1

EDITORIAL BOARD

R Parameswaran

W A Balakumaran

P Manoharan

S Ulaganathan

Printed at Sunitha Printers, Chennai – 600 002

VOL: 17 No. 1 JANUARY – MARH 2018

QUARTERLY JOURNAL OF SAFETY ENGINEERS ASSOCIATION

G1, Vinoth Foundations, 95/5, Sundaramurthy Gramani Street, Virugambakkam, Chennai-600092.

Tel : 044-2377 4060 E-mail: seaindiachennai@gmail.com Website: www.seaindia.org

INDIAN SAFETY ENGINEERSEA (INDIA)

(Regn No: 1391 / 2000)

[Registered under Societies Act, 1975]

FROM THE DESK OF PRESIDENT

Dear Members,

Greetings to you all in this New Year.

We are happy to inform you that the one day work shop on “Internal Safety Audit” went on well on February 10th 2018 withthe full co operation of SEA India members and the servicesrendered by the officials from the Directorate of Industrial Safetyand health, Government of Tamil Nadu.

The scheduled Factory visit and the Professional Developmentprogram couldn't be conducted in this quarter due to unforeseencircumstances.

However we have arranged the factory visit to Daimler India on6th April 2018.

Our web site on job Portal has been successfully launched andnow active.

SEA India members are requested to upload their CVs andutilize this long felt service.

Further arrangements are being made to conduct the next annualGeneral Body meeting during the first week of May 2018. Asnew team of office bearers are to be elected in this AGM, membersare requested to participate in this AGM and elect suitable andservice minded members to serve in this organization.

Also members are requested to suggest amendments if any to beincorporated in the Bye laws so that it can be discussed in theAGM and the Bye Law amended for the future.

With Best Wishes,

R Parameswaran

PresidentSEA India94440 09819

Inside... Page

From the Desk of President 1

Workshop on

“Internal Safety Audit” 2

Internal Safety Audit –

An Introduction 3

Safety in Construction

Industry 4

Portable Ladder Safety 7

Layers of Protection

Analysis (LOPA) 10

Mental Health in Work Place 12

CASE STUDY 14

Trapped in between

Prime Mover Cabin and

Cabin Door

IN THE NEWS 15

Government urges manufacturing

sector to have more Behavioural

Safety Codes

National Safety Day/Week 15

2

Workshop on “INTERNAL SAFETY AUDIT”

Mr K Kaliannan, Director, Directorate of Industrial Safety & Health, Government of Tamil Nadu delivered

the presidential address and inagurated the Work shop.

Mr B Udayachandran, Head of Works Engineering, Lucas TVS Ltd, Padi, R Paramrswaran, President,

SEA India and P Janarthanam, Joint Secretary, SEA India are in the dias.

REMINDER

As we want to update the postal addresses of all SEAIndia members, you are all requested

to send your current postal address and active email ID (personal) to us at the earliest to:

seaindiachennai@gmail.com

Kind Attention of Members....SEA India wants to share the experience and innovative knowledge on Environment, Health

and Safety related topics among our safety professionals.

If any of our Members want to deliver talk on EHS topics, please contact our Secretary, SEA

(India) for utilizing their services in the ensuing professional development programs being

conducted once in every quarter.

Also, if any of our members want to conduct implant training program in their factories, they

can contact our secretary for organizing such program at nominal cost.

Success stories in improving EHS system in your unit and interesting case studies which may

be useful to our members and safety alerts can be sent to our Mail ID for publication in this

journal.

The source of information will not be disclosed in any form.

3

INTERNAL SAFETY AUDIT – AN INTRODUCTION

Over 7 600 people die each day

from work-related accidents or

diseases - that's over 2.78 million

every year.

The burden of occupational

injuries and diseases is significant,

both for employers and the wider

economy, resulting in losses from

early retirements, staff absence,

besides injury costs and property

damage. Though most of the

enlightened managements have

integrated safety in their

operational systems, still accidents

do occur due to gaps in

understanding Men, Machines,

Materials and Environment in the

work area.

Safety Audits are conducted as

required under statutes or on the

managements' initiative.

Standards are available to conduct

Safety Audit. Some of the popular

standards are:

* IS: 14489

* OHSAS 18001

* ISRS (International Safety

Rating System)

A comprehensive Audit system is

being introduced by ISO

(International Standards

Organisation). It is ISO 45001-

2018 and will be in force in March

2018. As per clause 9(2) of the said

standard, Internal Audit should be

conducted, periodically, to check

the performance of Safety, Health

and Environment systems.

A team of trained technical

persons is formed to conduct

Audit. The team members are

chosen from the field, who are

aware of the local conditions and

the attitude of the shop floor

people. The team, after

conducting the Audit submits the

report to the Chief Executive of

the plant, who in turn directs the

concerned to take follow up

action. This system is more

practical and action is taken to

remove or contain the hazard

potential. The Internal Audit also

minimizes the observations, during

External Audit, thus improving

the image of the company.

In the initial stages, the audit can

be once in three months.

Depending on the compliance

with the observations, it can be

done once in six months. It is to

be done two months earlier to

external audit so that their

observations can be minimised.

Generally accepted procedure for

conducting Internal Safety Audit

is described as under:

1 Identify the hazardous areas

in the plant. It may be based

on the incidents reported,

contract work, work

environment problems,

external auditors' obser-

vations etc., ( Examples)

* House Keeping

* Materials Handling

* Machinery safety

* Fire Protection and

Prevention

* Working at Heights etc.,

2. Divide the main Audit areas

into sub areas, like (for House

Keeping)

* Waste, scrap

* Walkways, stairs

* Tools etc.

3. Prepare check list for each sub

areas (Example for Waste)

* Provision of containers

* Identification of containers

* Marking of location of

containers

* Removal of waste

* Disposal ,Etc.,

4. Decide norms of deviations

against;

* Provisions of statutes

* Standards

* Codes of Practice

* Norms of Professional bodies/

Associations

* Auditors experience and

expertise

5. Prepare a format with details

"Main areas" "Sub areas"

"Checks to be made" "Norms

and deviations"

6. Conduct Audit

7. Prepare a report and submit

to Chief Executive of the

plant.

The Internal safety audit has its

own advantages and limitations.

Some of them are:

* The team members are from

the plant and will know about

the local problems and the

likely deviations that may

occur in the day to day

operations. Hence it is more

practical.

* The correction of the

hazardous situation is faster as

(Contd. on next page)

4

audit report is available,

immediately.

* Better results could be

achieved as shop floor people

make the recommendations.

As the local people are

involved in the Audit, the

message reaches to most

people at shop floor.

Internal Safety ....(Contd. from previous page)

* Familiarity may be a block to

appreciate a problem

* Enough support may not be

available from the

management

* This will be an additional

burden on the auditors, unless

suitably motivated.

* The auditors may not have

adequate experience in the

field of safety.

If these limitations are taken care,

Internal Safety Audit will yield

good results.

SAFETY IN CONSTRUCTION INDUSTRY

Construction work is a hazardous

land-based job. Some

construction site jobs include:

building houses, roads, tree forts,

workplaces and repair and

maintain infrastructures. This

work includes many hazardous

task and conditions such as

working with height, excavation,

noise, dust, power tools and

equipment. The most common

fatalities are caused by: falls, being

struck by an object, electro-

cutions, and being caught in

between two objects. Construc-

tion work has been increasing in

developing and undeveloped

countries over the past few years.

With an increase in this type of

work occupational fatalities have

increased. Occupational fatalities

are individuals who die while on

the job or performing work related

tasks. Within the field of cons-

truction it is important to have

safe construction sites.

Nature of hazards

Hazards to construction workers

The leading safety hazards on

construction sites include falls,

being caught between objects, (Contd. on next page)

electrocutions, and being struck

by objects. These hazards have

caused injuries and deaths on

construction sites throughout the

world. Failures in hazard

identification are often due to

limited or improper training and

inadequate supervision of workers.

Areas where there is limited

training include tasks in design for

safety, safety inspection, and

monitoring safety. Failure in any

of these areas can result in an

increased risk in exposing workers

to harm in the construction

environment.

Falls are the leading cause of

injury in the construction

industry, particularly for elder and

untrained construction workers

Fall protection is needed in areas

including but not limited to

ramps, runways, and other

walkways; excavations; hoist

areas; holes; form-work; leading

edge work; unprotected sides and

edges; overhand bricklaying and

related work; roofing; precast

erection; wall openings; floor

openings such as holes; residential

construction; and other walking/

working surfaces. Other countries

have regulations and guidelines

for fall protections to prevent

injuries and deaths.

Motor vehicle crashes are another

major safety hazard on

construction sites. It is important

to be cautious while operating

motor vehicles or equipment on

the site. A motor vehicle should

have a service brake system,

emergency brake system, and a

parking brake system. All vehicles

must be equipped with an audible

warning system if the operator

chooses to use it. Vehicles must

have windows and doors, power

windshield wipers, and a clear

view of site from the rear window.

All employees should be properly

trained before using motor

vehicles and equipment.

Employees on construction sites

also need to be aware of dangers

on the ground. Cables running

across roadways were often seen

until cable ramp equipment was

invented to protect hoses and

other equipment which had to be

laid out. Another common

5

hazard that workers may face is

overexposure to heat and

humidity in the environment.

Overexertion in this type of

weather can lead to serious heat-

related illnesses such as heat

stroke, heat exhaustion, and heat

cramps Other hazards found on

construction site include asbestos,

solvents, noise, and manual

handling activities.

Education and Safety

Construction workers need to be

properly trained and educated on

the task or job before working,

which will assist in preventing

injuries and deaths. There are

many methods of training

construction workers. One

method is coaching construction

site foremen to include safety in

their daily verbal exchanges with

workers to reduce work-related

accidents. It is important that the

workers use the same language to

assure the best communication. In

recent years, apart from

traditional face to face safety

knowledge sharing, mobile apps

also make knowledge sharing

possible.

Another method is ensuring that

all workers know how to properly

use electronics, conveyors, skid-

steer, trucks, aerial lifts, and other

equipment on the construction

site. Equipment on the job site

must be properly maintained and

inspected regularly before and

after each shift. The equipment

inspection system will help the

operator make sure that a

machine is mechanically sound

and in safe operating conditions.

An employee should be assigned

to inspect equipment to insure

proper safety. Equipment should

have lights and reflectors if

intended for night use. The glass

in the cab of the equipment must

be safety glass in some countries

The equipment must be used for

its intended task at all times on

the job site to insure workers'

safety.

Each construction site should

have a construction site manager.

This is an occupational health

and safety specialist who designs

and implements safety regulations

to minimize injuries and

accidents. He or she also is in

charge of conducting daily safety

audits and inspections to ensure

compliance with government

regulations. Most construction

site managers have an entry level

experience or higher degree.

Before any excavation takes place,

the contractor is responsible for

notifying all applicable companies

that excavation work is being

performed. During excavation,

the contractor is responsible for

providing a safe work

environment for employees and

pedestrians.

Access and egress are also

important parts of excavation

safety. Ramps used by equipment

must be designed by a person

qualified in structural design. No

person is allowed to cross

underneath or stand underneath

any loading or digging equipment.

Employees are to remain at a safe

distance from all equipment while

it is operational. Employees who

have training and education in

the above areas will benefit their

co-workers and themselves on the

construction site.

Media safety campaigns

Road construction safety remains

a priority among workers. Several

states in U.S. have implemented

campaigns addressing construc-

tion zone dangers and encoura-

ging motorists to use caution

when driving through work zones.

National Work Zone Safety

Awareness Week is held yearly.

The national event began in 1999

and has gained popularity and

media attention each year since.

The purpose of the event is to

draw national attention to

motorist and worker safety issues

in work zones.

Preventing Accidents and

improving Safety

Site preparation aids in preventing

injury and death on construction

sites. Site preparation includes

removing debris, leveling the

ground, filling holes, cutting tree

roots, and marking gas, water, and

electric pipelines. Another

prevention method on the

construction site is to provide a

scaffold that is rigid and sufficient

to carry its own weight plus four

times the maximum intended load

without settling or displacement.

Ways to prevent injuries and

improve safety include:

• Management safety

• Integrate safety as a part of

the job

• Create accountability at all

levels

Safety in ....(Contd. from previous page)

(Contd. on next page)

6

• Take safety into account

during the project planning

process

• Make sure the contractors

are pre-qualified for safety

• Make sure the workers are

properly trained in

appropriate areas

• Have a fall protection system

• Prevent and address

substance abuse to employees

• Make safety a part of

everyday conversation

• Review accidents and near

misses, as well as regular

inspections

• Innovative safety training,

e.g. adoption of virtual reality

in training

• Replace some of the works by

robots (many workers may

worry that this will decrease

their employment rate)

• Adoption of BIM (Building

Information Modelling) with

three dimensional printing to

make the building model first

before put into real practice

The employees or employers are

responsible for providing fall

protection systems and to ensure

the use of systems. Fall protection

can be provided by guardrail

systems, safety net systems,

personal fall arrest systems,

positioning device systems, and

warning line systems. Making

sure that ladders are long enough

to safely reach the work area to

prevent injury. Stairway, treads,

and walkways must be free of

dangerous objects, debris and

materials. A registered

professional engineer should

design a protective system for

trenches 20 feet deep or greater

for safety reasons. To prevent

injury with cranes, they should be

inspected for any damage. The

operator should know the

maximum weight of the load that

the crane is to lift. All operators

should be trained and certified to

ensure that they operate forklifts

safely.

Operational Excellence Model to

improve safety for construction

organizations

There are 13 safety drivers

associated with this model to

improve safety for construction

organizations:

1. Recognition & Reward

2. Employee Engagement

3. Subcontractor Management

4. Training & Competence

5. Risk Awareness, Manage-

ment & Tolerance

6. Learning Organization

7. Human Performance

8. Transformational Leadership

9. Shared Values, Beliefs, and

Assumptions

10. Strategic Safety

Communication

11. Just & Fair Practices and

Procedures

12. Worksite Organization

13. Owner's Role

Each safety driver mentioned

above has some sub-elements

attributed to it.

Personal protective equipment

Hard hats and steel-toe boots are

perhaps the most common

personal protective equipment

worn by construction workers

around the world. A risk

assessment may deem that other

protective equipment is

appropriate, such as gloves,

goggles, or high-visibility clothing.

Hazards to non-workers

Many construction sites cannot

completely exclude non-workers.

Road construction sites must

often allow traffic to pass through.

This places non-workers at some

degree of risk.

Road construction sites are

blocked off and traffic is

redirected. The sites and vehicles

are protected by signs and

barricades. However, sometimes

even these signs and barricades

can be a hazard to vehicle traffic.

For example, improperly designed

barricades can cause cars that

strike them to roll over or even be

thrown into the air. Even a simple

safety sign can penetrate the

windshield or roof of a car if it

strikes from certain angles.

The majority of deaths in

construction are caused by

hazards relating to construction

activity. However, many deaths

are also caused by non

construction activities, such as

electrical hazards. A notable

example of this occurred when

Andy Roberts, a father of four,

was killed in 1988 in New York

while changing a light bulb at a

construction site when he came

into contact with a loose bare wire

that was carrying two thousand

volts of electricity and died.

Safety in ....(Contd. from previous page)

7

PORTABLE LADDER SAFETY

Introduction:

Ladders are indispensable tools.

We take them for granted in our

day-to-day work and use them

extensively in virtually all

industries. Though they come in

many sizes, shapes, and styles,

they all serve the same purpose -

to help us move vertically. Each

year in Oregon, about 500

workers are seriously injured when

they fall from ladders - you don’t

have to fall far to get hurt.

Workers injured in falls from

ladders are usually less than 10

feet above the ladder’s base of

support.

Why do people fall from ladders if

they’re so easy to use? In general,

most ladder falls involve portable

ladders that move, tilt, or shift

while a worker is climbing or

descending. Unstable or slippery

base surfaces are the primary

reasons ladders fall over. Other

reasons for ladder falls include a

misstep or a slip of the foot, loss

of balance, an overreach, and

being struck by a vehicle or other

object.

Workers can reduce ladder fall

risks by doing the following:

* Frequently inspect and

maintain ladders

* Match tasks to appropriate

ladders

* Set up ladders correctly

* Climb and descend ladders

properly

* Use ladders whenever there is

a 19” break in elevation

(required)

Employers too, have a

responsibility:

Workers must be trained so they

understand safe work practices

and can use them effectively. At

a minimum, the training program

must include;

* The nature of fall hazards in

the work area,

* Correct procedures for

erecting, maintaining, and

disassembling fall protection

systems that may be used;

* Proper construction, use,

placement, and care in

handling all ladders

* Maximum intended load-

carrying capacities of the

ladders to be used.

Ladder Ratings:

Before you use a ladder, check its

rating. Be sure not to subject it

to a work load greater than its

rated capacity. All portable

ladders receive one of four ratings,

based on their maximum working

load (the maximum weight they

can safely support). The ratings

are:

Rating Working Load

Extra heavy duty (I-A) 300 pounds

Heavy duty (I) 250 pounds

Medium duty (II) 225 pounds

Light duty (III) 200 pounds

Types of Portable Ladders (most

common):

Workers climb up or down to do

all sorts of tasks, so it’s not

surprising that ladders come in

different types to help them

accomplish those tasks. Portable

ladders are either self-supporting

(such as the standard stepladder)

or non-self-supporting (such as

the straight ladder).

Single portable or straight ladder

This is the most

common type of portable

ladder and has the

widest range of

applications.

When used on slippery

surfaces, this ladder

must have slip- resistant

feet or be secured to

prevent it from sliding.

Rubber or neoprene

ladder shoes are

recommended for

smooth, dry surfaces,

and spikes are

recommended for snow

or ice.

Single portable ladders must not

be longer than 30 feet and are

intended for use by only one

worker at a time.

Standard

stepladder

The standard

stepladder, a

general purpose

ladder, has flat

steps and a

hinged back.

These stepladders should be used

only on surfaces that offer firm,

level footing such as floors,

platforms, and slabs. They are

intended to support only one

worker at a time.

(Contd. on next page)

8

Portable ....(Contd. from previous page)

* Remember not to stand on, or

work from, the top step.

* The ladder must have a metal

spreader or locking arm.

Extension or section ladder

Extension ladders offer

the greatest length in a

general purpose ladder.

The ladder consists of

two or more sections that

travel in guides or

brackets, allowing

adjustable length.

* The sections must be

assembled so that the

sliding upper section

is on top of the lower

section.

* Each section must

overlap its adjacent

section a minimum

distance, based on the ladder’s

overall length.

Example: A 14’ landing would

require a 24’ ladder(to

accommodate overlap, three foot

extension, and 4:1 ratio)

* Up to 36 feet, the minimum

overlap is 3 feet.

* Over 36 through 48 feet, the

minimum overlap is 4 feet.

* Over 48 through 60 feet, the

minimum overlap is 5 feet.

Note: Install positive stops on

individual ladder sections to

ensure the required overlap.

Extension ladders are for use by

only one person at a time.

Make sure that extension ladders

have a non-slip bases if there’s a

chance the ladder can slip. Cord-

face ladder shoes (located at the

foot of the ladder where the

ladder makes contact with the

working surface) are recommen-

ded for wet surfaces, rubber or

neoprene ladder shoes for smooth

dry floor surfaces, and steel spikes

for ice or snow.

Be especially careful if you use an

extension ladder on oily, metal, or

concrete surfaces. Place the

ladder securely and tie it off to

prevent it from slipping.

Using Ladders:

At the beginning of each job:

* Select the appropriate ladder

for your task or job.

* Inspect the ladder before you

use it. Make sure it’s in sound

condition, clean, and

undamaged.

Inspect for the 3Ds - Defects,

Damage, and Deterioration.

Placing a Ladder:

* Move the ladder near the

work you’re doing.

* Angle the ladder properly.

The base should extend not

less than one-fourth the

ladder’s length. The

minimum slope should be 50

degrees.

* Place a solid rest for the rail

tops across window opening.

* Protect the base of a tall,

occupied ladder if it could be

struck by vehicles or

pedestrians.

Avoid:

* Placing a ladder in front of an

unlocked, unguarded door.

* Placing a ladder on boxes,

tables, trucks, or other

moveable objects.

Securing a ladder:

* Nail or lash a ladder in place

if it will be used repeatedly in

the same spot.

* Select a ladder that will

extend at least 36 inches

above the access area it’s

serving.

Avoid:

* Working on ladders in exposed

areas during a severe storm or

strong wind.

* Working on ladders covered

with ice or snow.

* Using a portable ladder if an

approved stairway could be

used instead.

Ascending and descending:

* Face the ladder at all times.

* Grasp the side rails with both

hands; you have a better

chance of avoiding a fall if a

rung or step fails.

* Maintain the three point

principal (two hands, one foot;

one hand, two feet).

* Raise and lower heavy,

awkward loads with a hand

line or hoist.

* Attach light, compact tools or

materials to the ladder or to

yourself.

Avoid:

* Sliding down the ladder,

* Climbing when your hands or

shoes are slippery.

(Contd. on next page)

9

Portable ....(Contd. from previous page)

* Using your hands for carrying

items.

* Carrying awkward loads when

ascending or descending a

ladder.

Metal Ladders:

* Make sure steps and rungs

have a skid-resistant surface

that minimizes the risk of

slipping. (“Skid resistant”

means corrugated, knurled,

dimpled, or coated with skid-

resistant material.

Avoid: Using any ladder with

conductive side rails near

exposed, energized equipment.

(such ladders must be

permanently, legibly marked with

the words, “WARNING -- Do

Not Use Around Energized

Electrical Equipment.”)

General precautions:

* Place both feet firmly on the

ladder rungs and steps.

* Make sure only one person

stands on, or works from, a

standard ladder.

* Use a scaffold or a second

ladder if two or more people

are doing the same task.

* Immediately inspect any

ladder that has collapsed,

tipped over, or been exposed

to oil or grease. Clean and

repair the ladder if necessary.

* Remove defective ladders

from service. Tag or mark

defective ladders with the

words: “Dangerous, Do Not

Use.”

* Make sure an extension ladder

extends at least 36 inches

above an access landing.

* Keep the area around the top

and bottom of a ladder from

debris.

* Keep the load on the ladder

(including yourself) below its

maximum load capacity.

DO NOT

* Paint ladders. Paint concealsdefects. Use transparentpreservatives instead.

* Use ladders with broken,patched, oily, or cracked rails,rungs, or steps.

* Reach out over the side rails,lean, or turn excessively on aladder.

* Stand or sit on the top twosteps of a stepladder.

* Use a self-supporting ladderwithout first opening it up andsecuring the metal spreader orlocking device.

* Load a ladder beyond itsmaximum load capacity.

Transporting Ladders:

* When you hand-carry aladder, keep the front endelevated, especially aroundblind corners, in aisles, andthrough doorways. You’llreduce the chance of strikinganother person with the frontof the ladder.

* When you transport a ladderin a truck or trailer, place it

parallel to the bed. Avoidtossing, throwing, or droppingit in the bed.

* If you transport a long ladderon a short truck bed over longdistances, support the ladderso it won’t sag or bend.

* Drive slowly over roughterrain. Tie the laddersecurely to eliminate nicking,gouging, chafing, and roadshock; if side stakes areavailable, use them to preventlateral swing.

Maintaining and Repairing

Ladders:

It pays to have an effective laddermaintenance program. Periodicmaintenance will extend aladder’s life and cut replacementcosts. Maintenance includesregular inspection of the ladder,repairing damage and tighteningstep bolts and other fastenings.Neglected ladders quickly becomeunsafe ladders. Step bolts slacken,step sockets and other joints workloose, hole size increase –eventually the ladder becomestwisted and unstable.

Here are some other things to

consider in maintaining ladders:

* Replace lower steps onwooden ladders when one-fourthof the step surface is worn away.

* Don’t use cleats to repair rungladders.

* Employers who use manyladders should considerstocking repair parts. Typicalitems include ladder bolts,related hardware, and lowersteps or rungs.

DISCLAIMER: All information contained in this Journal, were obtained from sources, believed to be reliable and are collated, based on

technical knowledge and experience, currently available with the Editorial Board of SEA (India). While SEA (India) recommends reference

to or use of the contents by its members and subscribers, such reference to or use of contents by its members or subscribers or third

parties, are purely voluntary and not binding. Therefore the Editorial Board of this Journal or SEA (India) assumes no liability or responsibility

whatsoever towards any bad or undesired consequences.

10

(Contd. on next page)

LAYERS OF PROTECTION ANALYSIS (LOPA)

L O P A

Layers of Protection Analysis,

LOPA is a simplified risk

assessment method. It provides a

method for evaluating the risk of

hazard scenarios and comparing

it with risk tolerance criteria to

decide if existing safeguards are

adequate and whether additional

safe guards are needed. There are

various LOPA methods available.

LOPA does not suggest which safe

guards to add or which design to

choose but it does assist in

deciding between alternatives.

LOPA can be viewed as an

extension of Process Hazard

Analysis (PHA).

Typically it is applied after a PHA

has been performed. LOPA builds

on the information developed in

the PHA.

Why was LOPA developed?

Subjective engineering

judgement is used to identify the

need for additional safeguards in

PHA.

This can lead to disagreements

and possibly the implementation

of inappropriate measures to

reduce risks. It was recognized

that a more rational and

objective approach was needed.

Process designers used a variety

of protection layers or safe guards

to provide a defense in depth

against catastrophic accidents.

They are devices / systems or

actions that are capable of

2004. Functional safety: Safety

Instrumented Systems for the

Process Industry Sector, called

S84 herein , which can include

the use of LOPA.

What is involved in LOPA?

Individual hazard scenarios

defined by cause consequence

pairs are analyzed.

Scenario risk is determined by

combining scenario frequency and

consequence severity.

Individual Protection Layers are

analyzed for their effectiveness

and the combined effects of the

protection layers are compared

against risk tolerance criteria to

determine if additional risk

reduction is required to reach a

tolerable level.

Scenario frequency is determined

by combining initiating event

frequency, IPL failure probabilities

and the probabilities of enabling

events/conditions and the

conditional modifiers. Enabling

events or conditions do not

directly cause the scenario but

must be present or active for the

scenario to proceed, for example,

the process being in a particular

mode or phase. Commonly

considered conditional modifiers

are the probability that released

flammable/explosive material will

ignite, the probability that an

individual will be present to be

exposed to a hazard, and the

probability that an exposed

preventing a sceniorio from

proceeding to an undesired

consequence.

For example, they may be

• Inherently safe design features

• Physical protection such as

relief devices

• Post release physical

protection such as fire

suppression systems

• Plant and community

emergency response

• Safety instrumented systems

SIS

Ideally such protection layers

should be independent from one

another so that anyone will

perform its function regardless of

the action or failure of any other

protection layer or the initiating

event. When they meet this

criterion they are called

Independent Protection Layers(

IPL).

Not all safe guards meet the

independent requirements to be

classified as an IPL.. , Although

all I P Ls are safe guards. For

example, two stand by pumps that

are both electrically powered do

not fail independently in the

event of loss of power.

LOPA addresses safe guards that

are IPLs. Such safe guards

include SIS, also called interlocks

and emergency shutdown

systems. SIS are addressed by the

standard ANSI/ISAS84.00.01-

11

individual will actually be

impacted. Order of magnitude

estimates are used for

frequencies, probabilities and

consequence severity.

How do risk tolerance criteria

help?

Without risk tolerance criteria ,

there is a tendency to keep

adding safe guards in the belief

that the more added, the safer the

process. This can be a false

assumption. Eventually safe

guards will be added that are un

necessary. This reduces the focus

on safe guards that are critical to

achieving tolerable risk. Un

necessary safe guards also add

complexity that may result in new,

un identified hazard scenarios.

LOPA helps focus limited

resources on the most critical safe

guards.

How does LOPA relate to

Quantitative Risk Analysis

(QRA)

LOPA adds simplifying

assumptions for the numerical

information used. The

simplifications are intended to be

conservative so that QRA would

show less risk for a scenario than

LOPA.

How to Conduct PHAs to

facilitate LOPA?

LOPA studies will be easier to

conduct if the following issues are

addressed during the PHA.

Layers of....(Contd. from previous page)

• Clarify initiating events, i.e.

causes of hazard scenarios

• Provide sufficient scenario

detail

• Express consequences in a

form compatible with LOPA

• Record and identify candidate

IPLs, i.e. safe guards

• List all safe guards before

deciding if they are IPLs

• Consider identifying enabling

events/conditions and

conditional events

• Rank hazard scenarios so that

they can be screened for

LOPA

• Flag recommendations for

additional IPLs.

Are there other applications of

LOPA?

There are other applications also

as they can be extended to many

situations involving risk involved

decision making including:

• Design

• Capital improvement planning

• Management of change

• Evaluating facility siting risk

• Mechanical integrity programs

• Identifying operator roles

• Incident investigation

• Emergency response planning

• Bypassing a safety system

• Determining the design basis

for over pressure protection

• Determining the need for

emergency isolation valves

• Screening tool for QRA

What LOPA does and doesn't

do?

There are three issues for

protection layers :

• How safe is safe enough?

• How many protection layers

are needed?

• How much risk reduction

should each layer provide?

Risk tolerance criteria must be

established for LOPA and they

address the first issue.

LOPA helps to decide how much

risk reduction is needed and how

many protection layers should be

used. It does not help to decide

what specific IPLs should be used.

Purpose of performing LOPA.

• Provides an objective rational

and defensible basis for

recommendations to install or

not to install safe guards after

a PHA has been performed

• Meets the requirement of the

S84 standard for SIS. Note

that OSHA expects

compliance with S84.

• Provides the basis for a clear,

functional specification for

safety instrumented systems.

12

MENTAL HEALTH IN THE WORKPLACE

Globally, more than 300 million

people suffer from depression, the

leading cause of disability, with

many of these people also suffering

from symptoms of anxiety. A recent

WHO-led study estimates that

depression and anxiety disorders

cost the global economy US$ 1

trillion each year in lost

productivity. Unemployment is a

well-recognized risk factor for

mental health problems, while

returning to, or getting work is

protective. A negative working

environment may lead to physical

and mental health problems,

harmful use of substances or

alcohol, absenteeism and lost

productivity. Workplaces that

promote mental health and support

people with mental disorders are

more likely to reduce absenteeism,

increase productivity and benefit

from associated economic gains.

This information sheet addresses

mental health and disorders in the

workplace. It also covers difficulties

that may be created or exacerbated

by work such as stress and burnout.

Work-related risk factors for

health: There are many risk factors

for mental health that may be

present in the working

environment. Most risks relate to

interactions between type of work,

the organizational and managerial

environment, the skills and

competencies of employees, and

the support available for employees

to carry out their work. For

example, a person may have the

skills to complete tasks, but they

may have too few resources to do

what is required, or there may be

unsupportive managerial or

organizational practices.

healthy workplace is the

development of governmental

legislation, strategies and polices as

highlighted by recent European

Union Compass work in this area .

A healthy workplace can be

described as one where workers and

managers actively contribute to the

working environment by promoting

and protecting the health, safety

and well-being of all employees. A

recent guide from the World

Economic Forum suggests that

interventions should take a 3-

pronged approach:

• Protect mental health by

reducing work-related risk

factors.?

• Promote mental health by

developing the positive aspects

of work and the strengths of

employees.?

• Address mental health

problems regardless of cause.

The guide highlights steps

organizations can take to create a

healthy workplace, including:

• Awareness of the workplace

environment and how it can be

adapted to promote better

mental health for different

employees.

• Learning from the motivations

of organizational leaders and

employees who have taken

action?

• Not reinventing wheels by

being aware of what other

companies who have taken

action have done?

• Understanding the

opportunities and needs of

individual employees, in

Risks to mental health include:

• inadequate health and safety

policies;

• poor communication and

management practices;

• limited participation in

decision-making or low control

over one's area of work;

• low levels of support for

employees;

• inflexible working hours; and

• unclear tasks or organizational

objectives.

Risks may also be related to job

content, such as unsuitable tasks

for the person's competencies or a

high and unrelenting workload.

Some jobs may carry a higher

personal risk than others (e.g. first

responders and humanitarian

workers), which can have an

impact on mental health and be a

cause of symptoms of mental

disorders, or lead to harmful use of

alcohol or psychoactive drugs. Risk

may be increased in situations

where there is a lack of team

cohesion or social support.

Bullying and psychological

harassment (also known as

"mobbing") are commonly reported

causes of work-related stress by

workers and present risks to the

health of workers. They are

associated with both psychological

and physical problems. These

health consequences can have

costs for employers in terms of

reduced productivity and increased

staff turnover. They can also have

a negative impact on family and

social interactions.

Creating a healthy workplace: An

important element of achieving a(Contd. on next page)

13

helping to develop better

policies for workplace mental

health?

• Awareness of sources of support

and where people can find help.

Interventions and good practices

that protect and promote mental

health in the workplace include:

• implementation and

enforcement of health and

safety policies and practices,

including identification of

distress, harmful use of

psychoactive substances and

illness and providing resources

to manage them;

• informing staff that support is

available;

• involving employees in

decision-making, conveying a

feeling of control and

participation; organizational

practices that support a healthy

work-life balance;

• programmes for career

development of employees; and

• recognizing and rewarding the

contribution of employees.

Mental health interventions should

be delivered as part of an integrated

health and well-being strategy that

covers prevention, early

identification, support and

rehabilitation. Occupational health

services or professionals may

support organizations in

implementing these interventions

where they are available, but even

when they are not, a number of

changes can be made that may

protect and promote mental health.

Key to success is involving

stakeholders and staff at all levels

when providing protection,

promotion and support

interventions and when monitoring

their effectiveness.

Available cost-benefit research on

strategies to address mental health

points towards net benefits. For

example, a recent WHO-led study

estimated that for every USD $1

put into scaled up treatment for

common mental disorders, there is

a return of USD $4 in improved

health and productivity.

Supporting people with mental

disorders at work

Organizations have a responsibility

to support individuals with mental

disorders in either continuing or

returning to work. Research shows

that unemployment, particularly

long term unemployment, can have

a detrimental impact on mental

health. Many of the initiatives

outlined above may help

individuals with mental disorders.

In particular, flexible hours, job-

redesign, addressing negative

workplace dynamics, and

supportive and confidential

communication with management

can help people with mental

disorders continue to or return to

work. Access to evidence-based

treatments has been shown to be

beneficial for depression and other

mental disorders. Because of the

stigma associated with mental

disorders, employers need to ensure

that individuals feel supported and

able to ask for support in

continuing with or returning to

work and are provided with the

necessary resources to do their job.

Article 27 of The UN Convention

on the Rights of Persons with

Disabilities (CRPD) provides a

legally-binding global framework for

promoting the rights of people with

disabilities (including psychosocial

disabilities). It recognizes that every

person with a disability has the

right to work, should be treated

equally and not be discriminated

against, and should be provided

with support in the workplace.

WHO response

At a global policy level, WHO's

Global Plan of Action on Worker's

Health (2008-2017) and Mental

Health Action Plan (2013-2020)

outline relevant principles,

objectives and implementation

strategies to promote good mental

health in the workplace. These

include: addressing social

determinants of mental health,

such as living standards and

working conditions; activities for

prevention and promotion of

health and mental health,

including activities to reduce

stigmatization and discrimination;

and increasing access to evidence-

based care through health service

development, including access to

occupational health services.

To assist organizations and workers,

WHO has produced the

"Protecting Workers' Health" series

which provides guidance on

common issues such as harassment

and stress that can affect the health

of workers. As part of the Mental

health Gap Action Programme

(mhGAP), which provides tools for

evidence-based health care,

WHO's technical instruments for

early identification and

management of alcohol and drug

use disorders and for suicide

prevention can also be useful for

improving mental health in the

workplace. WHO is developing and

testing IT-supported self-help tools

to address common mental

disorders, harmful use of alcohol

and psychological distress in low-

and middle-income countries.

Mental Health ....(Contd. from previous page)

14

TRAPPED IN/BETWEEN

PRIME MOVER CABIN

AND CABIN DOOR:

Description of Incident

A prime mover driver (acontractor) delivered a 20-footlong empty container to a factoryfor loading drums of chemical.When the Operations Managerfailed to contact the driver viawalkie-talkie, he sent a co-workerto look for him. The prime moverdriver was found unconscious andtrapped between the driver’s sideof the cabin and the cabin door ofhis prime mover parked at thefactory. The prime mover hadsurged forward causing the cabindoor to be wedged against theopen leaf of the factory main gate.The driver was pronounced deadby the ambulance crew.

Scene of the Accident

Scene of the accident.

1. The driver was found trappedbetween the driver’s side ofthe cabin and the cabin door.

2. This leaf gate was originallyfully opened and beside thekerb. Its hinges had to be cutand the gate shifted to this

position in order to extricatethe driver.

Possible Causes and

Contributing Factors

Medium

• The prime mover/trailer/container was parked in thefactory driveway which wassloping 2 degrees downwardstowards the main gate.

Man

• The driver parked the primemover in parallel to the openleaf of the main gate at thefactory entrance.

• The driver parked the primemover with its front wheelsturned towards the main gate.

• The driver was trying to getinto the prime mover cabinwhen it suddenly surgedforward.

CASE STUDY

force to push the prime moverforward.

Management

The management did not providea designated work area for safeloading/unloading operation.

Recommendations and Learning

Points

• Designate and clearlydemarcate a proper work areafor safe loading/ unloadingoperation.

• The prime mover should bedisconnected from the trailer/container during loadingunloading.

• Position wheel clamps underthe trailer and prime mover toprevent any unexpectedmovement during loading/unloading.

• Highlight in the Safe Work

Procedures for prime moverdrivers (including contractors)the dangers of parking:

i. On a slope;

ii. Next to an obstruction;

iii. With front wheels turnedtowards the obstruction; and

iv. With the prime mover andtrailer/ container connectedduring loading/unloadingoperation.

Machine

• The prime mover was leftconnected to the trailer/container during the loadingoperation. Although thehandbrake was engaged, theprime mover surged forward asthe weight of the drums thatwere being loaded into theinner end of the containercaused the trailer to press onthe tail end of the primemover. This created sufficient

Causal Analysis

Evaluation of loss • One fatality

Type of contact • Caught between prime mover cabin and cabin door

Immediate cause(s) • Insufficient clearance between prime mover and main gate

Basic cause(s) • Prime mover moved during loading operation

Failure of OSHMS • Hazard identification, risk assessment and risk control

• Operating procedures and safe work practices

• Contractors

15

IN THE NEWS

Government urges manufacturing sector to have more Behavioural Safety Codes

Inaugurating the Second National Conference of the forum of Behavioral safety (BESAFE), Mr Avneesh

Singh, Director General, Factory Advisory Service Labor Institutes, Ministry of Labour said “The Govt

is taking more positive approach towards the industrialization and urges the industry to implement more

number of Behavioural Safety Codes recommended by the ILO to avoid industrial accidents”. He added,

as of now only 43 codes have been recognized out of the total 188 codes stipulated by ILO. The

Behaviour Based Safety (BBS ) is in the very initial stage and will require more time for its implementation

in various sectors of the Indian Economy- Singh added.

Mr H L Kaila, Director, BESAFE, in his welcome address said around 12 lakhs people die in India

alone every year due to Behavioural causes.

“As per the figure given by ILO, around 23 Lakhs people die every year in the world due to such industrial

accidents of which 12 lakhs die in India only due to Behavioural Causes due to which the Global

Economy is not only losing the valuable Man power but also a big chunk of revenues" - he added.

ISO 45001 is now published

The world’s much anticipated International Standard for occupational health and safety (OH&S) has

just been published, and is set to transform workplace practices globally. ISO 45001:2018, Occupational

health and safety management systems - Requirements with guidance for use, provides a robust and

effective set of processes for improving work safety in global supply chains. Designed to help

organizations of all sizes and industries, the new International Standard is expected to reduce workplace

injuries and illnesses around the world.

According to 2017 calculations by the International Labour Organization (ILO), 2.78 million fatal accidents

occur at work yearly. This means that, every day, almost 7 700 persons die of work-related diseases

or injuries. Additionally, there are some 374 million non-fatal work-related injuries and illnesses each

year, many of these resulting in extended absences from work. This paints a sober picture of the modern

workplace - one where workers can suffer serious consequences as a result of simply "doing their

job".

ISO 45001 hopes to change that. It provides governmental agencies, industry and other affected

stakeholders with effective, usable guidance for improving worker safety in countries around the world.

By means of an easy-to-use framework, it can be applied to both captive and partner factories and

production facilities, regardless of their location.

David Smith, Chair of project committee ISO/PC 283 that developed ISO 45001, believes the new

International Standard will be a real game changer for millions of workers: “It is hoped that ISO 45001

will lead to a major transformation in workplace practices and reduce the tragic toll of work-related

accidents and illnesses across the globe.” The new standard will help organizations provide a safe

and healthy work environment for workers and visitors by continually improving their OH&S performance.

Smith adds: “World standards writers have come together to provide a framework for a safer workplace

for all, whatever sector you work in and wherever you work in the world.” More than 70 countries were

directly involved in the creation of this important document, developed by ISO/PC 283, Occupational

health and safety management.

16

The National Safety Day/Week is celebrated

in India every year to commemorate the

establishment of the National Safety Council

on 4th of March 1966.

During the whole week, various safety related

activities are conducted as per the safety

requirements.

NATIONAL SAFETY DAY/WEEK 2018

The theme for this year 2018 is “Reinforce

Positive Behavior at the work place to achieve

Safety & Health goals”.

SEA India pleads all our members to spread

this theme among all the employees and

achieve this goal.