A Novel Study of Hazard Identification and Risk Assessment in Textile Industry

Abstract

The work environment of textiles is risky and portrayed by different simultaneous chemical, physical and mechanical hazard exposure, which would prompt wounds of textile labourers. Health risks from working in the textile industry. This manuscript contains the details on the hazards and risk level present in one of south India\'s leading textile industry. This study also briefs about the need, method and result of the HIRA technique. The HIRA technique is adopted in the old rotary printing department and dyeing department to assess the risk levels in terms of quantified values. The control measures were also developed for each area and activities identified with potential safety issues. It is found that the identified hazards majorly categorized under Physical, chemical, ergonomics, material handling, health and electrical hazards. The risk level is quantified for all the hazards in the printing and dyeing department by multiplying the values of severity and probability.

Introduction

I. INTRODUCTION

Hazard Identification and Risk Assessment (HIRA) deals with the identification and quantification of risks that are exposed to, due to accidents resulting from the hazards present or handling of hazardous substances in the workplace.

This involves Hazard analysis which essentially is identification and quantification of the various hazards that are likely to occur in the industry as well as quantification of the consequences due to a particular hazard.

 The risk analysis estimates the probability as well as severity of a particular hazard over an exposed group of people, plant equipment or both.

For any industry to be successful, it has to be safe, reliable, and sustainable in its operations. The industry has to identify the hazards and assess the associated risks and to bring the risks to tolerable level.

Hazard Identification and Risk Assessment (HIRA) is carried for identification of undesirable events that can lead to a hazard, the analysis of hazard of this undesirable event, that could occur and usually the estimation of its extent, magnitude, and likelihood of harmful effects.

It is widely accepted within industry in general that the various techniques of risk assessment contribute greatly toward improvements in the safety of complex operations and equipment.

The objective of this work of hazards and risk analysis is to identify and analyse hazards, the event sequences leading to hazards and the risk associated with hazardous events.

 Many techniques ranging from the simple qualitative methods to the advanced quantitative methods are available to help identify and analyse hazards.

The use of multiple hazard analysis techniques is recommended because each has its own purpose, strengths, and weaknesses.

HIRA assists in identifying the most likely hazards which can have significant impact on workplace safety in an industry.

 It helps in devising effective management measures as well as engineering measures for both preventive as well as post-disaster management.

II. HAZARD IDENTIFICATION AND RISK ASSESSMENT

Hazards are the sources or situations which have the potential to cause undesired events. Risks are the combination of likelihood which creates a chance for the undesired events. All industries and workplace consist of Hazards and Risks which creates and cause the chances of accidents. In order to reduce those hazards and risks, the hazard identification and risk assessment have to be performed periodically. Hazard Identification and Risk Assessment is a tool used by industries to identify the hazards and providing control measures as per the risk priorities of each hazard. After the hazards are identified the risks can be assessed by quantitative and qualitative method to determine whether the identified risks are significant or non- significant.

HIRA is a combination of deterministic, probabilistic, and quantitative method. The deterministic methods take into consideration of the products, the equipment and quantification of the various targets such as people, environment, and equipment. The probabilistic methods are based on the probability or requency of hazardous situation apparitions or on the occurrence of potential accidents. The uantitative methods analyse various data numerically. The steps involved in HIRA are

1. Classify Work Activities
2. Hazard Identification
3. Risk Assessment
4. Monitor and Review

III. PROCESS DESCRIPTION

Its yarn storage area,

Front pass of Yarn loading point ,

The different yarn is segregation,

The yarn box move to fabric knitting room by the help of vehicle.

A. Fabric Knitting Machine

Knitting machine process

Knitting is a process of using long needles to interlink or knot a series of loops made by one continuous thread. Each loop or knot connects to another one, and when enough loops have been made, the result is a flat piece of material called a textile

Type of knitting machine

1. Circular Knitting Machine: In this machine the needles are implanted on a circular cylinder, which when used creates a seamless tube of fabric, by joining the stiches from the needles.
2. Single Jersey Machine: As opposed to double jersey machine, the Single jersey machine has only one cylinder one which one set of needles and sinkers are placed on. The diameter of this cylinder is generally around 30 inch, which can vary according to the machines type and requirement. The fabric manufactured on a Single jersey machine is known as “Single jersey fabric”, they have a plain thickness, almost half if compared to the Double jersey fabric. Both front and back side of this fabric is visibly different        
3. Double Jersey Machine: Double jersey machines have two sets of needles; one on dial and as well as on cylinder. There are no sinkers in double jersey machines. known as double jersey fabric
4. Interlock Double Jersey Machine: In this type of double jersey machines, the needles on the cylinder and the dial are placed opposite and alternatively. Interlock machine uses two types of latch needles instead only one type which is used generally in circular knitting machines.
5. Terry Single Jersey Machine: Terry fabrics are manufactured on Terry circular knitting machine using “Plush knitting technique”. In this technique generally—the one set of sinker loops are made longer than the ground fabric sinker loops this longer set of sinker loops form the velvet like pile on the fabric, both the threads, of pile and ground fabric are worked together to give a stable structure.

B. Dyeing Machine

The machine which is used to dyeing or coloring of materials like yarn, fabric, garments or any other materials is called dyeing machine. Dyeing machines come in all shapes and sizes to accommodate the various forms and quantities of textile materials

TYPES OF DYEING MACHINE

1. Soft Flow Dyeing Machine

In the soft flow dyeing machine water is used for keeping the fabric in circulation. The conception difference of this equipment from a conventional jets that operates with a hydraulic system is that the fabric rope is kept circulating during the whole processing cycle (right from loading to unloading).There is no stopping of liquor or fabric circulation for usual drain and fill steps. The principle working behind the technique is very unique.

There is a system for fresh water to enter the vessel via a heat exchanger to a special interchange zone. At the same time the contaminated liquor is allowed channel out through a drain without any sort of contact with the fabric or for that matter the new bath in the machine.

2. Jet Dyeing Machine

Jet dyeing machine is the most modern machine used for the dyeing of polyester fabric with disperse dyes. In these machines, both the fabric and the dye liquor are in motion, thereby facilitating a faster and more uniform dyeing. In jet dyeing machine, there is no fabric drive reel to move the fabric. The fabric movement by only force of water. It is economical, because of low liquor ratio. It is users friendly because comparison with long tube dyeing machine, to control the fabric movement four valves required. In jet dyeing machines and fabric dyeing machine, there is only one valve. Absent of reel, reduce connecting electric power, maintenance of two mechanical seal and breakdown time, if jet pressure and reel speed not synchronized.

In jet dyeing machines a strong jet of dye liquor is pumped out from an annular ring through which a rope of fabric passes in a tube called a venturi. This venturi tube has a constriction, so the force of the dye liquor passing through it pulls the fabric with it from the front to the back of the machine.

Thereafter the fabric rope moves slowly in folds round the machine and then passes through the jet again, a cycle similar to that of a winch dyeing machine. The jet has a dual purpose in that it provides both a gentle transport system for a fabric and also to fully immerse the fabric in liquor as it passes through it.

In all types of jet machines there are two principle phases of operation:

1. The active phase in which the fabric moves at speed, passing through the jet and picking up fresh dye liquor
2. The passive phase in which the fabric moves slowly around the system back to the feed?in to the jets

Jet dyeing machines are unique because both the dye and the fabric are in motion, whereas in other types of machine either the fabric moves in stationary dye liquor, or fabric is stationary and the dye liquor moves through it.

The design of the jet dyeing machine with its venturi means that very effective agitation between the fabric rope and the dye liquor is maintained, giving a fast rate of dyeing and good levelness. Although this design can create creases longitudinally in the fabric, the high degree of turbulence causes the fabric to balloon out and the creases disappear after the fabric leaves the jet. However, the rapid flow of the dye liquor can lead to a high degree of foaming when the machines are not fully flooded. The machines operate at low liquor ratios of about 10 : 1, so as with beam dyeing, exhaustion is good and water and energy consumption efficient.

C. Stenter Machine

Stenter machine is not only a dryer but also used for many other purposes. Here knitted and woven fabric in open width form is treated. This multipurpose machine is used for the following purposes:

1. Drying
2. Heat setting
3. Width control
4. Curing
5. Finishing chemical application
6. Selvedge printing
7. Uniform moisture control for pad batch dyeing
8. Loop control
9. Weft straitening
10. Pigment dye application
11. Any thermo fixation
12. Padding mangle

Here finishing like OBA treatment, dry-cross finish, moist cross finish, wrinkle free finish, easy care finish can be done along with width and shrinkage control.

WORKING PROCEDURE

Continuous drying is done in a stenter frame by convection. Blowers impinge hot air on both the top and bottom of fabric as the fabric passes through the chamber of the machine. Its frames are equipped with an endless chain on each side to grip the fabric by both selvages as it enters chamber.

The distance between the chains can be increased or decreased. In every chamber there are burners and blowers. The temperature of each chamber can be controlled individually. The fabric gripping in stenter, two systems are available:

a. Clip to grip coarse fabrics like twill fabric.

b. Pin to grip fine fabric.

D. Mechanical Finishing

A simple device which simulates the effects of calendaring is the domestic iron. Hot ironing makes garment smooth flat by removing its crinkles and creases. Besides making the fabrics free from creases by calendaring,

1. it is possible to raise the luster of the fabric, 
2. make it compact by closing the threads, 
3. impart a soft feel and ‘thready’ or 
4. linen like appearance to it

It reduces the yarn slippage as well as thickness of the fabric by varying the calendaring operation.

The need of calendaring arises mainly because the fabric when it is wet processed and dried, is in the least lustrous state and its surface is not smooth because of presence of highly crimped and wavy threads. To meet this need the fabric is passed between the rollers or bawls of a machine termed ‘Calender’ and this mechanical process

a. Raising

Raising is a process of lifting of a layer of fibres from the surface of the fabric so as to form a hairy surface or pile. The process imparts a warm and soft handle to both on the woven and knitted fabrics; in fact, the formation of a pile on the fabric can make it exceptionally soft. The pile also includes a large amount of air and since air is a bad conductor of the heat, the raised fabrics feel vary warm as well assoft. In the early days, only cotton and woolen fabrics were raised, but now besides these fabrics, man-made fibre fabrics also raised. If the fabric contains a woven or coloured pattern, the weave and pattern get subdued on raising and various colour blends.It is easier to raise the fabric in the wet state than in dry state. Therefore, moist raising is most widely adopted.

b. Shearing

Shearing means removing or taking off fibre ends by cutting. It is carried out to cut fibres of random length to produce a level pile and prevent pilling in case of synthetic fibres by resulting of the height of the fibres particularly to produce clean staple fibre fabrics. Napped fabrics are mostly sheared.

Knitted fabrics are sheared on a machine having a single cutting head per unit where in case of woven fabrics multiple sheared are used. The pile heights are regulated by adjusting the distance between the cloth rest and rotary blade.

c. Sanforising

A method of producing unshrinkable cotton fabric is to give it a thorough wash in a washing machine so as to allow it to shrink freely and then dry and finish it without stretching. This method however is not reliable and not suitable for commercial production.

d. Napping

In napping the surface of the cloth is raised, cut even and smoothed by a napping machine known as planetary napper.

e. Sueding

When a vary mild effect of raising is required a special type of machine called sueding machine is used. This consists of a vertical set of small diameter rotating rollers covered with an abrasive surface such as sand paper or emery cloth. There is a rubber covered pressure roll which presses the fabric against the abrasive covered cylinder. The abrasion of the fabric surface takes place when the fabric is open width presses between the pressure roller and abrasive covered cylinder. A vary sort pile thus raised according to the pressure of the fabric against these rollers which rotate in a direction of opposite to that of the fabric.

f. Setting and Heat-setting

During manufacturing processes like spinning, weaving or knitting, the fabric is subjected to stresses and strains and release of these distortions in fabric leads to distortions in fabric structure and woven design and also uneven shrinkage. The purpose of the setting is to stabilize the woven structure of the fabric in a regular and permanent manner by relaxing the stresses. The effect is bought about by agencies like heat, moisture, and pressure and generally no chemicals are used in the process.

HIRA RISK

YARN GODOWN

• Yarn Godown

The proposed action for the Hazards in Yarn godown is to electrical hazards in textile operation maybe related to electrical vehicle charging materials. Accident related to improper handling electrical vehicle charging ,

Injuries from charging  activities, maybe due to adapter problem or connecting terminal damage . To avoid those electrical rubber mat ,to avoid unauthorized persons are handling charging station, charging  station handling should remain within restricted zone under supervision, with particular attention paid to proximity of electrical cables and equipment’s. Locate machine tools at a safe distance from other work areas and from walkways.

Conduct regular inspection and repair of machine tools, in particular protective shield and safety devices/ equipment’s. Use appropriate PPE (Personal Protective Equipment’s) such as Helmets, Insulating gloves, safety shoes. Respiratory Hazards: Dust generated in textile  includes corttonbox  dusts, which are present in yarn godown,

The improper of cleaning process  Incase of fire incident to indicate the fire alarm switch and automatically sense  the smoke detector and additionally provide fire extinguisher.

• Fabric Knitting

The proposed action for the hazard in Fabric knitting is to electrical hazard and trolley movement, cleaning process in this operation maybe related to fabric machine. This machine due to create noise level .Its rotating parts maybe Entanglement of workers clothes and hairs due to rotating part, Finger or hand struck by in rotating parts.

The fabric due to shifting in fabric storage area by the help of trolley, Injury from the needle point changing and hot oil replacement shifting of materials maybe due to handling activity .to avoid those handling procedure given to the employees some materials handling only authorized person only should remain within restricted zone under supervision, with particular attention paid to proximity of electrical cables and equipment’s. Locate machine tools at a safe distance from other work areas and from walkways. Conduct regular inspection and repair of machine tools, in particular protective shield and safety devices/ equipment’s. Use appropriate PPE (Personal Protective Equipment’s) such as ear plug, apron ,head cap .Respiratory Hazards: Dust generated in Fabric knitting machine  includes yarn dusts, which are present in fabric knitting area.

• Dyeing

The proposed action for the Hazards in dyes kitchen shop is to implement First and foremost, using a less toxic or environment friendly abrasive media will give less dominant after effects on the atmosphere. Water based blasting media may be preferred due to its dust reduction property.

The proposed action for the hazard in dyeing is to chemical handling ,confined space , electrical hazard and trolley movement, cleaning process in this operation maybe  related to fabric machine. This machine due to create health .Its rotating parts maybe Entanglement of workers clothes and hairs due to rotating part, Finger or hand struck by in rotating parts. The fabric due to shifting in fabric storage area by the help of trolley,

Injury from the door handling ,maintain proper temperature and steam line handling and rejection water go to the etp collection tank  maybe due to handling activity .to avoid those handling procedure given to the employees some materials handling only authorized person only should remain within restricted zone under supervision, with particular attention paid to proximity chemical explosion ,and the  electrical cables and equipment’s. Locate machine tools at a safe distance from other work areas and from walkways. Conduct regular inspection and repair of machine tools safety valve ,drain valve ,temperature maintain properly in particular protective shield and safety devices/ equipment’s. Use appropriate PPE (Personal Protective Equipment’s) such as PPE (The nitrigul glove and respiratory mask, gum boot, pvc apron) .Respiratory Hazards: Dust generated in chemical handling   includes dyes formation of dusts, which are present in dyeing machine area.

• Stenter Machine

The proposed action for the hazard in stenter is to chemical handling and rotating parts, electrical hazard and trolley movement, hot surface machine, cleaning process in this operation maybe  related to stenter machine. This machine due to create health .Its rotating parts maybe Entanglement of workers clothes and hairs due to rotating part, Finger or hand struck by in rotating parts .The fabric due to shifting in fabric storage area by the help of  trolley,

Injury from the door handling ,maintain proper temperature and steam line handling and rejection water go to the etp collection tank  maybe due to handling activity .to avoid those handling procedure given to the employees some materials handling only authorized person only should remain within restricted zone under supervision, with particular attention paid to proximity chemical explosion ,and the  electrical cables and equipment’s. Locate machine tools at a safe distance from other work areas and from walkways. Conduct regular inspection and repair of machine tools safety valve ,drain valve ,temperature maintain properly in particular protective shield and safety devices/ equipment’s. Use appropriate PPE (Personal Protective Equipment’s) such as PPE (The nitrigul glove and respiratory mask, gum boot, pvc apron) .Respiratory Hazards: Dust generated in chemical handling   includes dyes formation of dusts, which are present in stenter  machine area.

• Mechanical Finishing

The proposed action for the hazard in mechanical finishing  is to drum rotating parts and knife or plate ,electrical hazard and trolley movement, hot surface machine ,cleaning process in this operation maybe  related to mechanical finishing  machine. This machine due to create health .Its rotating parts maybe Entanglement of workers clothes and hairs due to rotating part, Finger or hand struck by in rotating parts .The fabric due to shifting in fabric storage area by the help of  trolley,

Injury from the drum rotating parts, knife handling  and steam line handling ,  maybe due to handling activity .to avoid those handling procedure given to the employees some materials handling only authorized person only should remain within restricted zone under supervision, with particular attention paid to proximity  electrical cables and equipment’s. Locate machine tools at a safe distance from other work areas and from walkways. Conduct regular inspection and repair of machine tools in properly in particular protective shield and safety devices/ equipment’s. Use appropriate PPE (Personal Protective Equipment’s) such as PPE (The pvc apron, dust mask, ear plug) .Respiratory Hazards: Dust generated in machines includes dusts, which are present in mechanical finishing machine area.

Ware House

The proposed action for the hazard electrical hazard and physical hazard , fork lift and trolley movement ,cleaning process in this operation maybe  related to ware house. The fork lift due to create health hazard .Its rotating 360* stacker and fork lift any materials or human or rack parts maybe kit the person or fatal accident create the fork lift, so will be followed in ware house safety procedure, pins are insert and remove by the help of stacker machine ,the stacker machine charging place separate place

 Injury from the fork lift driver or other person and fork lift handling of  maybe due to handling activity .to avoid those all process fully knowledge and trained person   and  handling procedure given to the employees some materials handling only authorized person only should remain within restricted zone under supervision, with particular attention paid to proximity electrical cables and equipment’s. Locate rack tools at a safe distance from other work areas and from walkways. Conduct regular inspection and repair of fork lift machine tools in properly in particular protective shield and safety devices/ equipment’s. Use appropriate PPE (Personal Protective Equipment’s) such as PPE (The safety jacket or safety apron, safety helmet, safety goggle, safety shoe) .Respiratory Hazards: Dust generated in fabric and atmospare air includes fork lift movements, which are present ware house area.

• Boiler

The proposed action for the Hazards in boiler and thermo back is to implement Position yourself so that you are not hit by objects moving down the conveyor. Ensure that you can see the conveyor system when you are at the operating controls. Ensure that guards are in place for all moving parts of the drive system and in all zones where hazards such as in-running friction burns or boiler ire process entry  are present (includes above, sides, and below the conveyor). Guard all pinch points between the conveyor system and fixed objects. Locate guardrails around low level conveyors and areas where conveyors pass through the floor/ceiling. Locate emergency stop cut-off switches near the operator and along the length of the conveyor at approximately 30 metres (100 feet) apart (or closer). Ground belts on belt conveyors to prevent static build-up.

The proposed action for the Hazards in wood and coal storage is to implement by conducting pressure test for the steam and oil pipeline and automated and manual valves are strategically placed along the pipeline route to enable the pipeline to shut down immediately and sections can be isolated quickly as and when required.

The proposed action for the hazard in boiler and thermo back machine is to hot surface area, wood  and coal handling, hot oil chamber, steam line ,electrical hazard and trolley movement ,cleaning process in this operation maybe  related to boiler and thermo back  machine. This machine due to create health .Its rotating parts maybe Entanglement of workers clothes and hairs due to rotating part, Finger or hand struck by in rotating parts .The wood due to shifting in fabric storage area by the help of  trolley,

Injury from the steam line and oil pipe line,  maybe due to handling activity .to avoid those insulate and cover the steam and oil pipe line  handling procedure given to the employees some materials handling only authorized person only should remain within restricted zone under supervision, with particular attention paid to proximity electrical cables and equipment’s. Locate machine tools at a safe distance from other work areas and from walkways. Conduct regular inspection and repair of machine tools in properly in particular protective shield and safety devices/ equipment’s. Use appropriate PPE (Personal Protective Equipment’s) such as PPE (The heat resistive glove and leather apron, goggle and  safety shoe ,safety helmet, dust mask) .Respiratory Hazards: Dust generated in boiler machines includes dusts, which are present boiler and thermo back machine area.

ETP and RO Plant

The proposed action for the hazard sludge waste collection ,chemical handling, collection of waste water tank, processing tank ,electrical hazard and trolley movement ,cleaning process in this operation maybe  related to Etp and Ro plant. This ETP waste due to create health hazard .Its rotating drum parts maybe in clothes and hairs Finger or hand struck by in rotating parts .The sludge waste proper segregation and sludge waste are compressed machine. this machine will be great the air this air affect the human and air pollution.

Injury from the waste water and waste disposal handling of  maybe due to handling activity .to avoid those all process fully knowledge and trained person   and  handling procedure given to the employees some materials handling only authorized person only should remain within restricted zone under supervision, with particular attention paid to proximity electrical cables and equipment’s. Locate machine tools at a safe distance from other work areas and from walkways. Conduct regular inspection and repair of machine tools in properly in particular protective shield and safety devices/ equipment’s. Use appropriate PPE (Personal Protective Equipment’s) such as PPE (The pvc apron, glove, safety helmet, gum boot, goggle  ) .Respiratory Hazards: Dust generated in ETP plant  includes sludge waste, which are present ETP and RO plant machine area.

Power house

Proper management of the risks associated with aboveground storage tanks is essential. Everyone who works on or around the equipment or the fuel storage locations should be trained to identify and eliminate risks. They should also know how to conduct routine inspections of fuel storage containers, dispense fuel and operate pump shutoffs properly.

The generator machine run at the generate the noise so wear the ear muff,generator is automatically run by the power cut time, generator handle good knowledge electrical person only  allowed, the transformer is high voltage so any body circuit open or close wear the ppe and good handling electrical person only applicable. The transformer oil or other problem we are atten this person wear the ppe and proper earthing for transformer, panel board handling or breaker handling and really circuit person only knowledge electrical person only allowed, the E-waste are disposed in only authorized person , all the machine and panel board connect proper double earthing    

Conclusion

Hazard Identification and Risk Assessment (HIRA) study were made on the textile and various hazards of different process and their associated equipment’s were found. Recommendations are provided to reduce high level risk to low level. . Noise level is measured in various areas of the industry and suitable control measures are suggested. In textile industries, the working environment is high in temperature and hence heat stress, chemical handling index is calculated for the workers working in the Boiler and Dyeing area, ETP & RO plant suitable preventive measures are given. Health hazards associated with each process are found and suitable mitigation measures are given for safe handling of the chemicals. The KPI (KEY PERFORMANCE INDICATPOR) ,its new implementation of MENAKA MILLS UNIT-1 PVT LTD .the factory new update version of KPI table format and KPI schedule, sop o safety and health, list of deviation and monitoring inspection log ,list o PPE’s tabulated department wise , transport safety, key person, daily and monthly on field observe ,work permit system. The KPI and HIRA assessment details and schedule should be correctly followed and give to working awareness then successive run by factory.

References

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Copyright

Copyright © 2023 R. Vigneshwar, S. Karthikeyan. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.