Industrial Disasters – Causes & Way Forward – Explained Pointwise

India has experienced numerous industrial disasters over the decades, ranging from chemical leaks and mining accidents to factory fires and structural collapses. Recently, a lethal accident happened in the pharma unit of Sigachi Industries in Hyderabad that led to the death of 36 workers there. In fact, just yesterday 8 workers were killed in Tamil Nadu at a firework manufacturing unit in Virudhunagar district. Similarly, last year also a major accident happened in the pharma unit in Anakapalli near Vizag.

The frequency of such accidents raises the question of safety at industrial places in India & is likely to have a negative bearing on the manufacturing sector & trade from it for India. Thus, it is important to understand what steps the government has taken & should take to ensure that such disasters do not occur in future.

Some important INDUSTRIAL DISASTERS in India:

What are the CAUSES of industrial disasters in India?

1. Inadequate Inspections: Factory inspectorates and pollution control boards are often understaffed, underfunded, and lack the technical expertise to conduct thorough and frequent inspections of industrial units, especially those handling hazardous chemicals. This leads to lax enforcement of existing safety and environmental regulations.

2. Inadequate Training and Awareness: Many workers, especially contractual laborers, lack proper training in handling hazardous materials, operating machinery safely, and emergency response procedures. This often stems from industries trying to cut costs.

3. Lack of Safety Culture: A poor safety culture within an organization, where safety is not prioritized by management and employees alike, is a significant underlying cause. This can manifest as a disregard for safety protocols, shortcuts in operations, and a failure to report near misses.

4. Equipment Failure and Maintenance Issues: Neglecting regular maintenance, inspection, and repair of machinery, pressure vessels (like spray dryers mentioned in the Sigachi Industries blast), pipelines, and safety systems is a major cause. Worn-out components are prone to malfunction. Some older plants may use outdated technology and machinery that is inherently less safe or less efficient compared to modern alternatives. 

5. Inadequate Risk Assessments: Failure to conduct thorough Hazard Identification and Risk Assessment (HIRA) studies, Process Hazard Analysis (PHA), and Safety Audits to identify all potential risks and implement appropriate control measures.

6. Poor Siting: Locating hazardous industries too close to densely populated residential areas (for e.g. as seen in the Bhopal Gas Tragedy and Vizag gas leak) significantly increases the risk to human life in case of an accident.

7. Informal Sector Challenges: A significant portion of India’s industrial activity is in the unorganized or informal sector, which often operates outside regulatory oversight, making workers highly vulnerable to unsafe conditions.

What are the CONSEQUENCES of industrial disasters?

What INITIATIVES have been taken by the government to prevent such disasters?

1. Factories Act, 1948: This is the primary legislation regulating working conditions in factories, including provisions related to safety, health, and welfare of workers. It places responsibilities on factory owners to ensure a safe workplace. Post-Bhopal (1987 amendment), its scope was significantly extended to cover risks from hazardous industries, mandating safety committees, safety officers, and addressing dangerous operations.

2. Environment (Protection) Act, 1986: 

• Enacted in the wake of the Bhopal disaster, this umbrella act gives the central government wide powers to protect and improve environmental quality.
• Manufacture, Storage and Import of Hazardous Chemicals Rules, 1989: Notified under the EP Act, these rules detail the responsibilities of occupiers of industrial premises handling hazardous chemicals, including requirements for safety reports, on-site emergency plans, and public information.
• Chemical Accidents (Emergency Planning, Preparedness, and Response) Rules, 1996: These rules mandate the preparation of off-site emergency plans by district authorities for managing chemical accidents, and establish Crisis Groups at central, state, and district levels. 

3. Public Liability Insurance Act, 1991: This Act mandates industries handling hazardous substances to take out insurance policies. This insurance provides immediate interim relief to persons affected by accidents occurring while handling such substances, even without proving fault.

4. Occupational Safety, Health and Working Conditions Code, 2020: This is a recent consolidated code that aims to simplify and rationalize existing labor laws related to occupational safety, health, and working conditions. It extends provisions to more establishments and emphasizes employer duties, safety committees, and regular audits.

5. Guidelines on Chemical Industrial Disaster Management (2007): These comprehensive guidelines provide a framework for all stakeholders (industry, government agencies, local authorities) for prevention, preparedness, response, and mitigation of chemical industrial disasters. Key elements include:

• Risk mapping of Major Accident Hazard (MAH) units.
• Development of on-site and off-site emergency plans.
• Regular mock drills and exercises.
• Establishment of Emergency Response Centres (ERCs) and integration with other emergency services.
• Emphasis on HAZOP (Hazard and Operability Study) and HAZAN (Hazard Analysis) for early hazard identification.

What DISASTER MANAGEMENT MEASURES should be taken to prevent such industrial disasters?

1. Strengthening Regulatory and Enforcement Mechanisms: 

• Continuously review and update existing acts (Factories Act, EP Act, PLI Act) and rules (MSIHC, Chemical Accidents Rules) to incorporate latest scientific advancements, international best practices (e.g., EU’s Seveso Directive), and lessons learned from past disasters.
• Significantly increase the number of factory inspectors, safety officers, and environmental auditors. Ensure they are adequately trained, equipped with modern tools, and well-remunerated to attract and retain talent.
• Impose significantly higher penalties for non-compliance, including severe fines, imprisonment, and immediate closure of non-compliant units. Expedite legal proceedings against violators to ensure deterrence.

2. Fostering a Culture of Safety and Responsibility:

• Safety must be a core business value, not just a compliance requirement. Senior management must visibly commit to and invest in safety.
• Create a non-punitive environment where workers feel safe and encouraged to report near-misses, unsafe conditions, and procedural deviations without fear of reprisal.
• Conduct frequent and realistic mock drills for both on-site and off-site scenarios, involving all stakeholders, to test the effectiveness of emergency plans and identify gaps. Learnings from drills must be incorporated.

3. Advanced Risk Assessment Tools: Utilize Artificial Intelligence (AI) and Machine Learning (ML) for predictive analytics to identify potential failure points in equipment and processes based on operational data, enabling proactive maintenance.

4. Strategic Industrial Zoning: Implement and strictly enforce policies for locating new hazardous industries away from densely populated residential areas, schools, and hospitals. Re-evaluate and, where feasible, relocate existing hazardous units that are currently located in highly populated areas.

5. Adequate Resources: Ensure that emergency services (fire departments, hospitals) in industrial zones are adequately equipped and trained to handle industrial accidents, including chemical hazards.

CONCLUSION:
Industrial disasters are a threat to not only the economy of a rapidly industrializing country like India but also to its society. Stronger enforcement, modernized infrastructure, better training, and a culture of safety—especially in the informal sector—are urgently needed to prevent tragedies in the future. The Bhopal Gas Tragedy led to a rethinking on industrial safety, this blast in Telangana should do the same by fixing accountability & strengthening the regulatory framework in our country.