industrial hazards and safety prof. dr. basavaraj k. nanjwade m. pharm., ph. d department of...

INDUSTRIAL HAZARDS AND SAFETY

Prof. Dr. Basavaraj K. Nanjwade M. Pharm., Ph. D

Department of PharmaceuticsKLE University College of Pharmacy

BELGAUM-590010, Karnataka, IndiaCell No: 00919742431000

E-mail : [email protected]

24 August 2012 1KLE College of Pharmacy, Nipani

CONTENTS

• Introduction

• Types of hazards

• Recommendations and Suggestions

• Industrial effluent testing and treatment

• Discussion on industrial accident case studies

• Questions

• References


Industrial hazards:

It can be defined as any condition produced by

industries that may cause injury or death to

personal or loss of product or property.

INTRODUCTION


Heat and Cold

Burns

Heat stroke

Heat cramps

Foot sore

Immersion foot

Frost bite

Preventive Measures

A reasonable temp. of 20-250C must be maintained


24 August 2012 KLE College of Pharmacy, Nipani 7

Auditory Non auditory effects Preventive measures

a. At source:

• Source of noise can be enclosed with an insulation material or concrete wall.

• Proper maintenance of machinery

b. By distance

c. Personal protection against noise.


Noise have two type of effects

Equipment noise sources ,level & potential control solutions

Equipment Sound level in dBA at 3 feet

Possible noise control treatments

Air coolers 87-94 Aerodynamic fun blades,↓ revolutions/min ↑ pitch,↓ pressure drop

Compressors 90-120 Install mufflers on intake,& exhaust, enclosure the machine with casing, vibration isolation & lagging of piping system

Electric motors 90-110 Acoustically lined fun covers, enclosure 7 motor mutes


Heater & furnaces

95-110 Acoustic plenums, intake mufflers, lined & damped ducts

Valves <80-108 Avoid sonic velocities, limit pressure drop & mass flow, replace with special low noise valves

Piping 9-105 Inline silencers, vibration isolation

Equipment noise sources ,level & potential control solutions


Radiation Radiation are divided into two groups

Natural Man made

Cosmic rays Medical /dental x-rays isotopes

Environmental (radioactive elements e.g. uranium)

Occupational exposure

Internal (potassium,) Nuclear radioactive fallout

Approx 0.1 rad/yr Miscellaneous

Use of radio active substances by different industries


Somatic Genetic

i. Preventive measures

ii. Radiation source should be housed in a building that shields any surrounding area.

iii. Radiation badges should be worn.

iv. Periodical medical examination.

v. Proper use of lead shields & lead rubber aprons.


Effect of hazards

Causes

Smoking in the factory

Defective heating equipment, electrical equipment & wiring.

Explosive gas leakage.

Inadequate protection of electric motors

Sparking of electric wires & equipment

Protection & prevention

Types of fire


Fire & explosion hazards

Preventive measures• Prohibition of smoking in manufacturing areas.• Oxygen present in the inflammable atmosphere may

be ↓by dilution with gases such as nitrogen, co2,steam or combination of these.

• Hazardous operation should be isolated• Eliminating the ignition sources• Using fire resistant material in construction • Suitable emergency exits• Adequate venting



• Automatic sprinklers

• Equipment should design to meet the specifications & code of recognized authorities, such as ISA, API &ASME

• The design & construction of pressure vessels & storage tanks should follow API & ASME codes.

• Inspection



Chemical Hazards

Local

– Dermatitis

– Eczema

– Ulcers

– Cancer

Inhalation

– Gas Poisoning

Ingestion

Living tissue may be destroyed by chemical reactions such asDehydrationDigestion Oxidation


Source, effect & precautions of chemical hazards

Type/ source of chemical contaminant

Effect/ organ affected

Precautions to be taken

Acridines, phenothiazines

Dermatitis Cleanliness, removal of people from the areas as soon as first sign of skin reaction is observed.

Solvents like chloroform, benzene

Handle with care

Vegetable drugs like capsicum & podophyllum

Dust evolves, affects eye

Goggles are to be worn

Long term use of filter without cleaning

Dust explosion Regular cleaning


Source, effect & precautions of chemical hazards

Improper use of cleaning agents

contamination Follow established cleaning procedures

Working with radio pharmaceuticals

Hazards due to emitted radiation

Wearing lead coat, maintaining pressure of working area slightly less than atmospheric pressure

Underground tanks Difficulty in monitoring interior & exterior

Minimal use of underground tanks


• Tolerance levels for toxic chemicals set by federal regulations have to be followed.

• Strict observation of operations of all safety regulations


PREVENTIVE MEASURES

Biological hazards• Disease due to biological hazards Brucellosis (dairy industry) Byssinosis (textile industry) Bagassosis (sugar-cane) Loco motor disorder• Preventive measures

Periodic health check upPersonal protectionThe manufacturer should also provideFirst aid facilitiesInitial examinationFacility for vaccinationRoutine sanitation programme


Mechanical hazards• Accidents usually take place by the combination of unsafe

condition & carelessness.

• Most of industrial accidents are due to Faulty inspection Inability of employee Poor discipline Lack of concentration Unsafe practice Mental & physical unfitness for job Faulty equipment or improper working condition Improper training regarding the safety aspects


•In order to prevent mechanical accidents factories act lay down certain requirements

For cranesEnd buffersIndicating lampsSignals

Proof loading

upto20 tons 25% in excess

20 to 50 tons 5 tons in excess

above 50 tons 10% in excess


Mechanical hazards


Mechanical hazards

Building planning

• Floors must be of unskid/non-slippery type.

• Enough space for employees to work.

• Passages between working places.

• Proper arrangements of temperature control; like fans, A.C., heaters.



Building planning

• Careless handling of heavy materials and components should be avoided.

• Full use of mechanical material handling equipment.

• All material handling equipments should be repaired and maintained properly.

• Containers employed to transport liquids should not be defective or leaking.

Safe material handling


• Protection of head by using hard hats/helmets.

• Protection of ears by using earmufffs and plugs.

• Protection of face by using face marks, face shields.

Personal protective devices


Electrical hazards• Shocks• Sparking• Fire• Wiring faults

Preventive measures Proper maintenance of wiring & equipment High voltage equipment should be properly enclosed Good house keeping Water should not be used for dousing electric fire Worker should avoid working in electric circuits or

equipment in wet clothing or shoes.


Pollution hazards• Typesa. Air pollutionb. Water pollutionc. Thermal pollutiond. Sound pollution

Air pollution• Sources Automobiles Industries Domestic


i. Those suitable for removing particulate matter a. Ventilation

Exhaust ventilation Plenum ventilation

b. Air purifying equipmentii. Those associated with removing gaseous pollutants Water pollution1. Types of water pollutants Physical Chemical Physiological Biological24 August 2012 32KLE College of Pharmacy, Nipani

Preventive measures

2. Problems of water pollution3. Preventive measure a. Control of water pollutioni. Physical treatment Storage Filtrationii. Chemical treatmentiii. Biological treatment b. Treatment of industrial waste

Primary treatmentSecondary treatmentTertiary treatment


Preventive measures

c. Thermal pollution

• Effects Damage to aquatic environment Reduction in assimilative capacity of organic waste

• Various off stream cooling systems

i. Wet cooling towers

ii. Dry cooling towers

iii. Cooling ponds

iv. Spray ponds24 August 2012 34KLE College of Pharmacy, Nipani

Preventive measures

Recommendations & suggestions

Proper treatment & disposal methods for effluents should be adopted

An awareness program

Measures for increase efficiency of the water use


Classification of signs according to use –

(1) Danger signs.

The DANGER header is used when there is a hazardous situation which has a high probability of death or severe injury. It should not be considered for property damage unless personal injury risk is present.


2) Caution signs. (i)

The CAUTION header is used to indicate a hazardous situation which may result in minor or moderate injury. However, Caution should not be used when there is a possibility of death or serious injury.


(3) Safety instruction signs

General Safety Signs (SAFETY FIRST, BE CAREFUL, THINK) should indicate general instructions relative to safe work practices, reminders of proper safety procedures, and the location of safety equipment.


(4) Biological hazard signs.

The biological hazard warning shall be used to signify the actual or potential presence of a biohazard and to identify equipment, containers, rooms, materials, experimental animals, or combinations thereof, which contain, or are contaminated with, viable hazardous agents.


Pictograph

Pictograph means a pictorial representation used to identify a hazardous condition or to convey a safety instruction


Signal Word

Signal word means that portion of a tag's inscription that contains the word or words that are intended to capture the employee's immediate attention.


Tag

Tag means a device usually made of card, paper, pasteboard, plastic or other material used to identify a hazardous condition.


Danger Tags

Danger tags shall be used in major hazard situations where an immediate hazard presents a threat of death or serious injury to employees. Danger tags shall be used only in these situations.


Caution Tags

Caution tags shall be used in minor hazard situations where a non-immediate or potential hazard or unsafe practice presents a lesser threat of employee injury. Caution tags shall be used only in these situations.


Warning TagsWarning tags may be used to represent a hazard level between "Caution" and "Danger," instead of the required "Caution" tag, provided that they have a signal word of "Warning," an appropriate major message


Biological Hazard Tags

The symbol design for biological hazard tags shall conform to the design shown below:


Color Coding-Danger Tag

"DANGER" -- Red, or predominantly red, with lettering or symbols in a contrasting color.


Color Coding-Caution Tag

"CAUTION" -- Yellow, or predominantly yellow, with lettering or symbols in a contrasting color.


Color Coding-Warning Tag

"WARNING" -- Orange, or predominantly orange, with lettering or symbols in a contrasting color.


Biological Hazard Tag

BIOLOGICAL HAZARD -- Fluorescent orange or orange-red, or predominantly so, with lettering or symbols in a contrasting color.


Industrial effluent testing and treatment• Effluent is an outflowing of water from a natural body

of water, or from a man-made structure.• Water pollution or waste water discharge from the

industrial facilities.REASON OF TESTING

• To find out-Pollution load -Presence of toxic ingredients -Color, turbidity, odour and quality of water -pH and acidity / alkalinity -Suspended solids and dissolved solids -Phenolic compounds and oily materials


GUIDELINES FOR TESTING EFFLUENTS

• Samples may be collected at specific intervals and finally can be mixed before analysis.

• Containers made up of glass, polythene or any suitable plastic material may be used.

• Samples may also be refrigerated to avoid loss of volatile matter

• Samples could be preserved after adjusting the pH

• O2, CO2, CO may be estimated


• Effluents may be expressed as mg/ltr, ppm, %/ltr, and mcg/ltr

• Acidity / Alkalinity / Oil / Grease / CN / Phenol / Dyes content should be reported

TESTING OF WASTE WATER (EFFLUENT) TEST TREATMENT METHOD

pH

Acidic

Basic

Lime or NAOH

H2SO4


THE RESULTS OF TESTING ARE REPORTED AS FOLLOWS:

Suspended Solids Sedimentation

Oil and grease -grease taps

-skimming

Cyanide

Chlorinated & complex with pyridine pyroxolene

-Colourimetrically

-alkaline chlorination

-oxidation with ozone

-oxidation with H2O2

Phosphates

-Convert to ammonium molybdatephosphates

-extracted with benzene/ isobutyl alcohol mixture

-organic phase treated with tin chloride (blue)

Colourimetrically

-ppt with chalk or lime

-coagulation with alum



Mercury

-treated with nitric acid and potassium dichromate soln- treared with tin chloride

Vapour determined by spectrophotometry

-Coagulation

-chelation with trimercaptotriazine

Phenolic compounds

Steam distillation-acidify (pH<4)- add CuSO4

soln-

Add aminoantipyrine soln- extracted with chloroform

calorimetrically

Removal by polymeric adsorbents



BIOLOGICAL OXYGEN DEMAND

• It is the amounts of oxygen required by micro organisms to bio chemically oxidize carbonaceous organic matter at 20 0C in 5 days.

• 10 mg/litre or less • Excess makes water toxic

MEASUREMENT

• Special designed bottle with flared cap• Incubated at 20 0C for 5 day measuring DO• Microorganism added if required


Dissol oxy in ppm (mg/ltr) = N(V) (8) (1000)

V1

V = Volume of sodium thio sulphate required.N = Normality

V 1= Volume of sample taken.

CHEMICAL OXYGEN DEMAND• Oxygen equivalent of organic matter present in waste water

that is susceptible to oxidation• Waste water sample is refluxed with a known excess of pot.

dichromate in a 50% sulphuric acid solution in presence of silver sulphate and mercuric sulphate


• The organic matter of the sample is oxidised to water, carbon dioxide and ammonia

• The excess of dichromate remaining untreated in the solution is titrated against standard ferrous ammonium sulphate

• COD(mg/l) = (V1-V2) x N x 8 x100

XWhere,V1 = Volume of ferrous ammonium sulphate solution consumed in blank

V2 = Volume of ferrous ammonium sulphate solution consumed for test solution

X= Volume of sample takenN= Normality of ferrous ammonium sulphate solution24 August 2012 58KLE College of Pharmacy, Nipani

CHEMICAL OXYGEN DEMAND

Limit for Discharge into Systems

Sr. No. Parameters Tolerance limits

1 pH 5.5 – 9.0

2 Oil and grease 10

3 Total suspended solid, mg/l 100

4 BOD, mg/l 30

5 COD, mg/l 50

6 Mercury 0.01

7 Arsenic, mg/l 0.20

8 Cyanide, mg/l 0.10

9 Sulphides, mg/l 2.00

10 Phosphates, mg/l 5.0024 August 2012 59KLE College of Pharmacy, Nipani

Waste Water Treatment

Waste Water Pretreatment

• Attempted to render the effluent suitable for further treatment

• Equalization

Concentrated waste is diluted if necessary

-by mechanical mixing

-by aeration mixing

• Neutralization

• Removal of Grease and Oils


Primary Treatment of Waste Water

• Removal of large floating or suspended particle by physical and chemical treatment

Screening• Large particles are removed • Coarse screen of metal bars or heavy wires spaced 25-50

mm apart• Finer materials are separated by screening through 0.8-6

mm meshes Grit Chambers • Removal of particles by centrifugal action and friction

against tank walls• Diffused air used for mixing pattern


• It is used

To prevent any damage to equipment

To avoid settling in pipe bends



Chemical Reaction• Involves agglomeration of tiny particles into large

particles Flocculation

-by mechanical stirring and by chemical flocculants Precipitation

-Large amount of suspended solid formed Coagulation

-Formation of large and quick settling flocs by

a) Reduction of charges and repulsive force

b) Adsorption on long chain molecular structure



Secondary Treatment of Waste Water

• It is a biological process • C, H, and O sources are available • Nitrogen should be 5% of the BOD• Phosphorus should be 20% of mass of nitrogen• Environmental conditions are providedAdvantages• Continuous waste treatment is favored• Low cost systemDisadvantages• Prior prediction of biological degradability is not possible• Solubility limits biodegradability


Activated Sludge Process• Microbial Floc is suspended in tank

• Air is continuously supplied

• Biological degradation of waste into CO2 and H2O

• Bacterial flora grows and remains suspended in the form of floc called as “activated sludge”

• 20% of sludge is recycled

• 6 to 24 hours aeration is required



• Advantages

-Removal of soluble organic substance, colloidal matter, particulate matter, inorganic substance

-Produce high quality effluent

• Disadvantage

-Maintenance cost is high

-Growth of anaerobic bacteria fungi etc



Activated Sludge Process


• Microorganisms are attached to fixed bed

• It acts as a filter

• Bed is maintained at height of 2.5 meter

• Gelatinous film is formed

• Effluent is sprayed over the surface

• Slots at the bottom for air inlet

• Aerobic metabolism occur on the surface

• Anaerobic metabolism occur at the bottom


Trickling filtration process

Trickling Filtration Process


Advantages• Produce effluent of consistent quality• Aerobic and anaerobic digestion are achieved• More economical• Sludge can be removed quickly

Disadvantage• Cost for ventilation duct for air supply is high• Efficiency decreases in the winter


Trickling Filtration Process

Oxidation Ponds • Depth should be 1 to 2 meters.• Bottom and sides are lined with polyethylene, cement.• Oxygen released by algae, carbon dioxide generate from

biodegradative

• Aerobic oxidation producing carbon dioxide and water.

Advantage:

• Operation is simple and economical.

Disadvantages:

• Required disinfections

• Use for wastes having low BOD.24 August 2012 71KLE College of Pharmacy, Nipani


Tertiary Treatment Of Waste Water

• Meant for polishing the effluents.• Bacteria are removed by keeping in maturation

ponds.• Chlorinated, if still contain bacteria.• Methods are more expensive than biological

treatment. Coagulation :• Reaction take place upon addition of the

coagulants.-Metal salts-Organic Polymers

• In water, form insoluble product with impurities.24 August 2012 72KLE College of Pharmacy, Nipani

Coprecipitation :

• Ions in solution phase precipitate with the carrier molecule by

-Adsorption Process

-Inclusion Process Filtration

• Most common type in addition to disinfection.

• Practiced prior to the chlorination.

• Should be done after coagulation.

• May be made up of sand, activated charcoal.



Adsorption

• Involves treatment with activated carbon.

• Useful for removal of pesticides



REFRENCES• Pharmaceutical Production and Management By C. V. S. Subrahmanyam

• www.geocities.com

• www.britannica.com

• http://nptel:iipm.ac.in

• www.waste_management_world.com

• Sewage and Industrial Effluent Treatment, 2 nd edition By John Arundel

• The Theory & Practical of Industrial Pharmacy By Leon Lachman, Herbert A. Lieberman, Joseph Kiang, 3RD Edition Varghese Publishing House.

• www.osha.gov


http://www.geocities.com/

http://www.britannica.com/

http://www.waste_management_world.com/

THANK YOU


Cell No: 00919742431000E-mail : [email protected]

industrial hazards and safety prof. dr. basavaraj k. nanjwade m. pharm., ph. d department of...

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