CHEMICAL SAFETY ANALYSIS IN WATCH MANUFACTURING INDUSTRY by IRJET Journal

1.INTRODUCTION



current status Datacollection

Key Words: chemical analysis, Gap assessment, flammableandtoxicchemicals

improve safety

The objective of the project is to analyze the chemical in various aspects and identify the safety improvements need to be done in the chemical handling process like Loading / unloading, Storing, Transporting, and Disposal. In watches and wearables unit there are number of active chemicals used for the manufacturing or supporting the manufacturing process. In the project, main area of focus is the most active chemical usage in various departments and their divisions. In the area, 53 percentage of total chemical handling and usage was happening so the area was having high risk of accidents and possible health hazard among workers who handling and working with chemical. Through GAP analysis workbook we can obtain the safety gaps between the current state and the ideal state. At the end, the safety GAPs were recommended with the solution in the hierarchy of Elimination, Substitution, Engineering Control, Administrative Control, and PPE

practices Identifyinggaps

Agapanalysisisamethodofassessingtheperformanceof a business unit to determine whether business requirements or objectivesare being metand, ifnot,what steps should be taken to meet them. A gap analysis may also be referred to as a need’s analysis, needs assessment orneed gapanalysis.The"gap"inthegapanalysisprocess referstothespacebetween"whereweare"asapartofthe business (the present state) and "where we want to be" (thetargetstateordesiredstate).GAPanalysisisaformal way to identify the current gaps between desired levels andactuallevelsofperformanceitcanbeapplyforallkind of industries and organization to analysis from certain processtowholesystemperformance. 1:GapAnalysisChart TO CONDUCT THE PROCESS Process the andreviewingthecurrent system best incurrentsystemwith idealsystemorindustrial recommendationto in best

In watches and wearable division mainly focus on producing wrist watches and wearables. In a process of manufacturing involves with few toxic and flammable chemicals it is having some significant risks during chemical storing, handling, transporting and disposing. In the watch and wearable division there are number of chemicals for the process usage. This project mainly focused on the safety improvements need to be done for reducing the risk for the workers in the process of chemicalhandlinginwatchandwearabledivision. Theprocessofchemicalworkdoinginsidethefactorywas classifiedasfollows Purchasing and receiving the chemical for the storagearea Storingthechemicalinthechemicalstoragearea Handling of chemical (loading and unloading of chemicalfrom/toshopfloor) Transportation of chemical from storage to work location Disposalofchemicalfromemptystoragesection

Fig 2:

2.1 STEPS

practice Giving

potentialareas TIME CurrentSystem andPractice Standardsand

andindustrial

Fig



2. METHODOLOGY

Steps 2.1.1 Data collection and reviewing

practicesPERFORMANCE ImprovementSafety



status Determinestandard



International Research Journal of Engineering and Technology (IRJET) e ISSN: 2395 0056 Volume: 09 Issue: 01 | Jan 2022 www.irjet.net p ISSN: 2395 0072 © 2022, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page785 CHEMICAL SAFETY ANALYSIS IN WATCH MANUFACTURING INDUSTRY MAHESH RAJ R1 , Dr MUTHUKUMAR K2 , JISHIN JAYAN T3 1PG Scholar, Industrial Safety Engineering, Department of Mechanical Engineering, BIT, Tamilnadu, India 2Professor, Industrial Safety Engineering, Department of Mechanical Engineering, BIT, Tamilnadu, India 3Assistant professor, Industrial Safety Engineering, Department of Mechanical Engineering, BIT, Tamilnadu, India *** Abstract -

The analysis can be done through various prospect like properties, chemical group, state of matter, and through NFPArating Step 1: Analysis the chemical based on state of matter like solid, and Tablegas1: Stateof Step 2: Analyze the chemical based on chemical group Chemical group of CHEMICAL

3. DATA ANALYSIS

2.1.3 Identifying gaps in current system with ideal system or industrial practice

2.1.4 Providing Suitable Recommendation to improve safety in potential areas Safety gap obtained from the GAP assessment workbook was identified with best engineering solution. Recommendation for the gap fulfilment was assist by hierarchy of Elimination, Substitution, Engineering Control,Administrativecontrol,andPPE.

Matter

Thecomparisionwasdonebetweenthecurrentpractices, existing safety devices and PPE’s with the standard ideal stateandIndustrialbestpracticesinchemicalhandling.As a result we obtained the gap between the ideal and the presentstate.

liquid

2.1.2 Determine standard system and industrial best practices

Count

NAME In OrganicAcid 17 In OrganicBase 5 In OrganicCompound 77 Remaining 157 OrganicAcid 9 OrganicCompound 38 Grand Total 303 Table 2: Chemicalgroup Step 3: Analyze the chemical based on the properties of chemical Chart 1: PropertiesofChemical PROPERTIES Count of CHEMICAL Flammable 81 Non flammable 222 Non toxic 93 Toxic 210 Non stable 31 Stable 272 Non reactive 231 Reactive 72 Corrosive 126 Non corrosive 177 Grandtotal 303 Table 3:PropertiesofchemicalandNumberofchemicals STEP 4: Find out highly flammable, highly toxic, and highly reactive FLAMMAB LE 5% NON FLAMMAB LE 15% TOXICITY 14% NON TOXICITY STABLE6% 18% NON STABLE 2% REACTIVE 5% NON REACTIVE 15% CORROSIV E 8% NON CORROSIV E 12% Physical state Count of CHEMICAL NAMEGAS 5 LIQUID 166 SOLID 132 Grand Total 303

Chemical handling process for all chemicals used in production site was assess by using the Legal requirements, MSDS and industrial best practices. Ideal state of the chemical handling process was identified by usingtheliteraturepapersandapplicablestandards.

Thenextstepistoanalyzecurrentprocessesbycollecting relevant data on performance levels and how resources are presently allocated to these processes. This data can be collected from a variety of sources depending on what isbeinganalyzed

International Research Journal of Engineering and Technology (IRJET) e ISSN: 2395 0056 Volume: 09 Issue: 01 | Jan 2022 www.irjet.net p ISSN: 2395 0072 © 2022, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page787 Chart 2: Properties,Numberofchemicals HIGHLY FLAMMABLE CHEMICAL USED INSIDE THE PREMISES BASED ON NFPA RATING (LEVEL 4) 1) 1 butanol 2) Ammoniumsulphide 3) Boronnitridespray 4) Formicacid 5) Formicacid LRgrade 6) GTNstripper 7) Metstrips 60 8) Nickeladditive 22 9) Niplexa20 HIGHLY HEALTH HAZARD CHEMICAL BASED ON NFPA RATING (LEVEL 4) 1) Hydrofluoricacid comm.Grade 2) Hydrofluoricacid LR/SQgrade 3) Mercuricsulphatecrystals 4) Niplexb 5) Nitricacid ARgrade 6) Nitricacid cpgrade 7) Silicagelblue5 8mesh 8) Standardpotassiumdichromate(k2cr2o7) HIGHLY REACTIVE CHEMICAL BASED ON NFPA RATING (level 3) 1) GTNstrippercode:129 2) Silvernitrate 25grams 3) ThegraphshowstheremainingchemicalsNFPA levelvsNoofchemical. Thefollowingtablesshowstheremaininglevelof chemicalbasedonNFPArating: ratingFlammability No of chemical LEVEL0 145 LEVEL1 97 LEVEL2 24 LEVEL3 27 LEVEL4 9 Table 4: Flammabilitylevel RatingReactivity No of chemical LEVEL0 202 LEVEL1 75 LEVEL2 23 LEVEL3 2 Table 5: Reactivitylevel Toxicity Rating No of chemical LEVEL0 23 LEVEL1 155 LEVEL2 74 LEVEL3 42 LEVEL4 8 Table 6: Toxicitylevel STEP 7: TO FIND OUT THE HIGHLY FLAMMABLE LIQUID AND THEIR USAGE INSIDE THE DEPARTMENT Chart 3: HighlyFlammableChemicalandtheirUses 47%42%11% NUMBER OF CHEMICAL HIGHLYFLAMMABLE HIGHLYTOXIC HIGHLYREACTIVE 14451350 810815 0 500 1000 1500 2000 NICKELADDITIVE-22 HIGHLY FLAMMABLE CHEMICAL IN KG 2021-22 2020-21 2019-20 2018-19

International Research Journal of Engineering and Technology (IRJET) e ISSN: 2395 0056 Volume: 09 Issue: 01 | Jan 2022 www.irjet.net p ISSN: 2395 0072 © 2022, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page788 Docno: Rev: Date Pageno: Classification: Referance: S.no CurrentPractice Recommendation(As PerISStandard) 1 Noadequatespaceinsidethestorageroom Theworkercouldn'twalkfreely. Thedrums shouldbestacked in anorderlymannersothatallparts ofthestoragespaceareaccessible OISD 6.2Storageof chemicalshazardous Adequatespaceforstorageandpathways 2 Poormaintenanceofchemicalspillway Thereshouldbeprovisionto collectaccidentalspills forsafe disposal. OISD 6.2Storageof chemicalshazardous Provisionforaccidentalspills ofchemicalshouldbe maintainedproperly 3 Noavailabilityofchemicalspillkit Thereshouldbeprovisionto collectaccidentalspills forsafe disposal. OISD 6.2Storageof chemicalshazardous Chemicalspillkitmustbeusedforcollectingthe chemical 4 Excess storageofchemical chemicalshouldnotstored excessivelybeyondtheallocated area Industrialbestpractice Storeappropriatecontainers withintheallocated space. 5 Containers placedrandomlyoneoveranother Chemicalcontainers mustbe arrangedinmannerthatitshould notcollapse. Industrialbestpractice Storedachemicalinwellallignedway FromStandard(SafetyGap) LOGO Location: DEPARTMENT:SAFETY PROCESS:STORAGE GAPASSESSMENTFORCHEMICALHANDLING

OISD 6.2Storageof chemicalshazardous chemicalcontainers mustbestoredseperatelybased onchemicalcomposition

Chemicalcontainerare notsegregatedas per composition

Thedrums shouldpreferablybe storedinawellventilatedshed (preferablyawayfromprocess units)withimpermeablefloor slopingawayfromdrums.

OISD 6.2Storageof chemicalshazardous chemicalcontainers shouldbearrangedwith adequatespace

OISD 6.2Storageof chemicalshazardous Enclosertoavoidsunlightintrusion

9 Chemicalcontainers keptunderdirectsunlight (c)ToxicSubstances :These substances mustbestoredinwell ventilatedareas,preferablycool andcertainlyawayfromdirectsun rays.

International Research Journal of Engineering and Technology (IRJET) e ISSN: 2395 0056 Volume: 09 Issue: 01 | Jan 2022 www.irjet.net p ISSN: 2395 0072 © 2022 RJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal 789 6 storageareanotenclosed chemicalshouldbestoredunder enclosedplacetoavoidfallof sunlightandforeignmaterial intrusion Industrialbestpractice Storageareamustbeenclosed 7 oilspillageinstoragearea oilspillageinthestorageroom couldleadtoslip,trip,andfall Industrialbestpractice Needofgoodhousekeeping 8 chemicalcontainers arecloselyarranged

Thetanks shouldbelocatedsoas nottoposesafetyproblems dueto leakageandreactionwithother chemicals storednearby.The environmentatthelocationmust becompatiblewiththechemical stored.

Emptycans shouldnotbestored withoutchainin arack. Forcewindmaymoveempty containers outofits place

Expiredchemicalcontainers mustberemovedfrom storagearea emptycans placedwithoutchainguard

Smokedetectors canreducethe consequences offire Industrialbestpractice Installationofsmokedetectors NonavailabilityofPPEs inits placeandfirstaidbox. Usesuitablepersonalprotective clothing/equipment.Suitable breathingcanisters andfirstaid boxmustbeavailableatsitefor useincaseofemergency.

OISD 6.3Handlingof chemicalshazardous MakesuretheavailabilityofPPEs inits place NonavailabilityofMSDSinstoragearea MSDSwillbehelpfulinemergency situationsuchas accidentalspill, treatment,puttingoff Industrialbestpractice MakeavailabilityofMSDSinaneasyaccess area

Nonavailabilityofsmokedetectors instoragearea

Industrialbestpractice Providechainguards andstoreunderenclosed place

International Research Journal of Engineering and Technology (IRJET) e ISSN: 2395 0056 Volume: 09 Issue: 01 | Jan 2022 www.irjet.net p ISSN: 2395 0072 © 2022, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page790 11 Useofpoorelectricalextension (a)Allelectricalapparatus shall eitherbeexcludedfromtheareaof riskortheyshallbeofsuch constructionandsoinstalledand maintainedas topreventthe dangeroftheirbeingasourceof ignition; TNfactories rule1950 ScheduleXXIV Useofappropriatefireproofelectricalapparatus 12 Chemicalcontainers lefttoolonginits place. Requirements relatingtopossible physicalandchemicalchanges in storedchemicals (e.g.nottostore beyondtheexpirationperiod recommendedonthelabelandthe chemicalsafetydatasheet); ILO 6.7.Controlmeasures forthe storageof chemicalshazardous

International Research Journal of Engineering and Technology (IRJET) e ISSN: 2395 0056 Volume: 09 Issue: 01 | Jan 2022 www.irjet.net p ISSN: 2395 0072 © 2022, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page791 Docno: Rev: Date Pageno: Classification: Referance: Location: S.no CurrentPractice Recommendation(AsPerISStandard) 1 transportingchemicalbarrelinapallettrolley workersshouldattachhandlesorholdersto loads. OSHA2236 MaterialHandlingand Storage Usesuitablecardlesordrumhandlingequipments 2 transportingchemicalwithoutPPEs workersshouldalwayswearappropriate personalprotectiveequipmentanduseproper liftingtechniques. OSHA2236 MaterialHandlingand Storage UseappropriatePPEswhiletransportingchemicals 3 Manualhandlingofheavychemicalcontainers. Liftingof50litrechemicalcontainerscauses workersdiscomfortandbackpain Industrialbestpractice Usemechanicalhandlingequipments 4 Placingchemicalpumpoverthechemicalcontainer Keepingthechemicalpumpoverthechemical containerandmovingmaycauserollandfallof pumpfromitsplace. Industrialbestpractice chemicalpumpmustbehandledseperately. 5 No stopping mechanism Thereisnostopingmechanismattachedtothe trolley Industrialbestpractice stoppingmechanismwillhelpinasteepwayto avoidundesiredmovement FromStandard(SafetyGap) GapAssessmentForChemicalHandling Department:Safety Process :Transportation LOGO

International Research Journal of Engineering and Technology (IRJET) e ISSN: 2395 0056 Volume: 09 Issue: 01 | Jan 2022 www.irjet.net p ISSN: 2395 0072 © 2022, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page792 CONCLUSION Inthiswatchmanufacturingindustry,thereare303active chemicals inside the premises and 122 active chemicals inside the department and their divisions having its own potential hazards at every places and workers who handling with chemicals. By the analysis for chemical in variousaspectsandgapanalysisbycomparingthecurrent practicewithIndianstandardstoindicatethesafetygapin theprocess.Morereducethesafetygap,greaterthesafety would implement in the system. For every step, the hierarchy of principle has been taken into consideration forprovidingasolution. REFERANCES  Balaji G*, Potdar Aditee and Unnikrishnan Seema “Environmental Legislation for Chemical Management in India: An Agenda for Reforms” Journal of Environmental Research and Development Vol. 9 No. 02, October December 2014pageNo494 506.  Ranjith RamaVarma,Dr, Dr, Dr. N. A. Siddiqui “Study of gap analysis on HSE management system consolidated contractors’ company clean fuelprojectKuwait”IJISET InternationalJournal of Innovative Science, Engineering & Technology,Vol.3Issue2,February2016pageNo 535 542.  Miroslav Hernciar “Gap analysis of approaches to implementation of management systems” ResearchGate DOI: 10.12776/QALI.V1. #5 page No52 61  Maurizio BRUGLIERI, Roberto MAJA, Giovanna MARCHIONNI, Giovanni RAINOLDI Safety in HazardousMaterialRoadTransportation:Stateof the Art and Emerging Problem” ResearchGate January2008.  Manufacture, Storage and Import of Hazardous chemicalrule1989.  HazardouswastemanagementRule2016  “Technical EIA guidance manual for isolated storageshandlingHazardouschemicals”Prepared for the ministry of Environment and forests, GovernmentofIndia. Doc no: Rev: Date Page no: Classification: Referance : Location: S.no CurrentPractice Recommendation(As PerIS Standard) 1 Chemicalcontainersarenotdisposedsafely. Safe disposal of empty containers of hazardous chemicals should be done based on guidelines given by the Vendors. OilIndustry DirectorateSafety 6.3Handlingof chemicalshazardous Emptycontainersshouldbe disposedoff recommendedasbythevendor 2 stored container with used chemical in it Empty drums should be removed away and made free of its contents beforebeingkeptinsafeplace. OISD 6.2Storageof chemicalshazardous Useddrumsmustbedrained offtoasafeplaceand seggregated LOGO FromStandard(SafetyGap) GapAssessmentForChemicalHandling Department:Safety Process :Disposal