FIRE AND MECHANICAL EQUIPMENT SATYANARAYANAV MPharm I sem Department Of Pharmaceutical Sciences UNIVERSITY COLLEGE OF PHARMACEUTICAL SCIENCES KAKATIYA UNIVERSITY WARANGAL500609 ID: 1038248
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1. INDUSTRIAL HAZARDS DUE TO FIRE AND MECHANICAL EQUIPMENTSATYANARAYANA.V( M.Pharm I sem )Department Of Pharmaceutical SciencesUNIVERSITY COLLEGE OF PHARMACEUTICAL SCIENCES, KAKATIYA UNIVERSITY,WARANGAL-500609.
2. CONTENTSINTODUCTIONTypes of hazards in a pharmaceutical industryFireClassification of firesClassification of hazardous areasPotential cause for a firePrevention of fireMechanical Hazards with equipmentSafety aspects in the pharma industryDisaster management planConclusionReferences
3. Introduction HAZARD is a term associated with a substance that is likely to cause an injury in a given environment.INDUSTRIAL HAZARD is any condition produced by industries that may cause: injury to a personnel, (or)One which may lead to loss of property, products etc; (or) A substance that might proove fatal to the personnel
4. TYPES OF HAZARDS IN AN INDUSTRYFire ChemicalsElectricalMechanicalMiscellanious Pharmaceutical BiologicalPersonnelEnvironmental
5. CHEMICAL HAZARDSVolatility of solventsFlammabilityExplosivityStabilityCorrosivityReactivityRadioactivity
6. ELECTRIC HAZARDS BASED over protective devicesShort – circuit fault protectve deviceOpen circuit fault protective devicesRatings and sizes of surge –protective capacitors
7. Measures to be takenUse of high quality electricalsElectrical equipment maintananceProper handling of chemicalsCHEMICAL SAFETY CARDSExpertsRetailer
8. CHEMICAL DATA SHEETA chemical safety data sheet provides the following basic information about the chemical: Identification : Name of the substance or preparation Name, address and telephone number of the company/supplier/undertaking Composition and information on ingredients Hazards identification First-aid measures Fire-fighting measures Spillage, accidental release measures Handling and storage Exposure controls and personal protection
9. Physical and chemical properties Stability and reactivity Toxicological information Ecological information Disposal considerations Transport information National regulations and references Other information
10. Chemical safety data sheets are published under several names such as: INTERNATIONAL CHEMICAL SAFETY CARD, ICSC CHEMICAL SAFETY CARD CHEMICAL INFO-SHEET MATERIAL SAFETY DATA SHEET, MSDS PRODUCT SAFETY DATA SHEET HEALTH AND SAFETY DATA SAFETY DATA SHEET.
11. Miscellaneous hazardsPharmaceutical BiologicalPersonnelEnvironmental
12. FIRE HAZARDSFire: The self-sustaining process of rapid oxidation of a fuel which produces heat and light Fire is an exothermic chemical reaction between oxygen and fuel at certain temperature.Three things essential for the combustion of fire are;Fuel (any combustible material)Oxygen (At concentrations above 23 % in air, the situation becomes dangerous due to the increased fire hazard)Temperature
13. Classification of firesMost fires that occur will fall into one or more of the following categories Class A: Fires involving ordinary combustible materials, such as paper, wood, and textile fibers, where a cooling, blanketing, or wetting extinguishing agent is needed. Class B: Fires involving flammable liquids such as gasoline, thinners, oil-based paints and greases. Extinguishers for this type of fire include carbon dioxide, dry chemical* and halogenated agent types.
14. Class C: Fires involving energized electrical equipment, where a nonconducting gaseous clean agent or smothering agent is needed. The most common type of extinguisher for this class is a carbon dioxide exinguisher Class D: Fires involving combustible metals such as magnesium, sodium, potassium, titanium, and aluminum. Special dry powder* extinguishing agents are required for this class of fire, and must be tailored to the specific hazardous metal.
15. Class K: Fires involving commercial cooking appliances with vegetable oils, animal oils, or fats at high temperatures. A wet potassium acetate, low pH-based agent is used for this class of fire.
16. Classification of hazardous areasZone 0: an area in which a atmosphere is present continously or is present for long periods.Zone 1: an area in which a flammable atmosphere is likely to be present periodically or occasionally during normal operations.Zone 2: an area in which a flammable atmosphere is likely to be present peridically or occur in normal operations.
17. POTENTIAL CAUSE FOR A FIREImproper design or layoutslack of proper work design processElectricityChemicalsHousekeeping Improper Storage Flammable LiquidsCombustible materialsEquipment Lack of proper ventilation Carelessness
18. Actions in the event of fireFire detectionRaising the alarmCalling the local fire brigadeFirst aid – fire fighting practiceevacuation
19. PREVENTION OF A FIREWell planned design and layoutProper ventilated systemsChemical data sheetsProper training of personnelProper maintenance of surroundingsuse of fire extinguishers, alarms ,sensors, detectorsFire fighting equipmentSprinkler systems
20. Extinguishment TheoryRemoving Heat Removing Fuel Reducing Oxygen WILL Inhibit Chemical Chain Reaction
21. FIRE EXTINGUISHERSThe fire extinguishing agents are classified into Water and water based agents portable extinguishers soda acid extinguishers antifreeze extinguishers foamDry chemical Carbon dioxideHalon1301( bromo tri fluoromethane)Vaporizing liquidDry powders for combustible metals
22. FIRE EXTINGUISHERSNon-Magnetic stored pressure deionized water mist fire extinguisherHalotron 1 Fire extiguisher.ABC Dry chemical fire extinguisherCarbon dioxide (CO2) Portable fire extinguisher K Class Wet chemical extinguisher.
23. Characteristics of extinguishersWater extinguisher 30-40 ft. 60 sec.Dry chemical 5-20 ft. 8-25 sec.CO2 extinguisher 3-8 ft. 8-30 sec.
24. “Quick-Check” Is It Ready To Use ?Check the gauge. The pressure indicator should be in the green zone. (CO2 extinguishers do not have pressure gauges.)The extinguisher should have a current inspection tag.The pin and handle should be secured with a plastic tab seal.4. The extinguisher and hose should be free of any visible damage.
25. The P.A.S.S. MethodPull the pin.Aim the hose or nozzle.Squeeze the lever.Sweep the agent.
26. FIRE EXTINGUISHERSDry Chemical - Works on class A, B, and C fires (Multipurpose).Carbon Dioxide - Works on class B and C fires. Water - Works on class A fires. Foam - Works on class A and B fires. Halogenated - Works on class A, B, and C fires. Dry Powder - Works on class D fires. Wet Chemical - Works on class K fires.
27. FIRE ALARMS
28. Smoke detectorFire sensorsSpinkler systemsHeat detectors
29. Mechanical hazardsINTRODUCTION:Mechanical hazards may occur due to the large numbers and different designs of equipment, crowded workplace conditions and frequent interaction between workers and equipment Hazardous electrical, pneumatic and thermal energy must be released or controlled before working on active equipment and utilitiesWorkers are protected from sources of hazardous energy by Implementing lock out / tag out procedures.Interlocked guards, control switches, emergency stop devices and operator training are important means of reducing mechanical hazards.
30. HAZARDS WITH MECHANICAL EQUIPMENTWAREHOUSING RAW MATERIAL WEIGHING GRANULATE PREPARATION SUPPOSITORY AND PESSARY PRODUCTIONOINTMENT PASTE CREAM GEL PRODUCTIONTABLET & CAPSULE PRODUCTIONSOLUTION PREPARATION CONTAINER STERILIZATION CONTAINER FILLING INSPECTION FREEZE DRYINGPACKAGINGPALLETIZATION WAREHOUSING:FINISHED PRODUCTS SHIPMENT CONTAINER FILLING
31. WAREHOUSINGWORK PHASE DESCRIPTION Incoming and out going goods store (raw materials, excipients, labels, printed information materials)The raw materials and excipient store is generally located close to the production areas. Products are stored on multi-level racks and shelves. Manually operated trolleys and electrical pallet handlers are used to move boxes/containers. EXPECTED INJURIESMuscular-skeletal complaints.Cutting injuries
32. Electronic and/or mechanical weighing scalesThe pharmaceutical industry uses the classic single/twin platter mechanical scales. The more modern electronic scales are characterised by a metal box enclosing the apparatus and by a weighing system generally including a platter. Electronic scales are fitted with local powder/dust exhaust devices or laminar flow exhaust hoods.RISK FACTORS: Exposure to dustEXPECTED INJURIES: Allergic asthma, contact dermatitis
33. Work performed in the presence of moving machinery parts DESCRIPTIONManual cleaning of certain machine may entail the operator being snagged, dragged or crushed by the machine’s parts in motion. By way of an example, an operator may clean a mixer/blender by pouring the cleaning fluid in the vat and starting the machine in order to better clean the internal surfaces.Other operators may accidentally start the machine while staff is cleaning the machine’s internal parts. EXPECTED INJURIESLesions and bruises. PREVENTIVE MEASURES Hazardous zones must be shielded by fixed guards or fitted with interlocking safety devices to reduce the risk of operators being snagged and dragged. Machinery must be fitted with emergency shut down and accidental start-up lockout devices such as safety devices blocking machine start up when power is restored after a temporary blackout.
34. PROCESSING OF SEMI-SOLID PHARMACEUTICAL FORMS RISK FACTORS: Fatiguing tasks and work posturesDESCRIPTIONCareful cleaning of plant systems especially where processing of semi-solid pharmaceutical forms particularly rich in lubricating agents such as suppositories, ovules and ointments takes place, require manual operations involving fatiguing tasks and anomalous work postures. EXPECTED INJURIESMuscular-skeletal complaints. PREVENTIVE MEASURES - Consider the feasibility of employing built-in, closed-cycle automatic washing and/or sterilization systems (cleaning in place). - Accurate task organization and operator information and training.
35. GRANULATE PREPARATION EQUIPMENT AND MACHINERY Miller/grindersCompactorTwin Whisk BlenderPlanetary or crown wheel Blender Rotating Tub BlenderFluid Bed Granulator-DryerDynamic Tunnel Dryer SystemDynamic Revolving Drum Dryer SystemVacuum DryersRISK FACTORS : Exposure to dust DESCRIPTIONOperators may be exposed to dust during miller/grinder loading/unloading, compacting, blending and granulation operations. ESTIMATEField assays have yielded ambient air dust concentration levels ranging from 342 to 3.462 µg/m3 in the blender shop, from 307 to 1.884 µg/m3 in the granulator shop. EXPECTED INJURIESAllergic asthma, contact dermatitis. Specific pharmacological effects due to active principles. PREVENTIVE MEASURESUse of completely automated load/unload systems.Use of protective hoods fitted with absolute filters.
36. EXPOSURE TO NOISE DESCRIPTIONThe sources of noise in this work phase are: miller/grinders, compactors, blenders and granulators. Notwithstanding the use of sound dampening devices, noise levels may be quite high. EXPECTED INJURIESContinuous exposure to medium-high noise levels may cause hearing injuries (noise-induced hypoacusia) and extra-hearing complaints. Injuries and complaints may result also from exposure to noise levels lower than the thresholds for which legislation prescribes the use of specific preventive measures.In addition to communication and work performance-related complaints, the following disorders may also arise: cardiovascular effects (high blood pressure, etc.); psychic disorders (asthenia, irritability, depression, insomnia); digestive tract disorders. PREVENTIVE MEASURESPreventive measures established in cases of employee noise exposure exceeding 80 dB(A). Decrease the exposure time
37. MANUAL LOAD HANDLINGDESCRIPTIONMachine hopper loading operations in this phase may be performed manually. EXPECTED INJURIESMuscular-skeletal complaints PREVENTIVE MEASURESUse of mechanical/electrical handling devices or automated loading systems.Two operator handling of heavy loads.Manual load handling is permitted for loads up to 30 kgs.(males) and 25kgs.(females). Handling of loads exceeding these limits shall be performed using appropriate devices and/or shall be performed by two operators.Operator information and training.
38. OINTMENT, PASTE, CREAM AND GEL PRODUCTION EQUIPMENT AND MACHINES Turbo-emulsifier (blender-homogeniser) Manually operated trolleysBulk storage tanksRisk factors: Exposure to dustDESCRIPTIONLoading active principles into the emulsifiers is typically performed manually. Operators insert a suction nozzle connected to the emulsifier into the bins containing the active principles or excipients.ESTIMATE: Field data typically reports that an operator performs approximately two active principle and excipient emulsifier loading cycles per 8 hour working shift. Loading operations total 90 minutes resulting in 0,76 mg/m3. mean operator dust exposure levels.TLV-TWA threshold values reported by firms are 0.5 mg/m3 for active principles and 10 mg/m3 for gelling excipients. EXPECTED INJURIESActive principle-specific induced injuries. PREVENTIVE MEASURES- Use of automated loading systems
39. Container Filling And Packaging EQUIPMENT AND MACHINES Manually operated trolleysPlastic stopper vibrator Tube FillerPackaging machineLabelling machinesBoxing machines
40. Risk factors: Manual load handlingESTIMATE: Load handling data furnished by a drug company may be broken down as follows: - empty tube feed: package weight 5 kgs, feed frequency 3/min.;- filled tube transfer: weight 10.8 kgs, frequency 2/min.;- labeller feed: weight 7 kgs, frequency 1/min.EXPECTED INJURIES: Muscular-skeletal complaints. PREVENTIVE MEASURESUse of electric powered or mechanical devices or automated systems.Manual load handling operations are limited to loads up to 30kgs for men and 25 kgs for women.Heavier loads shall be handled employing appropriate means and/or shall be performed by two operators.Contd…
41. SAFETY ASPECTS IN THE PHARMA INDUSTRYStandard operating proceduresHandling of hazardous materialsWater supply and drainageFloors and floor coveringsEmergency exitsBack up plan if anything goes wrongSpecially trained personnel Health polices and insuranceWritten proceduresSafety auditsRisk analysisAppropriate training and education to employeeRegular monitoring of workplaceWritten documentation of policiesCreate awareness of the environmentInvolvement of the personnelContingency plan
42. DISASTER MANAGEMENT PLANDisaster management plan is essential as it:Reduces the amount of thinking time required after the incident occurredContains the incident and minimizes the extent of the damage to the resources and business.Reduces the conduct of disaster to a set of predetermined rules and a system of orderly procedure to make orderly and rationalThe success in disaster management depends on :Reliable early detectionCareful planningEfficient personnelProper training of all personnel concernedProblem free communication
43. CONCLUSIONFrom the previous discussion it is clear that the safety aspects must be considered by the pharmaceutical industry not only in the interest of the employees or property but also in terms of the neighboring environment as well.The source of possible hazards , risk analysis, control procedures ,preventive measures &contingency plan are the main five essentials for ensuring a complete work atmosphere in the industry
44. REFERENCESG.D.Muir,”Hazards in Chemical Industries”, 2nd edition.Reigel’s Handbook of Industrial Chemistry, 9th edition.James Sward Brick, James C.Boylan, Encyclopedia of Pharmaceutical Technology,volume-4.www.fda.govwww.friesnoop.comwww.pubmed.comwww.agricum.comwww.teoma.comwww.altavista.com
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