HAZARD IDENTIFICATION,

RISK ASSESSMENT AND

CONTROL
ie-solutions
Mechanical Engineering Faculty
Universiti Teknologi Malaysia

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 SLIDE NAVIGATOR
1. Hazard Identification and Risk
Assessment – An Introduction
2. The Concept of Hazard Operability
3. The Concept of Hazard Analysis
4. Hazard-Safe System of Work

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 1.0
Hazard Identification and Risk
Assessment – An Introduction

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 1.1 BASIC DEFINITIONS
• Hazard – anything that can cause harm
(chemicals, electricity)
• Risk – chance of harm actually being done
• Danger – relative exposure to a hazard (little
danger due to control measure)
• !!!Hazard identification – hazard sources, form in
which hazard occurs, work place, persons
exposed

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 1.2 THE CONCEPT OF
HAZARD MANAGEMENT

• Modify the workplace to suit the people

9 Identifying the hazards
9 Assessing the risk
9 Controlling the risk
9 Review/update the steps (PDCA) – new technology,
standards, legislation

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 1.3 GENERAL APPROACH
• Critical appraisal of all activities
• Complete understanding of working situation
• Requirement for hazard identification:
9 Previewing legislation and codes of practice

9 NIOSH/DOSH published information

9 Review relevant Malaysian and international standards

9 Review industry or trade association guidance

9 Review other published information

9 Develop a hazard checklist

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 1.3 METHODS OF HAZARDS
IDENTIFICATION
Eleven methods of identifying hazards:
1. Conduct walk through survey/audits
2. Review information from designers or
manufacturers
3. Assess adequacy of training or knowledge
required
4. Analyse unsafe act, injury data and accident
5. Analyse work processes
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 1.3 METHODS OF HAZARDS
IDENTIFICATION
6. Job safety analysis
7. Consulting with employees
8. Observation
9. MSDS/CSDS or product label
10.Advice from specialist
11.Employees’ complaint

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 1.3 REMINDER ON TYPES OF
HAZARDS
• Hazard inherent at the workplace
(mechanical hazard, toxic properties,
noise)
• Hazard resulting from equipment failure,
power failure, chemical spills, leakage etc.

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 1.4 THE BASIC ELEMENTS OF
RISK ASSESSMENT OF HAZARD

• Select the type

• Assess the likelihood (chances) of hazard
• What are the consequence (type)
• How many people (extent) are exposed and for
how long (severity)

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 1.4 QUALITATIVE RISK
ASSESSMENT OF HAZARD
• Qualitative likelihood of a hazardous event:
9 Very likely – could happen frequently
9 Likely – could happen occasionally
9 Unlikely – could happen, but only rarely
9 Highly unlikely – could happen, but probably never
will

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 1.4 QUANTITAVE RISK
ASSESSMENT OF HAZARD
• Uses numerical values for likelihood and
consequences
• Restricted to sensitive components of
major hazard installation

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 1.4 RISK FROM HAZARDOUS
EVENTS

• Fatality
• Major injuries (irreversible)
• Minor injuries (reversible)
• First aid injuries
• Property damage
• Environmental damage
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 1.4 MEASURE OF RISK LEVELS
• Most serious (high risk),
• medium risk
• least serious (low risk),

!!!!Tackle anything with high risk

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 1.4 RISK CONTROL
INFORMATION
Obtain from:
• Codes of practice
• Industry or trade associations
• Specialists
• MSDS/CSDS
• Manufacturers and suppliers

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 1.4 LEVEL OF HAZARD RISK
CONTROL
• Administrative level–
– time limit, SOP, safety rules
– Use more than one control measures
– Develop and maintained reporting and recording
system
– Permit-to-work system for high risk activities
• Ground level
– Personal Protective Eqpt. – last resort, suitability,
limitation
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– Maintained safety devices
 1.4 ELEMENTS OF SYSTEMATIC RISK
IDENTIFICATION AND ASSESSMENT
(SYSTEMS ENGINEERING)

• Consideration of OSH during design and

planning
• Consider all possibilities
• Applying the concept of probability (of
occurrence & effect)

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 2.0
THE CONCEPT OF HAZARD
OPERABILITY (HAZOP)
STUDIES

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 2.1 INTRODUCTION
• Hazard and operability studies
• Normally for new design or process
• Started in the chemical industries
• Achieved through structured, multi
disciplinary brain storming session
involving chemists, engineers, production,
safety, designers etc.

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 2.1 INTRODUCTION
• Examine each stage of the process by
asking a series of “what if” questions
• Design out risks at the early stages of a
new project
• Focus on fire, explosion, toxic release,
offensive odour, and environment

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 2.2 Failure Mode and Effect
Analysis (FMEA)
• Evaluate kinds of failure that could happen and
their effect in terms of maximum potential loss
• Part of HAZOP study
• Performed at the component level to determine
possible ways equipment could fail and their
effects
• Control and eliminate equipment failure and
provide information for maintenance and
operational manual

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2.2 Failure Mode and Effect
Analysis (FMEA)

System Component Failure mode Failure Effect

Scrubber Water Pump Motor malfunction Environmental
Pollution

Broken shaft

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 2.2 FMEA for Boiler
Component Function Failure Mode Cause Effect Current
control
Relief valve Release Incorrect Lack of Boiler Weekly
extra spring maintenance explosion inspection
pressure position

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 2.3 Fault Tree Analysis (FTA)
• Logical method of analyzing how and why a disaster
could occur
• Graphical technique that start with the end event which
is the accident or disaster
• Work backwards to find the initiating event or
combinations of events
• Probability of disaster can be calculated, use reliability
analysis
• Based on principle of multi causality that traces all
branches of event
• Obtain data on components from manufacturers
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 2.3 Fault Tree Analysis

No Flow (T)

Pump Failure Control Valve (C) failure to regulate

flow of water through pump

Failure Pump (A) Failure Automatic Stand by

Pump (B)

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 3.0
THE CONCEPT OF
HAZARD ANALYSIS
(HAZAN)

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 3.1 INTRODUCTION
• Objective –
– To analyze the safety of major hazard
installation
– And to ascertain the magnitude of potential
problem and its potential harm

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 3.1 HAZAN should indicate
• Worst events
• Route to those events
• Time scale to lesser event which might lead to
worst events
• Size of lesser events if their development is
halted
• Relative likelihood of events
• Consequences of each event
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 3.1 GENERAL APPROACH
• Examine type - Which toxic, flammable, reactive or
explosive substances constitute a major hazard
• Examine origin- Which failures could cause abnormal
conditions leading to accident
• Examine consequences - of accident for workers, the
public, environment
– worst possible and express in quantifiable terms

• Considering prevention of accident

• Considering accident mitigation

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 3.2 COUPLING HUMAN ERROR
ANALYSIS TO HAZAN

• Adding human performance to the hazard analysis

• Factoring human elements into reliability analysis
• Considering errors in man-machine interaction
• An input to Failure Tree Analysis
• Can estimate failure rates of routine performance

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 3.2.1 TECHNIQUE OF HUMAN
ERROR ANALYSIS
• Technique for Human Error Prediction (THERP):
9 Identification of human activities which create a
hazard
9 Estimation of failure rates
9 Sum effect of human failures on the system

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 3.3 JOB SAFETY ANALYSIS
(JSA)
• Method of hazard identification and
formulating safe work procedures
• Basis for job training
• Priority of jobs for JSA:
9 Accident frequency and severity
9 Newly established or infrequent job

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 3.3 Basic Procedure for JSA
• Select the job to be analyzed
• Break the job into its components in
chronological sequence
• Observe and examine each component to
determine potential hazards
• Develop preventive measures
• Formulate written job safety instruction
• Review safe systems of work
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 3.3 Example of narrative style
format for changing car tyres
Parking the vehicle
• Drive vehicle off the road to an area well clear of traffic, even if it
requires driving with a flat tyre.
• Choose a firm, level area so that you can jack up the vehicle
without moving
• Turn on the hazard warning lights to alert passing drivers, so that
they will not hit you
• Apply the parking brake, leave the transmission in gear or PARK,
place blocks in front and back of the wheel diagonally opposite to
the flat. These actions will help prevent the vehicle from rolling.
Removing spare and tool kit
• To avoid back strain, turn the spare up into an upright position in
its well. Stand as close to the trunk as possible and slide the
spare close to your body. Lift out and roll to flat tyre.

and so on …………
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 4.0
HAZARD-SAFE
SYSTEM OF WORK

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 4.1 HAZARD SAFE SYSTEMS
OF WORK
• Formal procedure from systematic examination
of tasks to ensure hazards are eliminated
• Examples where safe system will be required:
9 Cleaning and maintenance
9 Changes to normal procedures, methods or
materials
9 Working alone or away from the work place
9 Breakdowns or emergencies
9 Control of the activities of contractors
9 Vehicle loading, unloading and movements
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 4.2 BASIC STEPS FOR HAZARD
SAFE SYSTEM
• Assess task
• Identify hazard, assess risk and identify
control method
• Identify of safe methods
• Implement the system
• Monitoring the system

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 4.2.1 Assessing Task
• All aspects of task must be looked at and
put in writing
• Done by supervisors and workers
• What is used – plant, machinery,
substances, electrical needs, human
failures, emergency work, short cut etc.

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 4.2.3 Identifying safe methods
• Simple written methods or permit-to-work
system
• Involve setting up the task, authorization,
planning of job sequences, approved safe
working method, lockout, tag-out, tests
etc.

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4.2.4 Implementing The System
• Adequate information and understood by
everyone
• Supervisor to devise and maintain safe
system of work
• Training is required
• Stop work when problem appear

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 4.2.5 Monitoring The System
• Requires regular check to ensure
compliance and appropriateness
• Is the system workable, implemented,
procedures still effective, problem rectified
• Complied with regulations

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 4.3
EXAMPLES OF HAZARD-
FREE SYSTEM & PRACTICES

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 4.3.1 PERMIT-TO-WORK

• Formal, written authority to a tradesperson to carry out

maintenance
• For non- routine maintenance critical to production
• As permanent record of precautions for maintenance
• Give protection to a tradesperson

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 4.3.1.1 ISSUING AND
SIGNING-OFF OF PERMIT-TO-
WORK
• Issued by a person familiar with equipment, who knows
the hazard, trained in the permit system and authorized
to issue the permit
– The job has been assessed, safety precaution has been taken,
clearly defined safety precaution to be taken by the tradesperson

• Sign off by tradesperson when the job is completed and

person who accept the plant back

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 4.3.1.2 PERSON ISSUING
PERMIT-TO-WORK
• People given the authority to issue permit to
work:
9 Have intimate knowledge of the plant and hazard
9 Have demonstrated a responsible attitude to safety
9 Prepare to admit ignorance and consult if in doubt
9 Mature and senior enough to resolve conflicts
9 Can obtain the tradesperson confidence
9 From operating or production staff
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 4.3.1.3 Level of authorization:
• Standard – ordinary permits to work, no authority
for hot work, people at first line supervisory level
• Standard and hot work (welding, brazing, cutting
or spark producing operations) – all ordinary
permit to work, hot work ,no authority for
confined space
• Full authorization –all permits to work including
confined space
• Special authorization – high voltage work

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 4.3.1.4 For Regular
Maintenance
• Recurrent maintenance – define
procedures needed
• Person authorized to issue permits require
training
• Audit permit-to-work system – permits are
issued to all maintenance work and
followed all the time and ensure high
standards of permit

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 4.3.1.5 LOCKING OUT
• Locked off power to the plant, operating
handles of valves
• Key retained by the tradesperson during
the time he is doing the work
• All those involved know and follow the
proper procedure

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 4.3.2 INSPECTIONS
• Types of inspection:
9 Statutory – compliance with legislation
9 Safety and Health Officer, executive
9 Safety and Health Committee
9 Scheduled, planned inspections

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 4.3.2 INSPECTIONS
General Approach
• Implement inspection procedures with checklist prepared
• Involve front line supervisors – identify hazards and implement
remedial action
• Safety and Health Committee to conduct quarterly inspection

• Require knowledge of plant and facilities, regulations and standards

• Results of inspection – list of actions, who is responsible and time

frame

• Record all preventive actions, follow up and assess effectiveness

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 4.3.2.1 INSPECTION
CHECKLISTS
• Well designed checklist:
9 Ensure items are not overlooked
9 Enable a standardized approach
9 Underpin a system of accountability for
performance assessment
• Tailored to the specific needs of the
organization, and
• Allow a systematic walkthrough

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 4.3.2.1 INSPECTION
CHECKLISTS
ABC Manufacturing
Safety Checklist
Department:
Date:
Name:

HOUSEKEEPING CHECK EMERGENCY CHECK

Foyer Exit
Floor surface Fire escape route
Escalator Fire alarm
Stairways Assembly point
Safety sign Written procedures
Car parking Fire extinguisher
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 4.3.3 AUDITS
• Full blown comprehensive audit or mini
audit
– Example of specific aspect - fire protection,
electrical safety
• As a tool for proactive approach - risks are
within control and policy is achieved
• Examination result and report the status

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 4.3.3.1 AUDIT CENTRES
• Audit item vary with location
• Examples:
9 Fire fighting facilities
9 Slip and trip hazards, floor surface
9 Ladders and stairways
9 Safety apparatus
9 Manual handling
9 Lighting
9 Warning signs
9 Emergency arrangements
9 Accessibility for maintenance and emergency
9 Management of hazardous substances

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 4.3.2.2 Procedure Audit
• Identification of what procedures exist
• Evaluation of procedures:
9 Are they in place?
9 Are people aware of them?
9 Are they being complied with?
9 Are they adequate?

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 4.3.5.2 Procedure Audit
Example – Safety Procedure
• Apply checklist and WHAT IF technique on:
9 Operating procedures – correct, up-to-date
9 Safety equipment – check performance, identification
9 Permit system – procedures, application
9 Housekeeping and orderliness
9 Contingency plan – procedures, equipment,
preparedness
9 Training – content, method, level
9 Incident investigation
9 Contractors – training, procedures

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 4.3.4 WORKPLACE PLAN
• Comply with all relevant regulations – Factories and
Machinery Act 1967, Occupational Safety and Health Act
1994, Environmental Quality Act 1974, Akta Bomba etc.
• Review all accidents and determine prevention
strategies
• Document procedure for recording and reporting
accidents
• OSH consideration incorporates into design, purchase,
material, product etc.
• Regular workplace inspection
• Identify hazards, assess and control risk
• OSH related specific employee data – skills, experience,
training, exposure to hazards, health monitoring records

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Thank You

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