INDUSTRIAL HAZARD

CHAPTER 4CHAPTER 4

CONTENTCONTENT

ErgonomicsErgonomics

Health and Toxic SubstancesHealth and Toxic Substances

Environmental Control and NoiseEnvironmental Control and Noise

Flammable and Explosive MaterialsFlammable and Explosive Materials

Fire Protection Fire Protection

Electrical Hazards Electrical Hazards

Personal Protection and First Aid Personal Protection and First Aid

Material Handling and Storage Material Handling and Storage

Mechanical Hazards Mechanical Hazards

ErgonomicsErgonomics

““Ergonomics is a multidisciplinary science that studies Ergonomics is a multidisciplinary science that studies human physical and psychological capabilities and human physical and psychological capabilities and limitations. This body of knowledge can be used to limitations. This body of knowledge can be used to

design or modify the workplace, equipment, products, design or modify the workplace, equipment, products, or work procedures to improve human performance and or work procedures to improve human performance and

reduce the likelihood of injury and illnessreduce the likelihood of injury and illness””

““Ergonomik adalah kepelbagaian-bidang sains yang mempelajari Ergonomik adalah kepelbagaian-bidang sains yang mempelajari kemampuan dan batasan fizikal dan psikologi manusia… Digunakan kemampuan dan batasan fizikal dan psikologi manusia… Digunakan untuk merekacipta atau merombak tempat kerja, peralatan, produk-untuk merekacipta atau merombak tempat kerja, peralatan, produk-

produk, atau prosedur kerja untuk menambah-baik persembahan produk, atau prosedur kerja untuk menambah-baik persembahan manusia…. Mengurangkan kebarangkalian kecederaan dan manusia…. Mengurangkan kebarangkalian kecederaan dan

kesakitan…”kesakitan…”

(Source: ref. Work-Related)(Source: ref. Work-Related)

“Ergonomics bloopers: Never assume that people use product accordingto plan”

Designing Safety Features into Workplace MachinesDesigning Safety Features into Workplace Machines

Example of the application of ergonomics principles in the design of Example of the application of ergonomics principles in the design of machine controls:machine controls:

Design of punch press footswitchesDesign of punch press footswitches

A properly designed standard footswitch for activating a A properly designed standard footswitch for activating a mechanical power press has a cover to prevent the operator mechanical power press has a cover to prevent the operator or other personnel from accidentally stepping on the pedal or or other personnel from accidentally stepping on the pedal or switch.switch.

Controlling the Work EnvironmentControlling the Work Environment

-Physical environment that surrounds the worker in the workplace:-Physical environment that surrounds the worker in the workplace:

-Temperature of work environment-Temperature of work environment

-Humidity-Humidity

-Pollution-Pollution

Workplace Musculoskeletal DisordersWorkplace Musculoskeletal Disorders

Carpal Tunnel SyndromeCarpal Tunnel Syndrome a medical condition in which the median nerve is compressed at a medical condition in which the median nerve is compressed at

the wrist, leading to pain, paresthesias, and muscle weakness in the wrist, leading to pain, paresthesias, and muscle weakness in the forearm and hand.the forearm and hand.

Cumulative Trauma Disorders / Cumulative Trauma Disorders / Repetitive Strain InjuriesRepetitive Strain Injuries

caused by repetitive tasks,caused by repetitive tasks, is any of a loose group of conditions resulting from overuse of a tool, eg. computer, guitar or knife

Musculoskeletal Disorders (MSD)Musculoskeletal Disorders (MSD) Caused either by the work itself or by the employees' Caused either by the work itself or by the employees'

working environment. They can also result from fractures working environment. They can also result from fractures sustained in an accident. Typically, MSDs affect the back, sustained in an accident. Typically, MSDs affect the back, neck, shoulders and upper limbs; less often they affect the neck, shoulders and upper limbs; less often they affect the lower limbslower limbs

Health and Toxic SubstancesHealth and Toxic Substances

-Health hazard carry a great deal of impact because the potential harm -Health hazard carry a great deal of impact because the potential harm to exposed employees is great and the cost of correction of a single to exposed employees is great and the cost of correction of a single health hazard is high.health hazard is high.

--HealthHealth deals with the long term chronic exposure effects. (remember deals with the long term chronic exposure effects. (remember the 3 case-studies in chapter 1!)the 3 case-studies in chapter 1!)

--SafetySafety deals with the more obvious acute effects that do their damage deals with the more obvious acute effects that do their damage immediately. (acute=rapid effect)immediately. (acute=rapid effect)

-Toxic substances must be controlled for the health of the workers as -Toxic substances must be controlled for the health of the workers as well as to avoid OSHA citation.well as to avoid OSHA citation.

Toxic Substances Toxic Substances

Irritants (Iritasi)Irritants (Iritasi)

-Inflame the surfaces of the parts of the body by their corrosive action.-Inflame the surfaces of the parts of the body by their corrosive action.

-Effect skin, moister surface especially the lungs.-Effect skin, moister surface especially the lungs.

Example:Example:

-dust-dust-ammonia-ammonia-chlorine gas-chlorine gas-acid mists-acid mists

Toxic Substances Toxic Substances

Systemic Poisons (Keracunan sistem dalaman)Systemic Poisons (Keracunan sistem dalaman)

-Attack vital organs or systems of organs such as liver damage n etc.-Attack vital organs or systems of organs such as liver damage n etc.

Example:Example:

-lead-lead-carbon disulfide-carbon disulfide-Methyl alcohol (methanol)-Methyl alcohol (methanol)

Toxic Substances Toxic Substances

DepressantsDepressants

-Certain substances act as depressants or narcotics on the central -Certain substances act as depressants or narcotics on the central nervous system.nervous system.

-Affecting safety and health because interfere with the concentration -Affecting safety and health because interfere with the concentration of workers who operate machinery.of workers who operate machinery.

Example:Example:-Ethyl alcohol ( the ‘drinking’ variety of alcohol)-Ethyl alcohol ( the ‘drinking’ variety of alcohol)-Acetylene-Acetylene-Benzene-Benzene

Toxic Substances Toxic Substances

CarcinogensCarcinogens

-Substances that are known to cause or are suspected to cause -Substances that are known to cause or are suspected to cause cancer.cancer.

Example:Example:

-Vinyl chloride (cause a form of cancer of the liver)-Vinyl chloride (cause a form of cancer of the liver)-Polyvinyl chloride-Polyvinyl chloride

Toxic Substances Toxic Substances

Air ContaminantsAir Contaminants

-Gases easily contaminate the air because air consists of gases and -Gases easily contaminate the air because air consists of gases and gases readily mix. gases readily mix.

Eg; carbon monoxide, hydrogen sulfide and chlorine.Eg; carbon monoxide, hydrogen sulfide and chlorine.

-Vapors are also gases (liquids or solids) that release small quantities -Vapors are also gases (liquids or solids) that release small quantities of gases into the surrounding air.of gases into the surrounding air.

Eg; Gasoline and solventsEg; Gasoline and solvents

-Dusts (solid particles)-Dusts (solid particles)

Eg: Asbestos, coal, cotton and radioactive dustsEg: Asbestos, coal, cotton and radioactive dusts

Toxic Substances Toxic Substances

Air ContaminantsAir Contaminants

-Fumes are also solid particles, but are generally too fine to be called -Fumes are also solid particles, but are generally too fine to be called dust.dust.

Eg: Metal fumesEg: Metal fumes

Environmental Control and NoiseEnvironmental Control and Noise

--Environmental controlEnvironmental control: Involve strategies for dealing with air : Involve strategies for dealing with air contaminants problem, chiefly through contaminants problem, chiefly through

ventilation. ventilation.

--Industrial NoiseIndustrial Noise : Phenomenon that requires an understanding of the : Phenomenon that requires an understanding of the physics of sound-wave energy. physics of sound-wave energy.

Ventilation Ventilation

-Ventilation is the most obvious engineering solution to an air--Ventilation is the most obvious engineering solution to an air-contaminant problem.contaminant problem.

-The most desirable way to deal with air contaminant is:-The most desirable way to deal with air contaminant is:

change the process (isolate or enclose it) so that the change the process (isolate or enclose it) so that the contaminant is no longer produced.contaminant is no longer produced.

change the material usedchange the material used

Ventilation Ventilation

Design PrinciplesDesign Principles

-If the process cannot be changed or materials substituted, a well--If the process cannot be changed or materials substituted, a well-designed ventilation system may be the best solution.designed ventilation system may be the best solution.

--Exhaust ventilationExhaust ventilation is not the same as ordinary heating and air is not the same as ordinary heating and air conditioning. (design error can be made if this difference is not conditioning. (design error can be made if this difference is not considered) considered)

Figure 4.1 : Avoid sharp angles at duct entry

Ventilation Ventilation

Makeup AirMakeup Air

-Open windows and doors (traditional way to makeup air)-Open windows and doors (traditional way to makeup air)

-Recirculate the exhaust air after filtration and decontamination-Recirculate the exhaust air after filtration and decontamination

-Introduce the makeup air right at the point at which the contamination -Introduce the makeup air right at the point at which the contamination is taking placeis taking place

-Use a heat exchanger to recapture the energy of the exhaust air and -Use a heat exchanger to recapture the energy of the exhaust air and transfer it to the incoming make up air.transfer it to the incoming make up air.

Ventilation Ventilation

Figure 4.2 : Fan location – keep negative pressure within the duct

-The best exhaust ventilation systems are the “pull” types, not the -The best exhaust ventilation systems are the “pull” types, not the “push” types.“push” types.

-Within the exhaust duct, the fan should be placed at the end of the -Within the exhaust duct, the fan should be placed at the end of the duct if possible.duct if possible.

`Industrial Noise Industrial Noise

-Noise exposure cause a health problem-Noise exposure cause a health problem

-Noise can be defined as unwanted sound-Noise can be defined as unwanted sound

-In industrial sense, noise means excessive sound or harmful sound-In industrial sense, noise means excessive sound or harmful sound

-Sound level meter can be used to measure sound levels-Sound level meter can be used to measure sound levels

Noise prevention:Noise prevention:

a) Personal protective equipmenta) Personal protective equipmentb) elimination of the source of the noiseb) elimination of the source of the noise

Flammable and Explosive MaterialsFlammable and Explosive Materials

Flammable liquidsFlammable liquids (such as gasoline) have a flash point below 37.7 (such as gasoline) have a flash point below 37.700C C (100(10000F).F).

Combustible liquidsCombustible liquids have a flash point at or higher than flammable have a flash point at or higher than flammable liquids.liquids.

Explosive rangeExplosive range or or flammable rangeflammable range defines the concentration of a defines the concentration of a vapor or gas in air that can ignite from a source.vapor or gas in air that can ignite from a source.

Classes of flammable and combustible liquidsClasses of flammable and combustible liquids

Flammable LiquidsFlammable Liquids

Class I-AClass I-A Flash point below 73Flash point below 7300F, boiling point below 100F, boiling point below 10000F.F.Class I-BClass I-B Flash point below 73Flash point below 7300F, boiling point at or above 100F, boiling point at or above 10000F.F.Class I-CClass I-C Flash point at or above 73Flash point at or above 7300F, but below 100F, but below 10000F.F.

Combustible LiquidsCombustible Liquids

Class IIClass II Flash point at or above 100Flash point at or above 10000F, but below 140F, but below 14000F.F.Class III-AClass III-A Flash point at or above 140Flash point at or above 14000F, but below 200F, but below 20000F.F.Class III-BClass III-B Flash point at or above 200Flash point at or above 20000F.F.

ExplosivesExplosives

Explosives are classified according to degree of hazard.Explosives are classified according to degree of hazard.

Class AClass A is the most hazardous ( nitroglycerin, black powder and is the most hazardous ( nitroglycerin, black powder and dynamite).dynamite).

Class BClass B explosives include propellants, photographic, flash powders explosives include propellants, photographic, flash powders and some special fireworks.and some special fireworks.

Class CClass C explosives are manufactured articles that contain explosives explosives are manufactured articles that contain explosives in restricted quantities.in restricted quantities.

Fire ProtectionFire Protection

-Effective fire prevention requires anticipation of fire sources.-Effective fire prevention requires anticipation of fire sources.

-Cause of industrial fires are :-Cause of industrial fires are :

Overheated bearings or hot machinery and processes.Overheated bearings or hot machinery and processes. Clogged or dirty ventilation filters or ducts (when the clogging Clogged or dirty ventilation filters or ducts (when the clogging material is a flammable or combustible air contaminant).material is a flammable or combustible air contaminant).

Prevention :Prevention :

Effective preventive maintenanceEffective preventive maintenanceStrategy in housekeepingStrategy in housekeeping

Emergency Evacuation Emergency Evacuation

Alarm systemsAlarm systems

Fire Detection SystemsFire Detection Systems

-Smoke alarms and other detection devices-Smoke alarms and other detection devices

-Most detection systems are delicate instruments and will not -Most detection systems are delicate instruments and will not withstand the rigors of the industrial environmentwithstand the rigors of the industrial environment

-Conditions to be considered are dust, corrosive atmospheres, -Conditions to be considered are dust, corrosive atmospheres, weather exposure, heat from processes and mechanical damage.weather exposure, heat from processes and mechanical damage.

Fire Brigades Fire Brigades

Some firms may adopt a strategy in which employees are organized Some firms may adopt a strategy in which employees are organized into brigade to fight fire themselves.into brigade to fight fire themselves.

They have to consider :They have to consider :

Employee fitnessEmployee fitness

Firefighter trainingFirefighter training

Protective Clothing and ApparatusProtective Clothing and Apparatus

Fire ExtinguishersFire Extinguishers

-Fire extinguishers are still the most effective method of immediately -Fire extinguishers are still the most effective method of immediately controlling a very local fire before disastrous consequences ensue.controlling a very local fire before disastrous consequences ensue.

-Fire protection field classifies fires into four categories.-Fire protection field classifies fires into four categories.

-Wrong application of extinguishment medium to a fire can do more -Wrong application of extinguishment medium to a fire can do more harm than good.harm than good.

Fire ExtinguishersFire Extinguishers

Figure 4.3 : Four Classes of Fires and Appropriate Extinguishing Media

Another type of fire protection systems are:Another type of fire protection systems are:

Standpipe and Hose SystemsStandpipe and Hose Systems

Automatic Sprinkler SystemsAutomatic Sprinkler Systems

Fixed Extinguishing SystemsFixed Extinguishing Systems

Material Handling and StorageMaterial Handling and Storage

-Handling of material in manufacturing plant can be as hazardous as -Handling of material in manufacturing plant can be as hazardous as the industrial process itself.the industrial process itself.

-General hazards of material-handling equipment are :-General hazards of material-handling equipment are :

Being struck by an industrial truck or conveyor Being struck by an industrial truck or conveyor Automatic or remote control nature (conveyor accidents)Automatic or remote control nature (conveyor accidents)

-Material storage standards; bags, containers, or bundles stored in -Material storage standards; bags, containers, or bundles stored in tiers shall be “stacked, blocked, interlocked, and limited in height so tiers shall be “stacked, blocked, interlocked, and limited in height so that they are stable and secure against sliding or collapse.”that they are stable and secure against sliding or collapse.”

Industrial Trucks Industrial Trucks

-Category of material-handling equipment-Category of material-handling equipment

-Important factors that should be consider in reducing hazards -Important factors that should be consider in reducing hazards regarding industrial trucks:regarding industrial trucks:

Truck selectionTruck selection

OperationsOperations

Forklift driver trainingForklift driver training

PassengersPassengers

Parking and maintenanceParking and maintenance

Personal Protection and First AidPersonal Protection and First Aid

-Personal protective equipment (PPE) must be properly selected to -Personal protective equipment (PPE) must be properly selected to match the hazard.match the hazard.

-Employer must be trained to use PPE properly.-Employer must be trained to use PPE properly.

-Example:-Example:

Hearing protectionHearing protection Eye and face protectionEye and face protection Respiratory protectionRespiratory protection Head protectionHead protection

Hearing Protection Hearing Protection

-Important factor in selecting a type of noise protection is probably -Important factor in selecting a type of noise protection is probably effectiveness in reducing decibel level of noise exposure.effectiveness in reducing decibel level of noise exposure.

Various types of ear protection:Various types of ear protection:

Cotton ballsCotton balls Swedish woolsSwedish wools EarplugsEarplugs Molded Ear CapsMolded Ear Caps EarmuffsEarmuffs HelmetsHelmets

Eye and Face Protection Eye and Face Protection

Figure 4.4 : Appropriate PPE for various hazards

Respiratory Protection Respiratory Protection

Classification of respiratory protection devices;Classification of respiratory protection devices;

1. Air-purifying devices1. Air-purifying devices (a) Dust mask(a) Dust mask (b) Quarter mask(b) Quarter mask (c) Half mask(c) Half mask (d) Full-face mask(d) Full-face mask (e) Gas mask(e) Gas mask (f ) Mouthpiece respirator(f ) Mouthpiece respirator

2. Atmosphere-supplying respirators2. Atmosphere-supplying respirators (a) Air line respirator(a) Air line respirator (b) Hose mask(b) Hose mask (c) Self-contained breathing apparatus(c) Self-contained breathing apparatus

Head Protection Head Protection

-Implementation of hard hat rules-Implementation of hard hat rules

Figure 4.3 : Various types of hard hat

First Aid First Aid

-First-aid station may satisfy several additional functions besides -First-aid station may satisfy several additional functions besides providing immediate care for the injured.providing immediate care for the injured.

-First aid station is often used for :-First aid station is often used for :

Medical testsMedical testsScreening examinationsScreening examinationsMonitoring of acute and chronic effects of health hazardsMonitoring of acute and chronic effects of health hazards

-Provision of emergency showers and emergency eyewash stations on -Provision of emergency showers and emergency eyewash stations on job sites job sites

Electrical HazardsElectrical Hazards

-Electricity is the flow of negatively charged particles called electrons -Electricity is the flow of negatively charged particles called electrons through an electrically conductive material.through an electrically conductive material.

Sources of electrical hazards are:Sources of electrical hazards are:

Equipment failureEquipment failure Improper wiringImproper wiring Insulation failureInsulation failure Static electricity dischargeStatic electricity discharge Using metal ladders to work on electrical equipmentUsing metal ladders to work on electrical equipment Working on electrical equipment without ensuring that the Working on electrical equipment without ensuring that the

power has been shut offpower has been shut off Lightning strikesLightning strikes

Reduction of Electrical Hazards Reduction of Electrical Hazards

Method of reducing electrical hazards:Method of reducing electrical hazards:

Grounding of electrical equipment Grounding of electrical equipment

-safeguard people from electrical shock-safeguard people from electrical shock

-reduce the probability of a fire-reduce the probability of a fire

-protect equipment from damage-protect equipment from damage

Humidification Humidification

Use antistatic materialsUse antistatic materials

IonizersIonizers

Double insulationDouble insulation

Mechanical HazardsMechanical Hazards

Mechanical hazards are those associated with Mechanical hazards are those associated with power-driven machines, whether automated or power-driven machines, whether automated or

manually operatedmanually operated

Common Mechanical Hazards Common Mechanical Hazards

CommonMechanical

InjuryHazards

Puncturing

Cutting and

Tearing

Shearing

CrushingStrainingand

spraining

Figure 4.5 : Some common mechanical hazards

Safeguarding Safeguarding

Machine safeguarding is to minimize the risk of accidents of Machine safeguarding is to minimize the risk of accidents of machine-operator contact.machine-operator contact.

The contact can be:The contact can be:

An individual making the contact with the machine-usually the An individual making the contact with the machine-usually the moving partmoving part

From the machine via flying metal chips, chemical and hot From the machine via flying metal chips, chemical and hot splashes, and circular saw kickbackssplashes, and circular saw kickbacks

Caused by the direct result of a machine malfunction, Caused by the direct result of a machine malfunction, including mechanical and electrical failureincluding mechanical and electrical failure

OSHA’s Requirement for Machine Guarding OSHA’s Requirement for Machine Guarding

OSHA’s requirement for machine guarding are summarized as OSHA’s requirement for machine guarding are summarized as follows:follows:

a) Types of guardinga) Types of guarding

b) General requirements for machine guardsb) General requirements for machine guards

c) Guarding the point of operationc) Guarding the point of operation

d) Machines requiring point of operation guardsd) Machines requiring point of operation guards

e) Exposure of bladese) Exposure of blades

f) Anchoring fixed machineryf) Anchoring fixed machinery

Quiz 3

• Give one example of the effect of toxic the effect of toxic substances substances to human.to human.

Thank You

To be continued on next lecture