ABSTRACTS OF STUDIES OF DGFASLI DURING APRIL-JUNE 2009

Assessment of Airborne Chemical contaminants in the Work Environment of a Chemical Factory in Gujarat (Mandre, M.K., Industrial Hygiene Division, Central Labour Institute, Mumbai)

The study was conducted in a factory manufacturing Polystyrene products. The study was carried out to evaluate the exposure of Styrene & Ethyl Benzene vapours to the workers in the plant. During sampling, in Pelleting section, Process plant, near storage tank and instrumentation laboratory, the airborne concentrations of Styrene & Ethyl Benzene were found well below permissible limit of exposure. Some recommendations to improve the quality of Personal Protective Equipment, education training & workmen and provisions of workplace monitoring at the plant itself were suggested.

Assessment of Compressed Breathing Air Quality of a Maritime Training Institute in Maharashtra (Mandre, M.K., Industrial Hygiene Division, Central Labour Institute, Mumbai)

The Maritime Institute imparts training to the seafarer personnel. Breathing air is used by the trainees of the institute. Breathing air cylinders are filled with compressed air by using compressors. Evaluation level of contaminants like Oil mist, Carbon Monoxide, Carbon Di-oxide and Particulate Matter in the compressed breathing air has been undertaken. These contaminants in breathing air the standards as laid down by British Standard BS 4275 as well as Standard CAN3-Z180.1-M85 of the Canadian Standard Association.

Assessment of Airborne Chemical contaminants in the Work Environment of Chemical Factory in Gujarat (Mandre, M.K., Industrial Hygiene Division, Central Labour Institute, Mumbai)

The study was conducted in a Fertilizer & Chemicals plant of Gujarat. Petro-chemicals, fertilizers and other chemicals were produced in the plant. Assessment of airborne levels of Ammonia, Sulphur Dioxide, Oxides of Nitrogen, Benzene, Particulate Matters, Hydrofloric Acid, etc. was carried out at various locations in the plant. The air borne concentrations of Benzene, sulphur Dioxide, Ammonia and Particulate Matters at some locations were found exceeding the PLE/TLV limits. Recommendations such as to improve the working conditions, housekeeping and maintenance of all exhaust systems and use of personal protective equipment were suggested.

Study on Illumination and Ventilation Conditions of a Fertilizer Factory in Maharashtra (Subhash Chandra, Environmental Engineering Division, Central Labour Institute)

The illumination and thermal stress studies were carried out in a chemical plant in Maharashtra with the objectives to measure the prevailing illumination levels and thermal conditions at various work stations in the plant during the day time as well as night time and to suggest remedial measures. The observations were recorded at twenty-five different locations of the plant using necessary thermal stress and illumination related equipment. The findings were discussed in the light of the standard prescribed under Section 17 & 13 of the Factories Act, 1948. The study revealed that the thermal conditions exceeded the prescribed limits at most of the locations and illumination levels were below the prescribed normative limits at some places. Several recommendations were given for improvement of the working conditions.

Study on Consequence Analysis of a Power Plant in Haryana (Gautam, S.S., Sharma, S.C., Major Hazard & Chemical Safety Division, Central Labour Institute, Mumbai)

The study was carried out to find out the likely damages in case of loss of containment of HFO and LDO storage tanks 4000 KL and 1000 KL respectively and the distances that are likely to be affected by toxic chlorine in case of release from tonners. It was found that 1% lethal burns are possible upto distance of 26m from dyke wall in case of fire in the dyke wall for the HFO tank of 4000 KL. For LDO tank of 1000 KL, 1% lethal burns are likely upto about 18m from the dyke wall. The distances of levels dangerous to life in case of 60 min exposure of chlorine gas on release from vapour phase from an aperture of 0.5” upto a distance of about 360m in windward directions at day time 50%clouds and wind speed 1.5m/s. For wind velocities of 3 and 5 m/s, the distances were about 320 and 310m under the similar conditions. For liquid releases from 0.5” aperture, the 1% lethal distances were found to be 1600m, 1100m and 1000m respectively for wind speeds 1.5m/s,3m/s and 5m/s respectively.

Study of Dispersion Modelling for Instantaneous Release of Carbon Monoxide of a Producer Gas Plant in Orissa (Gautam, S.S., Sharma, S.C., Major Hazard & Chemical Safety Division, Central Labour Institute, Mumbai)

The document is a calculation of dispersion of carbon monoxide in case of rupture of bursting disc of 50 mm x 200 mm. The calculations for representative wind speeds i.e. 1.5, 3 & 5 meter/Second have been done to find out the maximum distances in the wind direction up to which the two levels of concern (IDLH & STEL) may reach. The maximum distances were found for the weather stability class F and the wind speed 1.5 meter /Sec. which are as follows: Distance of IDLH (1200 ppm) in wind direction: 84 Meters from the source; Distance of STEL (400 ppm) in wind direction: 161 Meters from the source. It has been suggested that the table of distances should be used keeping in view the conditions at the time of release. Emergency preparedness should be ensured for the maximum distances found in the calculations.

Study of Dispersion Modelling for Propane Storage Area of a Automobile Plant in Orissa (Gautam, S.S., Sharma, S.C., Major Hazard & Chemical Safety Division, Central Labour Institute, Mumbai)

The document contains the findings of estimation of damages likely on release on of Propane gas from a storage tank 50MT capacity. The calculations for a release through material discharge line of 3” diameter at the bottom of the tank, for wind speeds 1.5 M/S, 3 M/S & 5 M/S have been done to find out the maximum distances in the wind direction up to which the 60% of LEL (12000ppm), 10% of LEL (2000ppm) and TEEL (2100ppm) may reach. The maximum distances found for the weather stability class F and the wind speed 1.5 meter /Sec. are as follows: for 60% LEL (12000 ppm) 301 Meters from the source in wind direction; for 10% LEL (2000 ppm) 729 Meters from the source in wind direction; and for TEEL (2100 ppm) 711 Meters from the source in wind direction.In case of ignition of flammable cloud a flash of fire will take place causing physical damage of buildings to different extent. The maximum distances found were 213 meters for serious injury and 346 meters for Shutters blasts. After the flash fire, local jet fire will be formed at the point of leakage. There is no effect of weather stability class in heat radiations. The heat radiation from jet fires have been calculated for different wind speeds and different levels of RH. It was observed that maximum distances of LOCs were for 10% RH and wind speed 5.0 M/Sec. i.e. 55 Meters for Potentially lethal within 60 sec, 77 Meters 2nd degree burns within 60 sec.,and 118 Meters for pain within 60sec. The heat radiations from BLEVE have been calculated for different levels of RH. It was observed that maximum distances of LOCs were for 10% RH which were: 437 Meters for potentially lethal within 60 sec., 617 Meters for 2nd degree burns within 60 sec and 964 Meters for pain within 60 sec. The suggestions have been given to ensure the preparedness for the worst conditions.

Investigative Study of a Multi-fatal Accident of a Shoe Manufacturing Industry in Haryana (Gautam, S.S., Sharma, S.C., Major Hazard & Chemical Safety Division, Central Labour Institute, Mumbai)

The document is a report of investigation of a multi-fatality accident in a footwear industry. Slippers of synthetic materials like rubber; PVC, polyurethane, etc. were being manufactured in the factory. The explosion took place in a hall where the slippers were being assembled by applying adhesive solutions in various parts, their pasting, drawing and finishing by edge grinding. At 5.00 p.m. on 1^st May, 2009 a sudden explosion took place in the hall fracturing all the windows and damaging the building followed by subsequent fire. The event claimed lives of 14 workers with injuries to 25 others. Even though the management did not reveal the cause of accident, yet with the help of statements of the survived workers and circumstantial evidences available at the place of accident, it was concluded that a drum containing highly flammable liquid which had been brought from outside where the ambient temperature was about 45⁰C had started leaking from brim of the drum due to striking of drum on to the wall. This gave away two phase flow of liquid and vapour with pressure which got ignited on falling on the ground. After few moments when the vapour had spread sufficiently, a confined vapour cloud explosion has taken place.

Safety Audit at Thermal Power Plant in Uttar Pradesh (Mathur, S.B., Brij Mohan and Chakraborty A.K., Regional Labour Institute, Kanpur)

The Study found anomalies in status and conditions of service of Safety officers, safety policy not adopted, less participation of workers in safety committee, weaknesses in Permit to Work System, unqualified supervisors of subcontractor for erection jobs, untested and corroded slings etc. The report gives 107 recommendations for correcting the defects found. Some of them were improving the management system, improving the supervision, use of tested slings and other loose gears and ensuring qualified and well trained supervisors.

Safety Audit at a Paper Manufacturing Factory in Uttarakhand (Brij Mohan and Dwivedi, S.K., Regional Labour Institute, Kanpur)

The Study found deviations in the safety Management System, weaknesses in chemical Storage and process safety aspects. The report recommended strict compliance to permit to work system, review of on-site emergency plan, thorough examination of slings, structural stability test of washing section of pulp mill and CO sensors with alarm in the Producer gas plant and proper maintenance of the poke holes on the reaction chambers in producer gas plant.

Assessment of Capabilities & Management of Occupational Safety and Health in the State of Chhattisgarh (Shrivastatva, S.K., Rustagi, N.K., and Bhattacharya, Champak, Regional Labour Institute, Kanpur)

The Study found that only few factories are sending annual returns. It is recommended that efforts should be made to ensure compliance with the requirement of submission of annual returns in prescribed format by registered factories. Basic metal & alloys industries contribute to maximum number of fatal injuries; therefore during the inspection of basic metal & alloys factories, safety aspect should be given consideration by the factory inspectors. The need for training of workers in safety and health aspect was emphasised. It was recommended that the occupiers / the managers of the factories should be told about their statutory duties for implementation of suitable work procedures, permit to work system & safe system of work. The analysis of accidents with respect to the location of injuries reveals that hands and foot are the body parts which are frequently injured in accidents. This indicates that proper protection of these body parts is not ensured at workplace. It was recommended that all occupiers must be advised to send the reports duly filled and mention the NIC code of the industry. It was also suggested that form 22 may be changed accordingly to ensure that all required information is filled therein.

QUOTABLE QUOTES

· Broken tools can be replaced. You can't be.

· Don't let the light go out, wear eye protection.

· Informed is better than deformed.

· Living with your mistakes is harder than you think.... wear your safety gear.

· My job provides my paycheck, but safety takes me home.