisions

Article 22

This Convention does not revise any international labour Conventions or

Recommendations.

Article 23

The formal ratifications of this Convention shall be communicated to the

Director-General of the International Labour Office for registration.

1. This Convention shall be binding only upon those Members of the

International Labour Organisation whose ratifications have been registered with

the Director-General.

2. It shall come into force twelve months after the date on which the ratifications

of two Members have been registered with the Director-General.

3. Thereafter, this Convention shall come into force for any Member twelve

months after the date on which its ratification has been registered.

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Article 25

1. A Member which has ratified this Convention may denounce it after the

expiration of ten years from the date on which the Convention first comes into

force, by an act communicated to the Director-General of the International

Labour Office for registration. Such denunciation shall not take effect until one

year after the date on which it is registered.

2. Each Member which has ratified this Convention and which does not, within

the year following the expiration of the period of ten years mentioned in the

preceding paragraph, exercise the right of denunciation provided for in this

Article, will be bound for another period of ten years and, thereafter, may

denounce this Convention at the expiration of each period of ten years under

the terms provided for in this Article.

Article 26

1. The Director-General of the International Labour Office shall notify all

Members of the International Labour Organisation of the registration of all

ratifications and denunciations communicated to him by the Members of the

Organisation.

2. When notifying the Members of the Organisation of the registration of the

second ratification communicated to him, the Director-General shall draw the

189
attention of the Members of the Organisation to the date upon which the

Convention will come into force.

Article 27

The Director-General of the International Labour Office shall communicate to

the Secretary-General of the United Nations for registration in accordance with

Article 102 of the Charter of the United Nations full particulars of all ratifications

and acts of denunciation registered by him in accordance with the provisions of

the preceding Articles.

Article 28

At such times as it may consider necessary the Governing Body of the

International Labour Office shall present to the General Conference a report on

the working of this Convention and shall examine the desirability of placing on

the agenda of the Conference the question of its revision in whole or in part.

Article 29

1. Should the Conference adopt a new Convention revising this Convention in

whole or in part, then, unless the new Convention otherwise provides:

(a) the ratification by a Member of the new revising Convention shall ipso jure

involve the immediate denunciation of this Convention, notwithstanding the

190
provisions of Article 25 above, if and when the new revising Convention shall

have come into force;

(b) as from the date when the new revising Convention comes into force this

Convention shall cease to be open to ratification by the Members.

2. This Convention shall in any case remain in force in its actual form and

content for those Members which have ratified it but have not ratified the

revising Convention.

Article 30

The English and French versions of the text of this Convention are equally

authoritative.

3.2.7 ILO CONVENTIONS

C161 - Occupational Health Services Convention, 1985 (No. 161)

Part I. Principles of National Policy

Article 1

For the purpose of this Convention-

(a) the term occupational health services means services entrusted with

essentially preventive functions and responsible for advising the employer, the

workers and their representatives in the undertaking on-

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(i) the requirements for establishing and maintaining a safe and healthy working

environment which will facilitate optimal physical and mental health in relation

to work;

(ii) the adaptation of work to the capabilities of workers in the light of their state

of physical and mental health;

(b) the term workers' representatives in the undertaking means persons who

are recognized as such under national law or practice.

Article 2

In the light of national conditions and practice and in consultation with the most

representative organizations of employers and workers, where they exist, each

Member shall formulate, implement and periodically review a coherent national

policy on occupational health services.

Article 3

1. Each Member undertakes to develop progressively occupational health

services for all workers, including those in the public sector and the members

of production co-operatives, in all branches of economic activity and all

undertakings. The provision made should be adequate and appropriate to the

specific risks of the undertakings.

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2. If occupational health services cannot be immediately established for all

undertakings, each Member concerned shall draw up plans for the establishment

of such services in consultation with the most representative organisations of

employers and workers, where they exist.

3. Each Member concerned shall indicate, in the first report on the application

of the Convention submitted under article 22 of the Constitution of the

International Labour Organisation, the plans drawn up pursuant to paragraph 2

of this Article, and indicate in subsequent reports any progress in their

application.

Article 4

The competent authority shall consult the most representative organisations of

employers and workers, where they exist, on the measures to be taken to give

effect to the provisions of this Convention.

Part II. Functions

Article 5

Without prejudice to the responsibility of each employer for the health and

safety of the workers in his employment, and with due regard to the necessity

for the workers to participate in matters of occupational health and safety,

Part III. Action at The National Level

193
Article 8

Each Member shall, by laws or regulations or any other method consistent with

national conditions and practice and in consultation with the representative

organisations of employers and workers concerned, take such steps as may be

necessary to give effect to Article 4 of this Convention. Occupational health

services shall have such of the following functions as are adequate and

appropriate to the occupational risks of the undertaking:

(a) identification and assessment of the risks from health hazards in the

workplace;

(b) surveillance of the factors in the working environment and working practices

which may affect workers' health, including sanitary installations, canteens and

housing where these facilities are provided by the employer;

(c) advice on planning and organisation of work, including the design of

workplaces, on the choice, maintenance and condition of machinery and other

equipment and on substances used in work;

(d) participation in the development of programmes for the improvement of

working practices as well as testing and evaluation of health aspects of new

equipment;

(e) advice on occupational health, safety and hygiene and on ergonomics and

individual and collective protective equipment;

194
(f) surveillance of workers' health in relation to work; (g) promoting the

adaptation of work to the worker;

(g) contribution to measures of vocational rehabilitation;

(h) collaboration in providing information, training and education in the fields of

occupational health and hygiene and ergonomics;

(i) organizing of first aid and emergency treatment;

(j) Participation in analysis of occupational accidents and occupational diseases.

Part III. Organisation

Article 6

Provision shall be made for the establishment of occupational health services-

(a) by laws or regulations; or

(b) by collective agreements or as otherwise agreed upon by the employers and

workers concerned; or

(c) in any other manner approved by the competent authority after consultation

with the representative organisations of employers and workers concerned.

Article 7

1. 1. Occupational health services may be organised as a service for a single

undertaking or as a service common to a number of undertakings, as

appropriate.

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2. 2. In accordance with national conditions and practice, occupational health

services may be organized by-

(a) the undertakings or groups of undertakings concerned;

(b) public authorities or official services;

(c) social security institutions;

(d) any other bodies authorized by the competent authority;

(e) a combination of any of the above.

Article 8

The employer, the workers and their representatives, where they exist, shall

cooperate and participate in the implementation of the organisational and other

measures relating to occupational health services on an equitable basis.

Part IV. Conditions of Operation

Article 9

1. In accordance with national law and practice, occupational health services

should be multidisciplinary. The composition of the personnel shall be

determined by the nature of the duties to be performed.

2. Occupational health services shall carry out their functions in co-operation

with the other services in the undertaking.

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3. Measures shall be taken, in accordance with national law and practice, to

ensure adequate co-operation and co-ordination between occupational health

services and, as appropriate, other bodies concerned with the provision of

health services.

Article 10

The personnel providing occupational health services shall enjoy full

professional independence from employers, workers, and their representatives,

where they exist, in relation to the functions listed in Article 5.

Article 11

The competent authority shall determine the qualifications required for the

personnel providing occupational health services, according to the nature of the

duties to be performed and in accordance with national law and practice.

Article 12

The surveillance of workers' health in relation to work shall involve no loss of

earnings for them, shall be free of charge and shall take place as far as possible

during working hours.

Article 13

All workers shall be informed of health hazards involved in their work.

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Article 14

Occupational health services shall be informed by the employer and workers of

any known factors and any suspected factors in the working environment which

may affect the workers' health.

Article 15

Occupational health services shall be informed of occurrences of ill health

amongst workers and absence from work for health reasons, in order to be able

to identify whether there is any relation between the reasons for ill health or

absence and any health hazards which may be present at the workplace.

Personnel providing occupational health services shall not be required by the

employer to verify the reasons for absence from work.

Part V. General Provisions

Article 16

National laws or regulations shall designate the authority or authorities

responsible both for supervising the operation of and for advising occupational

health services once they have been established.

Article 17

The formal ratifications of this Convention shall be communicated to the

Director-General of the International Labour Office for registration.

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Article 18

1. This Convention shall be binding only upon those Members of the

International Labour Organisation whose ratifications have been registered with

the Director-General.

2. It shall come into force twelve months after the date on which the ratifications

of two Members have been registered with the Director-General.

3. Thereafter, this Convention shall come into force for any Member twelve

months after the date on which its ratification has been registered.

Article 19

1. A Member which has ratified this Convention may denounce it after the

expiration of ten years from the date on which the Convention first comes into

force, by an act communicated to the Director-General of the International

Labour Office for registration. Such denunciation shall not take effect until one

year after the date on which it is registered.

2. Each Member which has ratified this Convention and which does not, within

the year following the expiration of the period of ten years mentioned in the

preceding paragraph, exercise the right of denunciation provided for in this

Article, will be bound for another period of ten years and, thereafter, may

denounce this Convention at the expiration of each period of ten years under

the terms provided for in this Article.

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Article 20

1. The Director-General of the International Labour Office shall notify all

Members of the International Labour Organisation of the registration of all

ratifications and denunciations communicated to him by the Members of the

Organisation.

2. When notifying the Members of the Organisation of the registration of the

second ratification communicated to him, the Director-General shall draw the

attention of the Members of the Organisation to the date upon which the

Convention will come into force.

Article 21

The Director-General of the International Labour Office shall communicate to

the Secretary-General of the United Nations for registration in accordance with

Article 102 of the Charter of the United Nations full particulars of all ratifications

and acts of denunciation registered by him in accordance with the provisions of

the preceding Articles.

Article 22

At such times as it may consider necessary the Governing Body of the

International Labour Office shall present to the General Conference a report on

200
the working of this Convention and shall examine the desirability of placing on

the agenda of the Conference the question of its revision in whole or in part.

Article 23

1. Should the Conference adopt a new Convention revising this Convention in

whole or in part, then, unless the new Convention otherwise provides-

(a) the ratification by a Member of the new revising Convention shall ipso jure

involve the immediate denunciation of this Convention, notwithstanding the

provisions of Article 19 above, if and when the new revising Convention shall

have come into force;

(b) as from the date when the new revising Convention comes into force this

Convention shall cease to be open to ratification by the Members.

2. 2. This Convention shall in any case remain in force in its actual form and

content for those Members which have ratified it but have not ratified the

revising Convention.

Article 24

The English and French versions of the text of this Convention are equally

authoritative

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3.5 About Hazard Identification and Risk Assessment:

Hazard and risk

Hazard and risk are used interchangeably in everyday speech; consequently, to

avoid confusion when carrying out a risk assessment, both terms need to be

clearly defined and differentiated.

A hazard is anything that has the potential to cause harm, whether to the

detriment of the health or safety of a person, or damage to property, equipment

or the environment. The potential for harm is inherent in the substance or

machine or poor work practice, etc.

A hazard can, therefore, be anything – work materials, equipment (e.g.

machinery, tools, etc.), dangerous substances (dust, disease-causing micro-

organisms, chemicals, pesticides, noise, etc.), transport, by- products, poor

workplace layout, poor work organization, methods or practices, attitudes – that

has the potential to cause harm, injure people and/or damage their health.

There are an unlimited number of hazards that can be found in almost any

workplace. (See activity 1 on identifying hazards in the workplace.)

Risk is the chance or probability that a hazard will actually result in injury or

illness or damage to property, equipment or the environment, together with an

indication of how serious the harm could be, including any long- term

consequences

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 Risk = severity of harm x probability of harm

It is a combination of the probability (likelihood) of an occurrence of a hazardous

event and the severity of injury or damage caused by this event.

While hazards are intrinsic to a given substance or process, risks are not and so
will vary depending on the levels of risk reduction measures applied. For
example, pesticides are intrinsically toxic – they are hazardous – and spraying
them may pose serious health risks to farmers or farm workers. But where
those hazards are properly controlled, the risks can be reduced to acceptable
levels.

Similarly, 220volt mains electricity is also intrinsically hazardous but using safety
devices such as protective insulation sheathing, circuit breakers, fuses, residual
current devices and voltage transformers can reduce the risks to acceptable levels.

When deciding on the acceptability of risk, it is important to take into account the
gender, age and health of the workers for whom the assessment is being
conducted and also to bear in mind their input.

The difference between safety and health

When carrying out a risk assessment, the different nature of safety hazards and
risks and health hazards and risks has to be taken into account. This is especially
the case when evaluating the long-term health consequences of exposure to
workplace hazards and in the determination of appropriate risk controls.

Health hazards and the resulting risks are often less evident and, therefore, less
straightforward for an employer to deal with. Health problems caused by work
can develop unnoticed and, in some cases, may not appear until much later in
life. Early diagnosis and treatment may prevent a person’s condition from
worsening and may even save a life. The effects of repeated, often low dose,

203
exposure to a hazard over weeks, months and years – also have to be taken into
consideration. Examples include:

Exposure to chemical pesticides (insecticides, fungicides, herbicides, etc.). In

addition to poisoning (an immediate or “acute” health effect) some pesticides can
result in cancers, which can take as many as 20 years or more to show up. Such
effects are often associated with repeated, low- dose exposure.

Exposure to organic crop or animal dust can result in asthma, which again may
take years to develop. This too is often associated with repeated exposure and
may result in recurring, long-term illness/asthma attacks.

Carrying heavy and awkward loads over many years may result in permanent pain
and physical disability or impairment in later life.

Permanent disabilities or illnesses are referred to technically as “chronic” health

problems, meaning that they cannot be fully cured or “reversed”.

Stress at work:

The effects of stress are another area that may have to be considered in a
risk assessment. Stress is often not easy to define, and again its effects on
health may be long-term. Stress is part of what are often termed
“psychosocial hazards.”

The scope of a risk assessment

Depending on the size and complexity of the business or enterprise, and the
range of hazards (dangers) involved, the risk assessment can vary in scope.
The risk assessment may be used to evaluate safety and health at the level
of:

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The enterprise as a whole, covering all activities or processes and all the
workers.

A specific section of the workplace, e.g. a machine repair shop, covering a

specific group or number of workers.

A specific dangerous activity or process, e.g. problems with handling heavy

loads, which may pose a danger to specific group, groups or numbers
of workers

The business in terms of occupational safety and health

Different terms are sometimes used to refer to a business or enterprise and

its components. In safety and health terms, a “workplace” is considered as
anything from an agricultural field, farmyard, construction site, small
workshop, to a large machine shop in a factory or storage area in a
warehouse. The term “undertaking” often refers to the larger unit, or to the
whole “enterprise”. It may be necessary to decide at which level the risk
assessment should be carried out; whether this is at the level of the undertaking,
which may be made up of a series of work-places, a farm with a series of fields
or a factory with a series of different sections, for example, or at an individual
workplace. If a business is small, there may only be one workplace and so the
terms “workplace” and “undertaking” would, in this case, be identical.

workplace is shared?

If you share a workplace with another employer, or a self-employed person,

you will both need to:

205
tell each other about the specific risks in your business that may affect the
other employer; and cooperate and coordinate with each other to control
the safety and health risks.

Telling the other employers and self-employed people present in any

particular workplace about the risks to which your work could expose them,
and what risk control measures you are taking, is essential. You must also
think about the risks to your own workforce from those who share your
workplace.

Where workers from different enterprises work in the same workplace, those
assigned to carry out the risk assessments from each employer will need to
share information about the risks and the measures needed to tackle these
risks.

Risk Assessment

A workplace safety and health risk assessment is essentially a careful

examination of what, in your work or business, could cause injury or ill
health to people. It allows you to weigh up whether you have
implemented enough risk control measures or should do more to prevent
harm to those at risk, including workers and members of the public. The aim
is to make sure that no one gets hurt or falls ill.

A risk assessment involves identifying the hazards present in a business

(whether arising from work activities or from other factors, for example the
layout of the premises) and then weighing up the extent of the risks
involved, taking into account existing control measures already in place to
reduce the risks and deciding if you have to do more to ensure that no one
is harmed.

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The results of a risk assessment should help employers choose which good
practice measures, in the form of risk controls, are most appropriate.
Workers and others have a right to be protected from harm caused by an
employer’s failure to take reasonable risk control measures. The law does
not expect you to eliminate risk but it does require you to protect people as
far as you can. Doing the assessment and taking action is what
matters.

A risk assessment involves dealing with the levels of risk in the actual
conditions present at the time the risk assessment is carried out. It is
important to identify who may be at risk and the safety and health
consequences for EACH hazard separately as different risk control measures
to pre-vent or reduce the probability (likelihood) and severity of harm will
be required for each hazard.

The key to risk assessment is: do not overcomplicate the process. In carrying out
a risk assessment it is important to focus, and decide, on the risk control measures
that you need to put in place to make working conditions in your business safer
and healthier. Avoid getting bogged down or lost in lengthy discussions on the
degree of risk. Concentrate on deciding on the risk control measures and how to
put them in place and make them operational. The risks in SMEs are especially
familiar and the necessary risk control measures are also well known and easy to
ap-ply – you probably already know whether, for example, you have workers who
move heavy loads and so could harm their backs, or where people are most
likely to slip or trip. If so, check that you have reasonable risk control
measures in place to avoid injury. You can try to do it yourself, while involving
managers and workers. Involve as many workers as possible, in order to
encourage them to share ownership of the finished assessments.

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Risk assessment – a five-step process

The simplest and most straightforward way to carry out a risk assessment
is for the employer – or designated representative(s) – with the active
involvement of the entire workforce, to follow these five steps using the
template provided below:

Step 1: Identify the hazards.

Step 2: Identify who might be harmed and how.

Step 3: Evaluate the risk – identify and decide on the safety and health risk
control measures, involving two sub-steps:

Step 3.A: Identify what you are already doing in terms of existing risk
control measures

Step 3.B: Identify what further risk control measures are necessary

For sub-Steps 3.A. and 3.B., the risk control measures should be considered
and decided on, using the “hierarchy of risk control measures” in the
following order:

Risk Control Measure 1: Elimination or substitution of hazards

Risk Control Measure 2: Tools, equipment, technology and engineering

Risk Control Measure 3: Safe work methods, practices, organization,

information and training

Risk Control Measure 4: Hygiene and welfare

Risk Control Measure 5: Personal protective equipment

Risk Control Measure 6: Health/medical surveillance

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Step 4: Record who is responsible for implementing which control
measures and the timeframe. Implement the safety and heal th risk control
measures (deciding who is responsible for doing what, and by when).

Step 5: Monitor and review your risk assessment, and update when
necessary.

Risk assessment template

A model risk assessment form is provided overleaf for you to copy or adapt
and use, and is based on the above five steps. Examples of risk assessment
for various occupational sectors (see Part III) use this template format.
In the following pages we have used a simplified version to guide you
through the steps of the risk assessment.

Organize the risk assessment; select the person(s) to carry out the
assessment and ensure that they are competent.

Assess the risks and implement protective measures.

Consult the workers or their representatives about the organization of the

risk assessment, as well as the persons carrying out the assessment
and implementing the preventive measures.

Be in possession of an assessment of the risks.

Draw up assessment records, having first consulted the workers and/or their
representatives, or even having involved them in the work and making the
records available to them.

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Ensure that everyone affected is informed about any hazard, any harm to
which they may be at risk and all the protective measures taken to prevent
such harm.

If you, as an employer, do not feel particularly confident in your ability to

undertake a risk assessment, you can designate competent workers to carry
out activities designed to prevent injuries and ill-health at work, or provide
protection from risks of any type.

If you do designate a representative to carry out the risk assessment, the

person or persons should be “competent” for the task competent in the

Who carries out the risk assessment?

In many countries, the risk assessment is essentially the responsibility of

the employer. The employer has a duty to:

Ensure the safety and health of workers in every aspect related to work.

Organize the risk assessment; select the person(s) to carry out the
assessment and ensure that they are competent.

Assess the risks and implement protective measures.

Consult the workers or their representatives about the organization of the

risk assessment, as well as the persons carrying out the assess ment
and implementing the preventive measures.

Be in possession of an assessment of the risks.

Draw up assessment records, having first consulted the workers and/or their
representatives, or even having involved them in the work and making the
records available to them.

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Ensure that everyone affected is informed about any hazard, any harm to
which they may be at risk and all the protective measures taken to prevent
such harm.

If you, as an employer, do not feel particularly confident in your ability to

undertake a risk assessment, you can designate competent workers to carry
out activities designed to prevent injuries and ill-health at work, or provide
protection from risks of any type.

If you do designate a representative to carry out the risk assessment, t he

person or persons should be “competent” for the task competent in the
sense that they have a good knowledge of the workplace and work
processes, know where to find and how to make use of good practice and have
your authority behind them. A competent person is someone who has a
thorough knowledge of the tasks involved and of the working environment, the
ability to identify hazards and types and levels of risk, and an understanding of
the necessary risk controls and how to put them into practice, as well as the
authority to do so

Where such in house expertise is not available, you can employ the services
of a competent external person to help. In such a case, you would need to
check that they are familiar with specific work activities and have the abili ty
to assess them.

For the purposes of SMEs, in most circumstances the persons carrying out
the risk assessments do not need to be safety and health experts, but they
can demonstrate their competence by showing they have:

An understanding of the general approach to risk assessment.

The capacity to apply this to the workplace and the task at hand. This may
require:

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a. identifying safety and health problems;

b. assessing and prioritizing the need for action;

c. suggesting options available to eliminate or reduce risks and their relative

merit;

d. evaluating their effectiveness;

e. promoting and communicating safety and health improvements and good

practices.

The ability to identify situations in which they would be unable to adequately

assess the risk without help and the ability to advise on the need for further
assistance.

Active participation of the workforce .Remember that your risk assessment

should always be carried out with the active involvement of the workers.
The workers are often well aware of the hazards they face and tend to have
ideas and suggestions on how best to control the risks arising from these
hazards. They can help to come up with practical and cost-effective solutions
to implement.

It is not the responsibility of the workers to carry out a risk assessment –

this is the responsibility of the employer – but their active involvement will
make for a better risk assessment and more accurate and cost-effective risk
controls.

Risk assessments should not be carried out by the employer or t he

employer’s representative working in isolation. They should involve
workers and/or the worker representatives. Workers should be consulted as

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part of the assessment process itself and given information on any
conclusions reached, as well as on the risk control measures to be taken.

STEP 1: IDENTIFY THE HAZARDS

The first step of a risk assessment is to survey all the areas of the workplace
and identify any hazards – that is, those things that have the potential to
cause harm. This is one of the most important steps in the risk assessment
process. A hazard that is not identified cannot be managed. Consequently,
it is crucial that this step is as comprehensive as possible.

When you work in a place every day, it is easy to overlook some hazards,
so here are some tips to help you identify the ones that matter:

As an employer, or a designated worker or external service, you should:

Walk around your workplace and look at what could reasonably be expected
to cause harm.

Identify which work activities and processes are the most dangerous/hazardous,
and in which parts of the workplace (you may find it useful to use a checklist; in
any case, it is important to take notes to enable an eventual written risk
assessment to be drawn up).

Ask your workers, or their representatives, what they think about the
dangers of the jobs they carry out, and how workplace accidents and ill
health can be prevented. They may have noticed things that are not
immediately obvious to you or to an external service.

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Learn from experience of previous accidents and work-related ill health.
These often help to identify the less obvious hazards.

Remember to think about long-term hazards to health (e.g. high levels of

noise or exposure to harmful substances), as well as safety hazards.

If you are a member of a trade association, contact it. Many provide very
helpful guidance. Check manufacturers’ instructions or data sheets for
chemicals and equipment as they can be very helpful in signaling the
hazards and putting them in their true perspective.

Ask your workers if they can think of any hazard you have not identified or
any worker at potential risk that you may have missed.

STEP 2: IDENTIFY WHO MIGHT BE HARMED AND HOW

For EACH hazard that you have identified – and there might be many – you
need to be clear about who might be harmed and how. This means
identifying groups of your workers, and others such as the public, who are
at risk of exposure to the hazards, how they are at risk, and the
potentially negative consequences for their safety and health.

Risk assessment does not mean listing everyone by name but rather
identifying groups of people who are at risk of harm from a given hazard.
For example, it is sufficient to say “staff working in the woodworking
section” or “staff in the repair workshop” or “staff in the storeroom” or ”staff
working in the agricultural field gang” or “young workers”. If known, it would
also be useful to mention the numbers in each group.

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You may also need to identify “others” who may be at risk of harm from the
hazard you have identified. For example, people delivering supplies to your
workplace or collecting finished products; cleaners or those carrying out
maintenance or repair work in your enterprise; clients; and members of the
public at risk from your work activities (e.g. passers-by on streets where
buildings are being constructed or renovated). These should be considered
as persons at risk, but attention should also be paid as to whether their
presence may introduce new risks into the workplace.

You also need to be clear about how people might be harmed. What type of
injury or ill health problems might result among the group of workers

and/or others from the hazard you have identified. You need to assess their
immediate safety and the possible consequences on their health, as well as
longer-term consequences, namely health problems that may only appear
or become damaging later in life It is also important that you think about
groups of workers who may have particular safety and health vulnerabilities.
New or young workers, new or expectant mothers, and people with dis -
abilities may be at particular risk, for example.

As already mentioned, it is important to identify the safe ty and health

consequences for EACH hazard and anyone who may be at risk and how –
separately – as different risk control measures aimed at reducing the
probability and severity of harm will be required for each hazard.

In the table below, we continue filling in the example of the woodworking

workplace with the second step of the risk assessment. For each hazard
identified, the corresponding group(s) of workers who may be exposed to
the hazard need to be identified and recorded. Remember that this is a
hypothetical situation, offered for example only.

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STEP 3: EVALUATE THE RISK – IDENTIFY AND DECIDE ON THE SAFETY
AND HEALTH RISK CONTROL MEASURES

In Step 1, you identified the hazards and in Step 2 the different groups who
might be harmed, as well as the numbers involved in each group, paying
special attention to groups such as young workers, new or expectant
mothers, and workers with disabilities.

For each hazard identified, the core activity in risk assessment is to

identify, decide on, and implement the safety and health risk controls
following the order in which they are listed in what is termed the
“hierarchy of risk control measures”.

The hierarchy of risk control measures used in this training package has six
levels:

Risk Control Measure 1: Elimination or substitution of hazards

Risk Control Measure 2: Tools, equipment, technology and engineering

Risk Control Measure 3: Safe work methods, practices, organization,

information and training

Risk Control Measure 4: Hygiene and welfare

Risk Control Measure 5: Personal protective equipment

Risk Control Measure 6: Health/medical surveillance

The hierarchy of risk control measures has been developed by employers,

workers, labour inspectors, safety and health practitioners, and others
based on sound experience over many years. A worked example on
pesticide spraying in a coffee plantation (see page 31) makes use of this

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hierarchy of risk control measures and is included to help make the process
clearer.

The reason for deciding on and implementing the risk control measures in
the order in which they are listed in the hierarchy is first to identify and
decide on collective risk controls as they protect the work area and the
people working in it – before moving on to consider individual risk
controls, which simply protect an individual. For example, workers’ health
will be better protected against exposure to harmful dust if your risk
assessment first identifies dust extraction machinery as the main risk
control.

This gives collective protection to the work area and all per -sons in it rather
than relying solely on dust masks for individual workers, which will generally
not give anywhere near the same degree of lung protection, and, in
addition, offers a limited degree of protection to the worker wearing it.
Similarly, soundproofing a noisy machine controls noise more effectively
than individual ear protection and avoids workers having to wear such

Protection for their whole work shift.

It must be pointed out that Risk Control Measure 6 on health/medical

surveillance is not strictly a means of protection against exposure to
hazards, but is more a monitoring tool to ensure the measures of
protection are functioning adequately to prevent work-related illnesses. It can
reduce the effects of risks if illnesses are diagnosed and action taken to reduce
exposure before the illness develops further to a chronic or more serious
level.

At this stage in the risk assessment, Step 3 consists of two parts, both of
which use the hierarchy of risk control measures:

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Step 3.A: What are you already doing in terms of existing risk control
measures?

It is very likely that for some of the hazards identified you will already have
certain safety and health risk control measures in place. In this case, for
each hazard your risk assessment should identify and evaluate how effective
these existing measures are in reducing safety and health risks to workers
and other people. This means that you should evaluate and give your
informed opinion on how effective you believe these existing risk control
measures to be.

Identifying and evaluating the effectiveness of existing risk control measures

will also help you determine, in a more efficient and cost- effective manner,
which further risk control measures – if any – may be needed for a given
hazard.

If you conclude in Step 3.A that your existing risk control measures for a
given hazard provide adequate protection for workers, then no extra
controls or expenditure are needed for this particular hazard. So for this hazard
you can mark “No further action at this stage”

If you decide that your existing risk control measures for a particular hazard are
either absent or do not sufficiently reduce the risk of harm, you then proceed to
Step 3.B and identify and decide “What further risk controls are needed?” and
then implement them.

Step 3.B: What further risk control measures are needed? How to use the
hierarchy of risk control measures For each hazard identified, you should start
Step 3 of the assessment with Risk Control •Measure 1 and work your way through
to Risk Control Measure 6.

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Risk Control Measure 1:

Elimination or substitution of hazards start by considering Risk Control Measure

1, which is the best means of protection because eliminating or substituting the
hazard means you have effectively reduced the risk of exposure of anyone to the
hazard, and thus of being seriously harmed, to zero or as near to zero as possible.

Examples of Risk Control Measure 1 include:

Farming organically, in order to avoiding using a toxic pesticide.

Switching to a less toxic pesticide, or substituting a liquid pesticide which is

sprayed to one in granular form.

Trying a less risky option using different substances or work processes. The
process might be changed from one that uses a hazardous substance to one that
does not, such as using a water-based paint instead of a solvent based paint.

Some machine tools can be replaced with tools that are intrinsically safer, for
example using a pneumatic tool instead of an electrical one. Asbestos can be
effectively substituted by safer alternatives, of which there are many on the
market.

Replacing a noisy machine with a quieter one. On tall buildings, redesigning

windows so that they can be cleaned from the inside rather than relying on
potentially hazardous external access.

If you can successfully implement the measures identified in your Risk Control
Measure 1, then your risk assessment for the particular hazard STOPS HERE as
you have reduced the risk to zero, or as near as possible. Consequently, for this

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hazard only, you do not need to carry on identifying, deciding on and putting
into place Risk Control Measures 2 to 6.

If, however, in your risk assessment you decide that elimination or substitution is
not possible, you must then move on to considering the other risk control
measures that you need to identify, decide upon and put in place, starting with
Risk Control Measure 2 and working through to Risk Control Measure 6.

Risk Control Measure 2: Tools, equipment, technology and engineering

Where elimination or substitution is not possible, the next best solution is

to consider which tools, equipment, technology and engineering measures
can help reduce the risk from the hazard identified. Risk Control 2 measures
are good because they provide collective protection of the work area rather
than just protection for the individual.

Looking at good practice and seeking good advice can be very important in
respect of Risk Control Measure 2. Examples of such initiatives,
including some very simple and inexpensive measures, include:

Guarding of machinery – if adequate protection is not provided by the

manufacturer or if the machine is built to an old standard, improved
guarding will be needed.

Fitting noisy machines with a soundproofed enclosure, in order to reduce

noise levels, even if some risks do remain.

Completely isolating and/or enclosing some hazardous processes, for

example X-ray equipment or the solvent gluing section in a workshop Putting
a handrail around a high work platform Using something as simple as a
wheelbarrow or hand cart to carry heavy loads.

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Having work surfaces or work benches at correct heights for the people
working there, and providing suitable seating.

Using tools that are the correct height for the person, e.g. spade, shovels,
brushes, so that people do not have to bend unnecessarily.

Using sealed mixing and filling systems for chemicals and pesticides. Using simple
dust extracting equipment – local exhaust ventilation. Providing good lighting.
Often, simple, cost-effective equipment, tools, technology, or engineering will
drastically reduce the risk of harm from a hazard for the group or groups of
persons at risk, not simply for the individual.

Risk Control Measure 3: Safe work methods, practices, organization, information

and training

Your risk assessment will also need to examine and consider safe work methods
and practices, how the work can be organized, as well as training and
information requirements. Once again, you need to identify what you are already
doing and what extra control measures may need to be taken.

One of the simplest and most cost-effective ways of controlling risks at work is
for businesses to develop and implement safe methods and practices of work,
linked to information and training, sometimes referred to collectively as “safe
systems of work”. Many work accidents, and much ill health, occur simply
because the employer has not thought through and implemented safe work
methods, practices and organization, and managers, supervisors and workers are
not well informed about, or properly trained to implement, correct safety and
health procedures

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Organizing the job safely is well within the competence of employers, their
managers and super-visors, working together with the workforce. Risk control
measures are often simple and easy to put into operation; moreover, improving
safety and health and its organization is not costly and also promotes business
efficiency.

Examples of measures that can be taken under Risk Control Measure 3 include:
Ensuring clear procedures and instructions, written if necessary, on how to
operate machinery or carry out other tasks safely – for your workers, supervisors
and managers.

Providing appropriate safety and health information – instruction manuals, clear

labels on containers, warning signs, safety data sheets for chemicals, etc.

Planning or redesigning the layout of your workplace/enterprise – to avoid, for

example, workers having to cross in front of forklift trucks or other moving
vehicles, which will lessen the risk of being run into or run over.

Better housekeeping – keeping your workplaces tidy, and passages clear of

objects and clutter; wetting dust before sweeping it up.

Ensuring that your supervisors or managers are adequately instructed and trained
for the work they have to manage on your behalf, including training on,
and input into, workplace risk assessments.

Clear procedures and instructions for your supervisors and managers to follow.

Ensuring your supervisors and managers have sufficient authority to keep safety
and health standards up to scratch.

Ensuring there are procedures in place, for example if you, the boss, are away
from the work-place and the guard on a dangerous machine breaks.

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Ensuring your supervisors or managers have been instructed, and have the
authority, to stop the work on that machine until the guard has been repaired or
replaced

Ensuring that your supervisors and managers have the authority and means to
order a new guard in your absence.

Providing regular safety and health training for your workers, including training
on risk assessment.

Improving participation of and input from your workers in workplace risk

assessments, including implementation of risk control measures identified in the
risk assessment(s).

Providing specialized training for high risk work activities.

Risk Control Measure 4: Hygiene and welfare

In your risk assessment you next have to evaluate and decide if your existing
hygiene and welfare facilities are adequate to cope with the risks from the hazards
you have identified or if you need to do more. Most of these measures are not
strictly a means of protection against exposure to hazards, but they can reduce
the effects of hazards and they can make work more pleasant. Improving hygiene
and welfare can, for example, be done by:

Providing basic washing and sanitary facilities at the workplace.

Storing contaminated work clothing in a locker at work and not allowing

workers to take such clothing to their homes.

Providing simple first aid equipment and training certain workers to use it.

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Providing clean water and simple first aid for those of your workers working in an
agricultural crop field or on a construction site.

Risk Control Measure 5: Personal protective equipment

You then move on to consider Risk Control Measure 5. Apart from standard
items like boots and overalls, personal protective equipment (PPE) is one of the
last safety and health risk control measure for you to consider and exists only to
augment the other risk controls measures you have already put in place.

The idea is to keep the use of PPE to a minimum and not to use it as the main
method of protecting safety and health or require workers to wear/use it for long
periods. Your risk assessment should already have identified the combination of
risk control measures 2 to 4, which should provide adequate protection for the
groups of people who could be harmed. For example, if you have adequately
controlled the noisy machinery to safe levels there is no need for you to provide
ear plugs for your workers or for them to have to use them. Equally, if your dust
extraction equipment (local exhaust ventilation) is effective, there is no need for
workers to wear dust masks.

Unfortunately, PPE is often the first and only risk control measure considered and
provided. Much of it does not provide adequate safety and health protection. It
is uncomfortable to wear or use for long periods and often does not fit the user
well. People are of different shapes, sizes and genders – one size does not fit all

Personal protective equipment includes: Coveralls; Eye protection; Footwear;

Gloves; Hearing protection; Dust or chemical respirators; Disposable dust masks;
Safety helmets; Wet/cold-weather clothing.

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If, in your risk assessment, you judge that PPE is needed, the assessment should
include details of the types of PPE to be provided and the protection factor
for each item provided, whether these are gloves, dust masks, chemical
respirators or other equipment. You should also indicate in the assessment how
the PPE will be cleaned and maintained, and how often it should be replaced.
Remember that any PPE required should be provided at no cost to the worker.

Look at good practice and, if necessary, seek advice when selecting PPE.

When considering PPE, remember:

You need to consider and introduce other means of risk control first. Provide PPE
only as a last resort after putting into place the other risk control measures
identified in your risk assessment. PPE should never be the first, or only, line of
worker protection.

Technical and engineering controls (Risk Control Measure 2) provide long-term

collective solutions and are often cheaper than providing, replacing, maintaining
and storing PPE for many individual workers.

Collective protection measures protect all workers in the area, while

PPE only protects the individual wearer.

It is essential to involve your workers in the selection process as they often have
detailed knowledge of the way things work, where things may be malfunctioning
or the way tasks are carried out, all of which can help you.

Risk Control Measure 6: Health/medical surveillance

In your risk assessment, you may also need to consider if any health or medical
surveillance measures provided by qualified medical personnel are needed for
workers at high risk.

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As already mentioned, health and medical surveillance is not strictly a means of
protection against exposure to hazards, but is more a monitoring tool to
ensure the measures of protection are functioning adequately to prevent work-
related illnesses. However, it can help in mitigating the risk. Despite all your
efforts to control exposure to hazardous substances (e.g. chemicals dust,
micro-organisms and noise), some workers may still experience symptoms of
ill health, often later in life. You may need health/medical surveillance to monitor
and detect early signs of ill health, especially if workers are exposed to (for
example): Dusts that may cause asthma or other long-term lung disease.
Substances such as solvents that may cause dermatitis.

Pesticides that contain organ phosphorus (OP) compounds, such as insecticides,

sheep/animal dips, which can cause nerve poisoning.

Machinery operating constantly at sound levels of 85 to 90 decibels (A weighted).

Health/medical surveillance might include:

Biological or biological effect monitoring, e.g. blood tests to detect certain

hazardous chemicals.

Regular checks by a responsible person, e.g. a trained supervisor could look at

workers’ hands for signs of dermatitis.

Auditory/hearing tests.

Lung function tests if workers are exposed to high levels of hazardous dust.

Monitoring the causes of sickness absence, for example if workers are absent
from work due to illness, asking whether they or their doctor associate the illness
with their work.

Identifying a specific medical/health surveillance measure for a particular hazard

is not the same as having a general medical check-up. There is often confusion

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on this point. The health/medical surveillance risk control measure you use has
to be specific to the hazard/problem you have identified.

In conclusion, where elimination or substitution is not possible the hierarchy of

risk control measures gives priority to technical, equipment and engineering
controls combined with safe work methods, practices, organization, information
and training. The aim is to provide collective protection for workers, using PPE
only to boost the other risk controls and avoid workers having to wear PPE for
long periods (except for standard work items such as overalls and boots). It is
also necessary to identify which hygiene and welfare measures are needed and,
where appropriate, which health/medical surveillance measures would reduce the
likelihood of especially long-term harm.

In the table below, we continue filling in the example of the woodworking

workplace with the next steps (Steps 3.A and 3.B) in the risk assessment. For
each hazard identified we give some examples of measures that may be used to
reduce the risk, either indicating some measures that may already be used (Step
3.A) in our fictitious workplace or can be considered as a result of the risk
assessment (Step 3.B). Remember that this is a hypothetical situation and cannot
be taken as representative of the situation in any particular workplace.

STEP 4: RECORD WHO IS RESPONSIBLE FOR IMPLEMENTING WHICH RISK

CONTROL MEASURES, AND THE TIMEFRAME

When risk control measures are decided on, as per Step 3.B, you need to take
action to implement the measures. You also have to assign responsibility within
the enterprise for their implementation within a reasonable timeframe and
record the date they were acted upon and installed.

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The risk assessment has three distinct responsibilities within Step 4: Action by
whom in the enterprise? Action by when?

On what date was the risk control measure installed or activated?

This means that for each control measure indicated in your risk assessment, you
should specify the person(s) responsible for implementing the measure,
along with a date for its completion. The risk assessment should also be marked
up when the control measure has been successfully installed or activated.

When you evaluate risks it is common to find more problems than you can fix at
once. This is why it is important to prioritize, and tackle the most serious risks
first. This helps protect your workers, and makes for efficiency and cost
effectiveness in your risk control measures.

In any risk assessment, the degree of risk and thus prioritization for action is, to
a certain extent, based on personal judgments and opinion. However, you
should show that you have based your priorities for action on sound reasons. At
first, this may seem like a daunting task but remember the maxim, “keep it
simple”, and seek advice and good practice as appropriate.

As mentioned earlier, risk is a function of the possible severity of injury or illness

multiplied by the likelihood (or probability) of such harm occurring to workers. In
this case, when you are evaluating the level of a risk you should pay attention to
a number of things. For example:

How likely is a situation that may cause an accident to occur? Remember that this
is the situation at the time of the risk assessment, with the present methods of
work and the present precautions already in place – or not, as the case may be.
Is an event unlikely to occur, or even very likely to occur; is there something that
could reasonably be expected to occur, or is even certain or imminent? What

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contributory factors could be involved – rushing a job, for example, or poor
working conditions, or machinery that is difficult to use?

What are the consequences of the accident likely to be? What could happen in
the worst case scenario? If a worker slips or falls near a woodworking machine,
for example, there could be several possible outcomes, ranging from negligible
(no treatment needed) or minor injury (first aid treatment for a cut or bruise),
right through to serious injury or death if the worker gets a limb caught up in the
machine.

What is the scale or degree of the risk? In other words, how far would the
consequences of the accident reach – how many people, tasks, machines,
customers or product batches would be affected?

The table below can give you some guidance on how to evaluate risk. You can
also try using Ac-tivity 4 (page 56) to help focus your reasoning for evaluating the
degree of risk and prioritizing action to tackle the identified risks.

Using a risk matrix

Most small businesses will not need to use a risk matrix. However, such a tool can
be used to help you work out the level of risk associated with a particular issue.
A risk matrix does this by categorizing the likelihood of harm and the potential
severity of that harm. This is then plotted in a matrix (plural, matrices) as
illustrated below. The risk level determines which risks should be tackled first,
starting obviously with the highest risks.

Using a matrix can be helpful for prioritizing your actions to control a risk. It is
suitable for many assessments and, in particular, for more complex situations.
However, it does require expertise and experience to judge the likelihood of harm

229
accurately. Getting this wrong could result in fail-ing to take important risk
reduction measures or applying unnecessary measures.

Just as there are no set methods of doing risk assessment, so you will find a wide
variety of risk matrices, many of which are designed for use in larger enterprises.
Therefore, given that this module is designed for SMEs, we have chosen, by way
of example, a 3 by 3 risk matrix as we believe it is straightforward and easy to
use to set priorities for action. It can also help to avoid getting bogged down or
lost in lengthy discussions on the degree of risk, or prioritization

Classify work activities in accordance with their similarity, such as:

1. geographical or physical areas within/outside premises;

2. stages in production/service process;

3. not too big e.g. building a car;

4. not too small e.g. fixing a nut; or defined task e.g. loading, packing, mixing,
fixing the door

5. Hazard identification technique:

6. The employer shall develop a hazard identification and assessment

methodology taking into account the following documents and information:

7. any hazardous occurrence investigation reports;

8. first aid records and minor injury records;

9. work place health protection programs;

10. any results of work place inspections;

11. any employee complaints and comments;

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 12. any government or employer reports, studies and tests concerning the
health and safety of employees;

13. any reports made under the regulation of Occupational Safety and Health
Act,1994

14. the record of hazardous substances; and

15. any other relevant information.

The hazard identification and assessment methodology:

The hazard identification and assessment methodology shall include:

a. Steps and time frame for identifying and assessing the hazards. One must
define the steps for the identification of hazards and a time frame for this
identification. The following information should be included:

i) who will be responsible for the identification: for example, it may be the work
place health and safety committee, or an individual or individuals appointed.by
the committee;

ii) the way in which the identification reports are processed: for example, they
may be compiled and processed by the committee, or by individuals appointed by
the committee:

iii) the identification time frame: for example, the identification of hazards for
workshop A must be completed in December, for workshop B in April and for
workshop C in November.

b. The keeping of a record of the hazards. After having identified the hazards,
one must establish and maintain an identification record, either in print or
electronic format.

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c. A time frame for reviewing and, if necessary, revising the methodology. The
date for the review of the identification: for example, the review of the
identification method will be carried out every three years.

To complete hazard identification, one can use techniques to identify hazards.

Some examples of techniques include, but are not limited to:

i. work place inspections;

ii. task safety analysis or job hazard analysis;

iii. preliminary investigations;

iv. potential accident factors;

v. failure analysis;

vi. accident and incident investigations.

It is in your interest to adopt your own process and your own identification
techniques so that they match one management procedures and the size of
business. In fact, the identification method may vary depending on the size of the
work place.

Analyze and estimate risk:

Risk is the determination of likelihood and severity of the credible accident/event

sequences in order to determine magnitude and to priorities identified hazards. It
can be done by qualitative, quantitative or semi quantitative method.

A qualitative analysis uses words to describe the magnitude of potential

severity and the likelihood that those severity will occur. These scales can be
adapted or adjusted to suit the circumstances and different descriptions may be
used for different risks. This method uses expert knowledge and experience to
determine likelihood and severity category.

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In semi-quantitative analysis, qualitative scales such as those described above
are given values. The objective is to produce a more expanded ranking scale than
is usually achieve in qualitative analysis, not to suggest realistic values for risk
such as is attempted in quantitative analysis.

Quantitative analysis uses numerical values (rather than the descriptive scales
used in qualitative and semi-quantitative analysis) for both severity and likelihood
using data from a variety of sources such as past accident experience and from
scientific research. Severity may be determined by modeling the outcomes of an

event or set of events, or by extrapolation from experimental studies or past data.

Severity may be expressed in terms of monetary, technical or human impact
criteria, or any of the other criteria. The way in which severity and likelihood are
expressed and the ways in which they are combined to provide a level of risk will
vary according to the type of risk and the purpose for which the risk assessment
output is to be used.

In this guidelines qualitative and semi quantitative method uses as an example.

Likelihood of an occurrence:

This value is based on the likelihood of an event occurring. You may ask the
question “How many times has this event happened in the past?” Assessing
likelihood is based worker experience, analysis or measurement. Likelihood levels
range from “most likely” to “inconceivable.” For example, a small spill of bleach
from a container when filling a spray bottle is most likely to occur during every
shift. Alternatively, a leak of diesel fuel from a secure holding tank may be less
probable.

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Table A indicates likelihood using the following values:

Severity of hazard:

Severity can be divided into five categories. Severity are based upon an increasing
level of severity to an individual’s health, the environment, or to property. Table
B indicates severity by using the following table:

Risk assessment:

Risk can be presented in variety of ways to communicate the results of analysis

to make decision on risk control. For risk analysis that uses likelihood and severity
in qualitative method, presenting result in a risk matrix is a very effective way of

234
communicating the distribution of the risk throughout a plant and area in a
workplace.

Risk can be presented in variety of ways to communicate the results of analysis

to make decision on risk control. For risk analysis that uses likelihood and severity
in qualitative method, presenting result in a risk matrix is a very effective way of
communicating the distribution of the risk throughout a plant and area in a
workplace.

Risk can be calculated using the following formula:

L x S = Relative Risk

L = Likelihood
S = Severity

An example of risk matrix (Table C) is shown below:

To use this matrix, first find the severity column that best describes the outcome
of risk.Then follow the likelihood row to find the description that best suits the

235
likelihood that the severity will occur. The risk level is given in the box where the
row and column meet.

The relative risk value can be used to prioritize necessary actions to effectively
manage work place hazards. Table D determines priority based on the following
ranges:

Hazards assessed, as “High Risk” must have immediate actions, to resolve risk to
life safety and or the environment. Individuals responsible for required action,
including follow up must be clearly identified. A further detail risk assessment
method may require such as quantitative risk assessment as means of determine
suitable controls measures.

Control:

Definition: Control is the elimination or inactivation of a hazard in a manner such

that the hazard does not pose a risk to workers who have to enter into an area
or work on equipment in the course of scheduled work. Hazards should be

236
controlled at their source (where the problem is created). The closer a control to
the source of the hazard is the better. This method is often referred to as applying
engineering controls. If this does not work, hazards can often be controlled along
the path to the worker, between the source and the worker. This method can be
referred to as applying administrative controls. If this is not possible, hazards
must be controlled at the level of the worker through the use of personal
protective equipment (PPE), although this is the least desirable control.

Selecting a suitable control:

Selecting a control often involves:

1. evaluating and selecting short and long-term controls;
2. implementing short-term measures to protect workers until permanent
controls can be put in place; and
3. implementing long term controls when reasonably practicable.

For example, suppose a noise hazard is identified. Short-term controls might

require workers to use hearing protection. Long term, permanent controls might
remove or isolate the noise source.

Types of Control:

At the source of the hazard

a. Elimination - Getting rid of a hazardous job, tool, process, machine or

substance is perhaps the best way of protecting workers. For example, a
salvage firm might decide to stop buying and cutting up scrapped bulk fuel tanks
due to explosion hazards.

b. Substitution - Sometimes doing the same work in a less hazardous way is

possible. For example, a hazardous chemical can be replaced with a less
hazardous one. Controls must protect workers from any new hazards that are
created.
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Engineering control:

a. Redesign - Jobs and processes can be reworked to make them safer. For
example, containers can be made easier to hold and lift.

b. Isolation - If a hazard cannot be eliminated or replaced, it can some times

be isolated, contained or otherwise kept away from workers. For example, an
insulated and air-conditioned control room can protect operators from a toxic
chemical.

c. Automation - Dangerous processes can be automated or mechanized.

For example, computer- controlled robots can handle spot welding operations in
car plants. Care must be taken to protect workers from robotic hazards.

d. Barriers - A hazard can be blocked before it reaches workers. For example,

special curtains can prevent eye injuries from welding arc radiation. Proper
equipment guarding will protect workers from con tacting moving parts.

e. Absorption - Baffles can block or absorb noise. Lockout systems can isolate
energy sources during repair and maintenance. Usually, the further a
control keeps a hazard away from workers, the more effective it is.

f. Dilution - Some hazards can be diluted or dissipated. For example,

ventilation systems can dilute toxic gasses before they reach operators.

Administrative controls:

a. Safe work procedures - Workers can be required to use standardized

safety practices. The employer is expected to ensure that workers follow these
practices. Work procedures must be periodically reviewed with workers and
updated.

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b. Supervision and training – Initial training on safe work procedures and
refresher training should be offered. Appropriate supervision to assist workers in
identifying possible hazards and evaluating work procedures.

c. Job rotations and other procedures can reduce the time that workers are
exposed to a hazard. For example, workers can be rotated through jobs requiring
repetitive tendon and muscle movements to prevent cumulative trauma injuries.
Noisy processes can be scheduled when no one is in the workplace.

d. Housekeeping, repair and maintenance programs - Housekeeping includes

cleaning, waste disposal and spill cleanup. Tools, equipment and machinery are
less likely to cause injury if they are kept clean and well maintained.

e. Hygiene - Hygiene practices can reduce the risk of toxic materials being
absorbed by workers or carried home to their families. Street clothing should be
kept in separate lockers to avoid being contaminated by work clothing. Eating
areas must be segregated from toxic hazards. Eating should be forbidden in toxic
work areas. Where applicable, workers should be required to shower and change
clothes at the end of the shift.

Personal protective equipment:

Personal protective equipment (PPE) and clothing is used when other controls
measures are not feasible and where additional protection is needed. Workers
must be trained to use and maintain equipment properly. The employer and
workers must understand the limitations of the personal protective equipment.
The employer is expected to require workers to use their equipment whenever it
is needed. Care must be taken to ensure that equipment is working properly.
Otherwise, PPE may endanger a workers health by providing an illusion of
protection.

Monitoring controls:

239
The effectiveness of controls must be checked regularly. Evaluate and monitor
hazard controls during inspections, routine maintenance, and other activities.

Ask the following questions –

a. have the controls solved the problem?

b. is any risk to workers posed by the controls contained?

c. are all new hazards being identified?

d. are significant, new hazards appropriately controlled?

e. are accident reports being analyzed?

f. are any other measures required?

Document control activities to track their effectiveness, if necessary re-evaluate

hazards and implement new control measures.

Safe work procedures:

Through the completion of a Job Hazard Analysis, sometimes hazards are

identified and cannot be eliminated or engineered out of a particular task. Safe
Work Procedures are step by step instructions that allow workers to conduct their

240
work safety when hazards are present. A Safe Work Procedure identifies the
materials and equipment needed, and how and when to use them safety.

Safe Work Procedures are generally prepared for -

a. critical high risk jobs where accidents have or could result in severe injuries;
b. hazardous work where accidents occur frequently;

c. new or altered tasks have been introduced;

d. new equipment has been added to a process;

e. a job that requires many detailed tasks;

f. where two or more workers required for a job, and each must perform specific
tasks simultaneously; and

g. specific tasks are done infrequently.

Safe Work Procedures must include:

a. regulatory requirements;

b. necessary personal protective equipment;

c. required training;

d. worker responsibilities;

e. specific sequence of steps to follow to complete the work safely;

f. required permits; and

g. emergency procedures.

An example of a task that requires the development of a safe work procedure is

confined space entry. Individuals who must work within confined spaces must

241
ensure that safe work procedures are developed and followed to maximize life
safety.

Personal protective equipment (PPE):

Personal protective equipment means any equipment which is intended to be

worn or held by a person at work and which protects him against one or more
risks to his health or safety and any additional accessory designed to meet that
objective;

PPE is usually chosen to provide protection appropriate to each of type of hazard

present. There are specifications for the types of PPE used for protecting an
individual’s head, eyes, footwear, limb and body, fire retardant clothing,
respiratory, hearing, and personal flotation devices.

It may also include required apparel for example when traffic hazards are present
high visible and distinguishable “vests must be worn”

Documenting HIRA:

Responsibility and accountability

Proper management of hazards sporadically identified in the workplace can be

done through effective process. Ultimately, the individual or team who identified

242
the hazard must ensure proper communication of the hazard to the appropriate
workplace authority (manager, department head, or designated person). Each
HIRA must be fully documented. The HIRA form must be completed by the HIRA
team and signed by the in charge personnel of the area. Departments responsible
for the hazards and their control are required to maintain all records of
assessments for at least 3 years. (In some cases, legislative requirements will
determine the minimum time to retain records).

The appropriate authority is responsible for ensuring that effective and timely
controls are applied to the hazard and communicating the results back to the
originator. Management or employer must endorse and approve the HIRA results.
Employer must communicate all HIRA to employees, monitor the follow up action
and keep the records. The HIRA Form (Link below the page) is an example to
document the HIRA process.

Documenting process:

Instructions to team leader and persons conducting HIRA :

1. complete HIRARC Form. It is recommended to use a single form for each

work process;

2. record the names and designation of HIRAC team members;

3. outline the process workflow and indicate in the form under ‘process/
location column;

4. list all activities ( routine and non-routine) for each work process under the
“Work Activity” column;

5. identify the hazards associated with each activity and record in “Hazard”
column;

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 6. determine the effect of each hazard identified and record in “Effect”
column;

7. record any existing hazard control measures;

8. determine likelihood (L) from Table A and severity (S) from Table B for
each hazard. Assign P and C rating in respectively column. The existing
control measures should be take into consideration while determine (L)
and (S);

9. by using Risk Matrix ( Table C and D ) assign one risk and record in “Risk”
column;

10. based on the risk assigned, recommend appropriate risk control measures
( see Table D);

11. assign a suitable person to implement the recommended risk control and
indicate the follow up action date and status;

12. repeat the HIRA for other activities and process;

13. conduct another round of HIRA after control measures have been
implemented; and

14. review HIRA for every three years or whenever there are changes in
process

STEP 5: RECORD YOUR FINDINGS, MONITOR AND REVIEWYOUR RISK

ASSESSMENT, AND UPDATE WHEN NECESSARY

Taking action to implementing risk control measures is not the end of the risk
assessment process, Recording your findings: In Step 5, it is necessary to
record and display your findings, writing down the significant hazards you have
identified and the group(s) of workers and other people at risk. The risk control
measures to be implemented and the responsible person(s) and other information

244
noted in Step 4 must be recorded and readily available for workers, supervisors
and OSH inspectors to see.

There is no set format for recording your findings. The table given as an example
in this manual is designed to show the logical steps in a risk assessment and it is
also convenient for recording your findings in a simple and readily accessible
format. In reality, a risk assessment will be more extensive than the worked
example we have used here. There will be more hazards identified for more
processes. We have focused on only three hazards – wood dust, dangerous
machines and manual handling – whereas woodworking enterprises often give
rise to other risks such as chemical exposures, noise, slips, trips and falls, vehicles,
electrical problems, and fire.

Risk assessments for SMEs do not have to be academic papers. They may
sometimes be written by OSH professionals or experts but the intention is always
for the employer of an enterprise to implement the recommendations. So the
written risk assessment has to practical, as well as thorough. It should show that:

A proper investigation has been undertaken. All the significant hazards have been
identified and addressed, taking into account the number and vulnerabilities of
people who could be involved.

The precautions are reasonable and the residual risk is low.

This written record is a useful tool for employers, supervisors, workers and their
representatives alike, and should be kept for future use. It can be used as a
reference tool, to remind everyone to be aware of particular hazards and the
measures needed to reduce the associated risks. The risk assessment will also be
of interest to the labour or OSH inspectors as it allows them to see that the
employer is complying with his or her duties to provide a safe and healthy working
environment in accordance with the law.

245
Monitoring the effectiveness of the control measures:

You will also need to monitor and check the effectiveness of risk control measures
and ensure that they are maintained. Did the improvements identified in your risk
assessment work? For each of the hazards you identified, were the risks reduced
and the group or groups of persons better protected? Who will monitor and check
that the improved safety and health risk control measures are still effective? Who
will check that the new guarding procedures you identified for your dangerous

woodworking machines are being followed? Who will check that the local exhaust
installation you installed is still efficiently extracting the rubber dust and fumes.

Reviewing and updating your risk assessment:

The risk assessment is not a one-time activity. It needs to be reviewed from time
to time, at least annually if not more often. When you are running a business it is
all too easy to forget about reviewing your risk assessment until something has
gone wrong and it is too late. Why not set a review date for this risk assessment
now? Write it down and note it in your diary as an annual event.

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 CHAPTER 4

METHODOLOGY

247
 CHAPTER 4.0 METHODOLOGY

4.1 Planning and conducting of HIRA:

Process of HIRA requires 4 simple steps:

(a) classify work activities;

(b) identify hazard;

(c) conduct risk assessment (analyze and estimate risk from each hazard), by
calculating or estimating -

i. likelihood of occurrence, and

ii. severity of hazard;

d. decide if risk is tolerable and apply control measures (if necessary).

Flow chart for HIRA process

248
 CHAPTER 5

DATA COLLECTION AND ANALYSIS

249
 CHAPTER 5.0 DATA COLLECTION AND ANALYSIS

5.1 Data collection

Hazards identified in various stages of manufacturing are as below:

5.1.1 Storage of raw materials:

• Unsafe racking/ Top heavy racking

• Overloading/ Collision of vehicle with racking
• Damaged pallets
• Piling of materials
• Storage of sharps (i.e., sheets, knives, rods, blades, etc)
• Obstructed aisles/ inadequate storage space
• Accumulation of refuse or redundant material
• Standing on boxes/drums to remove materials
• Damaged containers for storage of hydraulic oils
• Unsafe storage of containers

5.1.2 Shifting / transferring of materials:

• Manual handling of materials

5.1.3 Mechanical handling of materials:

• Unsafe lifting of materials

• Pedestrian or employee interfaces
• Obstructed views
• Unprofessional behavior of operating person
• Operating at night/ insufficient illumination

250
5.1.4 Forging of raw materials

• Heat treatment process

• Hammering process

5.1.5 Machining of forged products

• Machine power up
• Manual data input
• Tool setup and operation
• Maintenance of the machine

5.1.6 Assembly operations

• Configuring the motor components to complete

5.1.7 Efficiency test for motors

• Testing of motors for torque, speed, flow, pressure, etc

5.1.8 Tig welding for power pack assembly

• Tig welding for power pack assembly

• Handling of welding operations

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5.2 Risk Assessment:

Likelihood of an occurrence:

Severity of hazard:

Risk assessment:

L x S = Relative Risk
L = Likelihood
S = Severity

An example of risk matrix (Table C) is shown below:

252
253
S.N ACTIVITY POSSIBLE CONSEQU- EXISTING L S R RECCOMMENDATION
O HAZARD ENCE CONTROL
IDENTIFIED MEASURES
1 Storage of Unsafe • Falling or • Use of proper 4 3 12 Use of rolling stairs for
raw racking/ Top rolling of stacking easy storage and
materials heavy racking material systems retrieval
• Multiple • Put lighter
injuries / weights on top
death due shelves
to fall of
objects
2 Transportat Overloading/ • Racking • Racking 4 2 8 Displaying safe working
ion/ Collision of collapse and protections load on racking systems
Storage of vehicle with falling of
raw racking material Bolting racks to floor or
materials • Property walls
and goods
damage

254
 • Death/
serious
physical
injury
3 Storage of Damaged • Serious • securely 2 1 2 Sufficient measures are
raw pallets injury due packaged and already available.
materials to being hit arranged
by falling • Inspection and
objects. removal of
• Damage to damaged
goods pallets.

4 Storage of Piling of • rolling of • avoid storage 3 1 3 Sufficient measures are

raw materials material and of materials in already available.
materials trip hazards floors
• injuries due
to tripping

255
5 Storage Storage of • serious or • Proper sealing 3 1 3 Sufficient measures are
process sharps (i.e., deep cut of edges already available.
sheets, knives, injuries • Shouldn’t
rods, blades, store sharp
etc) materials un
covered
6 Improper Obstructed • Trip hazards • Providing 3 4 12 Minimum 6ft distance
House - aisles/ • Injuries due more space between racks and
keeping inadequate to for storage pathways/ floor
storage space projections facilities openings
in pathway • Good
housekeeping
facilities

7 Improper Accumulation • Trip and fall • Storage area 2 2 4 The house keeping
House - of refuse or hazards floors must be system is adequate.
keeping redundant • Several kinds clean
material of hit injuries • Equip
employees for

256
 or bone maintenance
break and in-charge
• Harboring of of stores
rats and • Disposal/reuse
other pests of waste
materials and
other
defective
products
should be
done

8 Handling of Standing on • Falling from • No objects 4 3 12 Extension ladders with

raw boxes/drums height should be hand rails should be
materials. to remove causing placed above used.
materials sprains and 16ft high
fracture of • Use of ladders
bones must be

257
 • Damage to practiced
goods strictly
9 Storage of Damaged • Spillage or • Use 4 2 8 Separate disposal
Hudraulic containers for dripping on cardboards to methods should be used
oil storage of floors check leaks on and should be approved
hydraulic oils • Slip and fall containers by Factory inspector.
due to • wash
spillage contaminated
• Contact with skin
skin causing immediately
irritation • Wearing
• Contact with masks and
environment gloves while
causing using
ecological hydraulic
imbalance fluids
• Irritation, • Saw dust or
coughing sand should
and nausea be used for

258
 due to short cleaning the
term spills
exposure

10 Shifting / Manual • Strained • Manual 4 4 16 Use of mechanical

transferring handling of muscles handling handling devices such as
of materials materials • Lifting and trainings cranes, forklifts or
twisting of should be trolleys should be
packed given to the encouraged
materials employees
• Abrasion, • Appropriate Loads should be tied and
cuts and PPE’s should packed and lifted
exposure to be provided together wherever
oils • No weights possible
• Slips, trips exceeding
and falls one’s own
• Dropped physical
loads and capacities
damages

259
 • Broken should be
bones and lifted
fractures • Secure loads
before lifting
• Obstruction on
the aisles
should be
moved before
lifting loads
• Hazards on
the lifting
materials
should be
informed
before lifting
11 Mechanical Unsafe lifting • Equipment • Check controls 5 5 25 Emergency procedures
handling of of materials or control are should be ready when
materials failure functioning there is any unexpected
correctly load movement

260
 leading to before
fall operating
• Impact/crus • Safe working Stable stacking of
hing load should materials should be
• Trembling not be ensured.
due to exceeded
Unexpected • Work area
sling should be
movements clear
• Falling of • Slings should
loads due to be positioned
Incorrect correctly
stacking • Load balance
• Slinging of of the slings
ropes / should be
chains checked

261
12 Mechanical Pedestrian or • Severe • Operator 1 4 4
handling of employee injuries due should be
materials interfaces to falling aware of other
object operators /
• Death pedestrians
• Walking under
the loads
should be
avoided
• Exclude
workforce
from work
area

13 Mechanical Obstructed • Operator • Should not 3 3 9 Competent person

handling of views may not be travel when should give clear
materials able to see the load is physical and verbal
any blocking the instruction before
intrusions or operation

262
 projection on view of further
the way movement
• Tend to
material fall
and injury
14 Mechanical Unprofessional • Fall of loads • qualification 4 4 16 professionally trained
handling of behavior of • Injuries and certificates on operators
materials operating loss of operation
person property • supervision of
• death skilful
technician
should be
made
mandatory
15 Mechanical Operating at • no proper • increase 3 1 3 Operations of cranes at
handling of night/ vicinity of illumination nights are generally
materials insufficient hazards • forbid avoided.
illumination • fall of loads operation
when work

263
 area is less
illuminated

16 Forging of Heat • skin burns • wear 3 4 12 safety devices like

raw treatment due to protective automatic shut off
materials process contact with clothing – heat valves, air switches and
hot metal resistant exhaust fans should be
surfaces gloves, face checked before starting
• facial burns / shields, lab the operation
eye damage coats, suitable
by hot air safety shoes strictly follow
radiation etc manufacturer’s
from furnace • longer and instructions for lighting
• fire stable tongs the furnace
should be
used for hot
metal handling
• hot metals
should not be

264
 left un
attended
• use
appropriate
warning signs
to indicate hot
samples
• handling tools
should be
cooled
immediately
after use
• flammable
materials
around the
furnace area
should be
removed

265
 before
beginning
• keep work
area, jigs,
tools free from
oil
contamination
• obtain first aid
for all cuts and
abrasions and
protect them
with suitable
dressings
17 Forging for Hammering • eye dangers • all forging 4 4 16 eye protection should be
motors and process from flying equipment’s worn on hammering
drives objects should be
• hearing maintained for hearing protection
damage due safe working should be made
to noise condition necessary

266
• crushing • all materials face shields, gloves and
• cut by sharp should be safety shoes should be
edges made in such mandatory
• unintended a way they
energization don’t crack or
• fire splinter
• there should
be a safety
cylinder head
acting as a
cushion
• die keys and
shims should
be made of
material that
they don’t
crack

267
18 Machining Machine • cut injuries • Only 3 4 12
of forged power up • machine authorised Machine should not be
products failure/ void person should started when the doors
warranty use the and interlocks are not in
• eye or ear machine condition.
damages • Check for
• death damaged SOP’s should be
• power failure parts before provided and should be
• electrocution operating the carefully read before
machine starting the process.
• Emergency
stop button Proper authorization
should be must be given before
readily operating the CNC
available in machine
case of any
emergency
• Emergency
stop button

268
 should be
readily
available in
case of any
emergency
• Proper training
should be
given before
operation
• Modification of
programmes
during
operation
should be
avoided

19 Maintenanc Maintenance • Noise levels • Clean the filter 4 3 12 Repair and replacement
-e of CNC of the may exceed screen weekly of tools should be done
machine machine 80db by authorized personnel

269
• Get injured • Coolant tank
due to cover should Work permits should be
moving parts be removed maintained and strictly
• Corrosion of and cleaned practiced.
parts entirely
• Fire or • Do not use
explosion of plain water
machine coolant
• Electrocution • Rust inhibiting
coolant should
be used
• Toxic or
flammable
coolant should
not be used
• Power down
before any
maintenance
task

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20 Assembly Configuring • Falling • Weights 2 3 6 Qualified supervision
operations the motor object/comp should be must be available during
components to onent hazard counterbalanc assembly
complete • Cuts due to ed that they
abrasive, don’t fall Safe operating
acute or • Workers procedures and
sharp edges should not be assembly manuals
• Puncture or encouraged to should be kept readily
fracture due stand under available.
to hits the work
• Loss of material
structural • Post assembly
integrity of inspection
the should be
equipment made by
competent
person
• Stacking of
proper

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 blocking
material from
fall should be
encouraged
• The assembler
should be well
aware of the
dangerous
parts in the
motor and
hazards
involved in
process
• Safety shoes
and helmets
should be
worn to avoid
any kind of
bodily injures

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21 Efficiency Testing of • Structural or • Shafts should 1 2 2 The safety procedures
test for motors for integral be checked for are adequately followed.
motors torque, speed, damage in any hindered Hence the hazards are
flow, pressure, case of torques by minimal.
etc failure qualified
• Injuries due professional
to moving • LED flashlight
objects should be
• Spillage of used to check
hydraulic oils any kind of
chips, rasping
or shavings in
drain ports or
any openings.
• Competent
person should
be available in
the testing
area

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 • Proper
guarding
should be
available
around the
rotating or
moving
objects

22 Tig welding Interruption of • Electrocution • Touching of 4 3 12 Qualified person should

for power power sources • Skin burns lead inside the be employed before
pack • Exposure to welding set given work under
assembly electromagn with power on welding operation.
etic radiation should not be
encouraged
• Torches when
interrupted
temporarily
should be

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 placed away
from human
interaction
• Direct removal
of panels from
power source
should not
practised

23 Welding Handling of • Back injuries • Proper training 3 4 12 All kind of PPE like
process welding • Burns should be safety goggles, face
operations • Inhalation of given shields, ear muffs should
fumes • Work area be advised
should be
clean and tidy
27 UPS Electricity Men will be Ordinary push 5 3 15 Rubber mat shall be
operation failure affected by button are changed at regular
electric shock provided intervals as per the
standards

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28 Drainage Improper Affects the body Separate drainage 3 3 9 Verify whether the tank
system drainage parts system is capacity is adequate and
facilities provided periodic inspection for
cleaning
29 Electrical Electricity Chance of ON/OFF push 5 3 15 Periodic inspection shall
panel getting electric button are made be carried out.
shock of insulted
material. Rubber mat shall be
Rubber gloves are changed at regular
used. intervals as per the
Rubber mat are standards
used

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 CHAPTER 6

FINDING AND RECOMMENDATIONS

277
 CHAPTER 6.0 FINDINGS AND RECOMMENDATIONS

6.1 Findings from the study:

Significant risky operations are;

• Unsafe racking/ Top heavy racking

• Overloading/ Collision of vehicle with racking

• Obstructed aisles/ inadequate storage space

• Standing on boxes/drums to remove materials

• Damaged containers for storage of hydraulic oils

• Manual handling of materials

• Unsafe mechanical lifting of materials

• Obstructed views during lifting of materials

• Unprofessional behavior of operating person during mechanical lifting

• Heat treatment process

• Hammering of heat treated metals

• Machine power up for finishing the forged products

• Manual data input for machining the forged products

• Maintenance of the lathe machine

• Assemble and Configuring the motor components to complete the product

• Interruption of power sources during TIG welding

• Handling of welding operations and tools

• Improper drainage facilities

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 • Electricity failure in electric panels and UPS operation.

6.2 Recommendation on the study:

• Use of rolling stairs for easy storage and retrieval

• Displaying safe working load on racking systems
• Bolting racks to floor or walls
• Minimum 6ft distance between racks and pathways/ floor openings
• Safe ladders with hand rails should be used.
• Separate disposal methods should be used and should be approved by
Factory inspector
• Use of mechanical handling devices such as cranes, forklifts or trolleys
should be encouraged
• Loads should be tied and packed and lifted together wherever possible
• Emergency procedures should be ready when there is any unexpected load
movement
• Stable stacking of materials should be ensured
• Competent person should give clear physical and verbal instruction before
operation
• professionally trained operators
• safety devices like automatic shut off valves, air switches and exhaust fans
should be checked before starting the operation
• strictly follow manufacturer’s instructions for lighting the furnace
• Machine should not be started when the doors and interlocks are not in
condition
• Proper authorization must be given before operating the CNC machine
• Repair and replacement of tools should be done by authorized personnel
• Qualified supervision must be available during assembly

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• All kind of PPE like safety goggles, face shields, ear muffs, safety belts
should be advised strictly.
• Rubber mat shall be changed at regular intervals as per the standards to
prevent shock
• Verify whether the tank capacity is adequate and periodic inspection for
cleaning

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CHAPTER 7

CONCLUSION

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 CHAPTER 7.0 CONCLUSION

Safety is one of the most important aspects of industrial management today. The
Management of Maha Hydraulics Private Limited is committed to provide safe
working environment to all employees irrespective of cadre including contract
employees.

Hence this Hazard Identification and risk assessment project has been taken to
identify the possible potential hazards and risks involving in the industry. In this
Context, findings and recommendations are made in this project work may be
considered by the management to reduce the accidents.

The Industry should provide adequate Budget provisions to meet the demands for
sustenance of up keeping safe working environment and procurement of safety
equipment.

Achieving ZERO ACCIDENT and INCIDENT is the objective of the safety

organization in the Industry by way of strengthening safety, the Safety
promotional activities and employee’s involvement in eliminating of unsafe
conditions and unsafe Acts, the GOAL can be certainly achieved.

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 CHAPTER 8

BIBLIOGRAPHY

283
1. The Factories Act, 1948

2. Tamil Nadu Factories Rules, 1950

3. Occupational Health And safety Assessment Series 18001

– 2007

4. Occupational Health And safety Assessment Series 18002

– 2006

5. The Fundamentals of Industrial safety and Health by Dr.

K.U. Mistry

6. IS 15656: Hazard identification and Risk Analysis – Codes

of Practice

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