This document discusses industrial hazards and safety. It begins with an introduction defining industrial hazards as conditions produced by industries that can cause injury, death, property loss or loss of product. It then outlines various types of hazards like heat, cold, noise, radiation, chemicals and their preventive measures. The document also discusses effluent testing and treatment, recommending testing industrial wastewater to determine pollution levels and presence of toxic ingredients in order to properly treat the effluent before discharge. Signage and proper identification of hazards is also emphasized.

1. INDUSTRIAL HAZARDS AND SAFETY
Prof. Dr. Basavaraj K. Nanjwade
M. Pharm., Ph. D
Department of Pharmaceutics
KLE University College of Pharmacy
BELGAUM-590010, Karnataka, India
Cell No: 00919742431000
E-mail : nanjwadebk@gmail.com
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KLE College of Pharmacy, Nipani
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2. CONTENTS
•
•
•
•
•
Introduction
Types of hazards
Recommendations and Suggestions
Industrial effluent testing and treatment
Discussion on industrial accident case
studies
• Questions
• References
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3. INTRODUCTION
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.
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4. 24 August 2012
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5. 24 August 2012
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6. Heat and Cold
Burns
Foot sore
Heat stroke
Immersion foot
Heat cramps
Frost bite
Preventive Measures
A reasonable temp. of 20-250C must be maintained
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8. Noise have two type of effects
 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.
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9. 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
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10. Equipment noise sources ,level & potential control solutions
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
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12. 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
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13. Effect of hazards


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.
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15. Fire & explosion 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
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16. 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
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17. Fire & explosion hazards
• 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
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18. Inhalation
Local
– Dermatitis
– Gas Poisoning
– Eczema
– Ulcers
– Cancer
Chemical Hazards
Ingestion
Living tissue may be destroyed by chemical reactions such as
Dehydration
Digestion
Oxidation
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19. 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
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20. 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
Minimal use of
monitoring
underground tanks
interior & exterior
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21. PREVENTIVE MEASURES
• Tolerance levels for toxic chemicals set by federal
regulations have to be followed.
• Strict observation of operations of all safety
regulations
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22. Biological hazards
• Disease due to biological hazards
 Brucellosis (dairy industry)
 Byssinosis (textile industry)
 Bagassosis (sugar-cane)
 Loco motor disorder
• Preventive measures
Periodic health check up
Personal protection
The manufacturer should also provide
First aid facilities
Initial examination
Facility for vaccination
Routine sanitation programme
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23. 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
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24. Mechanical hazards
•In order to prevent mechanical accidents factories act
lay down certain requirements
For cranes
End buffers
Indicating lamps
Signals
Proof loading
upto20 tons
25% in excess
20 to 50 tons 5 tons in excess
above 50 tons 10% in excess
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25. Mechanical hazards
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26. 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.
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27. Building planning
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28. Safe material handling
• 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.
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29. Personal protective devices
• 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.
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30. 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.
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31. Pollution hazards
•
a.
b.
c.
d.
Types
Air pollution
Water pollution
Thermal pollution
Sound pollution
Air pollution
• Sources
 Automobiles
 Industries
 Domestic
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32. Preventive measures
i.
Those suitable for removing particulate matter
a. Ventilation
 Exhaust ventilation
 Plenum ventilation
a. Air purifying equipment
ii. Those associated with removing gaseous pollutants
Water pollution
1. Types of water pollutants
 Physical
 Chemical
 Physiological
 Biological
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33. Preventive measures
2.
3.
a.
i.


ii.
iii.
b.
Problems of water pollution
Preventive measure
Control of water pollution
Physical treatment
Storage
Filtration
Chemical treatment
Biological treatment
Treatment of industrial waste
Primary treatment
Secondary treatment
Tertiary treatment
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34. 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 ponds
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35. Recommendations & suggestions
Proper treatment & disposal methods for effluents
should be adopted
An awareness program
Measures for increase efficiency of the water use
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36. 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.
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37. 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.
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38. (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.
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39. (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.
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40. Pictograph
Pictograph means a pictorial representation used to
identify a hazardous condition or to convey a safety
instruction
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41. 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.
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42. Tag
Tag means a device usually made of card, paper, pasteboard,
plastic or other material used to identify a hazardous
condition.
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43. 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.
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44. 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.
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45. Warning Tags
Warning 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
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46. Biological Hazard Tags
The symbol design for biological hazard tags shall
conform to the design shown below:
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47. Color Coding-Danger Tag
"DANGER" -- Red, or predominantly red, with
lettering or symbols in a contrasting color.
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48. Color Coding-Caution Tag
"CAUTION" -- Yellow, or predominantly yellow, with
lettering or symbols in a contrasting color.
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49. Color Coding-Warning Tag
"WARNING" -- Orange, or predominantly orange, with
lettering or symbols in a contrasting color.
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50. Biological Hazard Tag
BIOLOGICAL HAZARD -- Fluorescent orange or
orange-red, or predominantly so, with lettering or
symbols in a contrasting color.
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51. 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
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52. 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
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53. THE RESULTS OF TESTING ARE REPORTED
AS FOLLOWS:
• 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
pH
TREATMENT METHOD
Acidic
Lime or NAOH
Basic
H2SO4
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54. THE RESULTS OF TESTING ARE REPORTED
AS FOLLOWS:
Suspended Solids
Sedimentation
Oil and grease
-grease taps
-skimming
Cyanide
Chlorinated & complex with pyridine
pyroxolene
-Colourimetrically
Phosphates
-Convert to ammonium molybdatephosphates
-extracted with benzene/ isobutyl alcohol
mixture
-organic phase treated with tin chloride (blue)
Colourimetrically
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-alkaline chlorination
-oxidation with ozone
-oxidation with H2O2
-ppt with chalk or lime
-coagulation with alum
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55. THE RESULTS OF TESTING ARE REPORTED
AS FOLLOWS:
Mercury
-treated with nitric acid and potassium
dichromate soln- treared with tin chloride
Vapour determined by spectrophotometry
Phenolic compounds
Steam distillation-acidify (pH<4)- add CuSO4
soln-
-Coagulation
-chelation with
trimercaptotriazine
Removal by polymeric
adsorbents
Add aminoantipyrine soln- extracted with
chloroform
calorimetrically
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56. 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
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57. Dissol oxy in ppm (mg/ltr)
V=
N=
V 1=
=
N(V) (8) (1000)
V1
Volume of sodium thio sulphate required.
Normality
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
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58. CHEMICAL OXYGEN DEMAND
• 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
X
Where,
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
taken
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N= Normality of ferrous of Pharmacy, Nipani sulphate solution
KLE College ammonium
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59. Limit for Discharge into Systems
Sr. No.
1
2
3
4
5
6
7
8
9
10
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Parameters
pH
Oil and grease
Total suspended solid, mg/l
BOD, mg/l
COD, mg/l
Mercury
Arsenic, mg/l
Cyanide, mg/l
Sulphides, mg/l
Phosphates, mg/l
KLE College of Pharmacy, Nipani
Tolerance limits
5.5 – 9.0
10
100
30
50
0.01
0.20
0.10
2.00
5.00
59

60. 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
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61. 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
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62. Primary Treatment of Waste Water
• It is used
To prevent any damage to equipment
To avoid settling in pipe bends
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63. Primary Treatment of Waste Water
 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
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64. 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 provided
Advantages
• Continuous waste treatment is favored
• Low cost system
Disadvantages
• Prior prediction of biological degradability is not possible
• Solubility limits biodegradability
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65. Secondary Treatment of Waste Water
 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
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66. Secondary Treatment of Waste Water
• 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
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67. Activated Sludge Process
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68. Trickling filtration 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
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69. Trickling Filtration Process
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70. 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
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71. Secondary Treatment of Waste Water
 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.
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72. 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.
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73. 
•

•
•
•
•
Tertiary Treatment Of Waste Water
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.
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74. Tertiary Treatment Of Waste Water
 Adsorption
• Involves treatment with activated carbon.
• Useful for removal of pesticides
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75. 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
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76. THANK YOU
Cell No: 00919742431000
E-mail : nanjwadebk@gmail.com
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