EEM3523 INDUSTRIAL SAFETY AND HEALTH

CHAPTER 2:
HAZARD AND THEIR CONTROL

Ir. Ngu Heng Jong

Email: ngu.heng.jong@ucts.edu.my
Office: AS1 , Ground Level, Room 12.
HAZARD

Hazard:
a source or situation with a potential for
harm in terms of human injury or ill,
health, damage to property, damage to
environment or a combination of these.
HEALTH

Health:
State of normal functioning of the body,
physically, psychologically and
physiologically
SAFETY AND RISK
Safety: The state of being relatively free from
harm, danger, injury or damage.

Risk: The chance or probability of the

hazard causing harm or damage to the
people, property or the environment.

Risk = [Likelyhood] X [Severity]

 CONCEPT OF SAFETY

“A thing is safe if
 Its risks fully known,
 Those risks would be judged acceptable by a
reasonable person in light of their settled
value principles.”
LION = HAZARD (SOURCE)
LION IN THE ZOO = HAZARD UNDER
CONTROL (LOW RISK)
LION IN THE OPEN SPACE ZOO = HAZARD UNDER
PARTIAL CONTROL (HIGHER RISK)
CONCEPT OF RISKS

 Probability of hazard causing harm and

damage
 A thing is not safe if it exposes us to
unacceptable risk.
 we take a risk when we undertake
something that is not safe.
 CONCEPT OF RISKS

In regard to technology, risk includes dangers of

 bodily harm
 economic loss
 environmental degradation
TASK

 Identify the possible hazard in the class

room that may occur.
PHYSICAL
HAZARDS BIOLOGICAL HAZARDS
& INJURIES

ERGONOMICs CHEMICAL HAZARDS

HAZARDS
OCCUPATIONAL STRESS
PHYSICAL
HAZARDS BIOLOGICAL HAZARDS
& INJURIES

ERGONOMICs CHEMICAL HAZARDS

HAZARDS
OCCUPATIONAL STRESS
PHYSICAL
HAZARDS BIOLOGICAL HAZARDS
& INJURIES

SICKNESS Absenteeism
Monitoring
Health Promotion & Hearing Protection &
Wellness Progr am Conservation

Regulatory
Program Planning &
Compliance
Evaluation
Disability management
Industrial Hygience Program
Emergency Preparedness
Health Surveillance
Medical care services Alcohol & Drug testing

Ergonomics Program

ERGONOMICs CHEMICAL HAZARDS

HAZARDS
OCCUPATIONAL STRESS
SOURCE OF HAZARDS

Classification & Potential Sources of Hazards

 Mechanical - Sharp points & edges, overload.
 Electrical - Insulation damaged or cover broken
 Biological - Exposed, airborne/blood borne microorganism.
 Chemical - Expose to carcinogens chemical
 Ergonomics - Expose to unnatural postures
 Psychological - Stress or violent at workplace.
HIRARC
HIRARC
Introduction to HIRARC.
Principles used in workplace to manage safety and health. Section 15 (2)(a) of
OSHA 1994: which reads “ the provision and maintenance of plants and systems of
work that are, so far as is practicable, safe and without risks to health”.

The purpose of HIRARC are as follows:-

 to identify all the factors that may cause harm to employees and others (the
hazards);
 to consider what the chances are of that harm actually be falling anyone in the
circumstances of a particular case and the possible severity that could come
from it (the risks); and
 to enable employers to plan, introduce and monitor preventive measures to
ensure that the risks are adequately controlled at all times.
HIRARC

HIRARC activities shall be plan and conducted –

a. for situation
 where hazard appear to pose significant threat;
 uncertain whether existing controls are adequate; or/and
 before implementing corrective or preventive measures.

b. by organization intending to continuously improve OSH Management

System.
 It should be the duty of the employer to assign a trained personnel to lead a
team of employees associated with one particular process or activity to
conduct HIRARC.
HIRARC

Hazard Identification
 To keep workplace safe and healthy. employers should identified the hazards
to which employees could be exposed.
 Employers should look for hazards in advance as part of their risk
management plan to prevent potential hazards.
Risk Assessment
 Is the process of evaluating the risk to safety & health from hazards at work.
 determine appropriate ways to eliminate or control the hazard.
Risk Control
 Is the process of implementing measures to reduce the risk associated with
a hazard.
 The control process must follow the control hierarchy, in order, as prescribe
in some health and safety legislation.
HAZARD IDENTIFICATION

 To keep workplace safe and healthy. employers should identified

the hazards to which employees could be exposed.
 Employers should look for hazards in advance as part of their risk
management plan to prevent potential hazards.
 Hazard is not always obvious, eg radiation effect. Effects can
be acute or chronic.
HAZARD IDENTIFICATION

 Special Techniques are required to systematically identify

hazards in complex activities, such as Hazard analysis
(HAZAN), hazard and operability studies (HAZOP), fault
tree analysis (FTA), event tree analysis(ETA).
Hazard Analysis (HAZAN)

HAZAN stands for Hazard Analysis and is a technique that

focuses on job tasks as a way to identify hazards before they
occur. HAZAN takes into account the relationship between
the employee, the task to be done, the tools at the workers
disposal and the surrounding environment. Once uncontrolled
hazards have been identified by a HAZAN analysis, steps can
be taken to either eliminate risks or reduce risk to an
acceptable level.
 Hazard Analysis (HAZAN)

TASK HAZARDS RECOMMENDATIONS

1. Reach into box to the right Strike hand on edge of metal Provide gloves and safety
of the machine, grasp casting box or casting; cut hand on shoes.
and carry to wheel burr. Drop casting on toes.
2. Push casting against wheel to Strike hand against wheel, Provide larger guard over
grind off burr. sparks in eyes. Wheel breakage, wheel. Install exhaust system.
dust, sleeves get caught Install exhaust system. Provide
safety goggles. Instruct
employee to wear short
sleeved shirts.
3.Place finished casting in box Strike hand against metal box Provide tool for removal of
to the left of the machine. or casting completed stock.
Hazard and Operability Studies
(HAZOP)

- Is structured technique, which may be applied

typically to a chemical production process,
identifying hazards resulting from potential
malfunctions in the process
HAZOP
(Hazard &
Operability)
Study
Hazard and Operability Studies
(HAZOP)
The HAZOP study is a formal procedure to identify hazards in
chemical process facility. The procedure is effective in
identifying hazards and is well accepted by the chemical
industry.
Before the HAZOP study is started, detailed information on
the process must be available. This includes up to date process
flow diagrams (PFDs), process and instrumentation diagrams
(P& IDs), detailed equipment specifications, materials of
construction and mass and energy balance.
The full HAZOP study requires a committee composed of a
cross-section of experienced plant, laboratory, technical and
safety professionals.
Hazard and Operability Studies
(HAZOP)

HAZOP is an
identifying technique
and not intended as a
means of solving
problems
DOCUMENTS NEEDED FOR
HAZOP STUDY

– Process Flow Sheet or digram ( PFS or PFD )

Preliminary – Description of the Process

HAZOP

– Piping and Instrumentation Diagram (P & ID)

– Process Calculations
– Process Data Sheets
– Instrument Data Sheets
Detailed – Interlock Schedules
– Layout Requirements
– Hazardous Area Classification
HAZOP – Description of the Process
PROCESS FLOW DIAGRAM (PFD)
Is a diagram commonly used
in chemical and process
engineering to indicate the
general flow of plant processes
and equipment.
The PFD displays the
relationship
between major equipment of a
plant facility and does not
show minor details such as
piping details and designations
Process Flow Diagram (PFD)
Example
P&ID

A Piping and
Instrumentation
Diagram - P&ID, is a
schematic illustration of P&ID represents the
functional relationship last step in process
of piping, design.
instrumentation and
system equipment
components.
P&ID EXAMPLE
HAZOP PROCEDURE

List of guide words

for generation of
process deviations

Possible Process Possible

Causes Deviations Consequences
Definitions
STUDY NODES

The locations (on piping

and instrumentation
drawings and
procedures) at which
the process parameters
are investigated for
deviations.
INTENTION

The intention defines

how the plant is
expected to operate in
the absence of
deviations at the study
nodes.
DEVIATIONS

Is a way in which the

process conditions may
depart from their
design/process intent
CAUSES

These are the reasons

why deviations might
occur
CONSEQUENCES

The results of the

deviation, in case it
occurs.
SAFEGUARDS

Facilities that help to

reduce the occurrence
frequency of the
deviation or to mitigate
its consequences.
GUIDE WORDS

A short word to create

the imagination of a
deviation of the
design/process intent.
Guide Words

Guide Words Meaning

No Negation of the design intend
Less Quantitative Decrease
More Quantitative Increase
Part of Qualitative Decrease
As Well As Qualitative Increase
Reverse Logical opposite of the intend
Other Than Complete Substitution
THE HAZOP PROCESS

Select Equipment Node

Choose Deviation OR Parameters & Guide

Words Identify Causes

Associate Consequences

Apply Risk Ranking

Agree Actions To BeTaken

Monitor Actions For Completion

Case
Study
Case Study 1: Preliminary
HAZOP on Reactor

Cooling Water Refer to reactor system shown.

The reaction is exothermic. A cooling system is
provided to remove the excess energy of
reaction. In the event of cooling function is lost,
the temperature of reactor would increase. This
would lead to an increase in reaction rate
leading to additional energy release.
The result could be a runaway reaction with
pressures exceeding the bursting pressure of the
reactor. The temperature within the reactor is
measured and is used to control the cooling
water flow rate by a valve.

Perform HAZOP Study

 Case Study 1: Preliminary
HAZOP on Reactor
Cooling
Water

Guide Word Deviation Causes Consequences Action

Other
No WellThan Another
No material
Cooling Waterpressure
Cooling source
water May be
T cooling If less check
cooling,
Reverse
As
More As Reverse
Reactor
More product
cooling
cooling flowin Failure
More
Control of waterin
valve Temperature
Less
Off-spec
cooling,
oo much product
cooling, Install
Instructhigh
Check valve
operators
besides cooling contaminated
valve ineffective and TAH will detect. If
flow
coils failure,malfunction
source
reactor resulting
operator in increase
reactor coolreactor
possible in
runaway temperature
maintenance
on procedures alarm
water backward flow effect on the
reaction detected, isolate
(TAH)
procedures and
fails to take action
reaction water source.
schedules
on alarm
Back up water
source?
Event Tree Analysis

 A bottom up approach starting with an

initiating event and looking at consequences.
 Can be quantified to give an estimate of the
probability of each outcome
Fault Tree Analysis

 Start with a loss, or unwanted consequences

as the “head event”
 Can be quantified to estimate the probability
of an unwanted head event from the known
probabilities of failure causes.
 Are useful for analyzing possible sources of
risk before loss occurs and for investigating
failures and accidents.
Steps in Drawing a Fault Tree

 Determine undesirable event which is to be

the head event.

 Determine all events which could

immediately cause the head event. It is
important not to skip to sub causes.
Steps in Drawing a Fault Tree

 Determine the relationship between the

causal event and the head event terms of
AND and OR gates.

 Determine whether any of the causal events

need further analysis if so repeat steps 2 & 3
Use of Fault Tree in Accident Analysis

 A fault tree can be used in a qualitative way

in accident analysis to help identify underlying
causes of accidents.

 The head event is the loss from the accident.

HIRARC

Risk Control
 Ranks risk control icluding :
i. Eliminations of hazard.
ii. Substitution of hazardous processes or materials with safer ones.
iii. Engineering controls.
iv. Administrative controls.
v. Personal protective equipment (PPE).
 WHAT IS A RISK ASSESSMENT?

 It is a way of determining risks and

dangers in work places
 Risk assessment include analysing
the possible hazard that could occur
within a workplace and finding a
solution in a safe manner. This
avoiding injury to an individuals and
damage to property
 WHAT IS A RISK ASSESSMENT?

 If the hazard cannot be avoid in a

safe way, then the risk assessment
will say that the activity shouldn’t be
carried out
WHY DO WE HAVE RISK ASSESSMENTS?
WHY DO WE HAVE RISK ASSESSMENTS?

“McDonald's coffee case”

$3 million

In 1992, 79-year-old Stella Liebeck bought a cup of

takeout coffee at a McDonald’s drive-thru in
Albuquerque and spilled it on her lap. She sued
McDonald’s and a jury awarded her nearly $3 million
in punitive damages for the burns she suffered.
WHY DO WE HAVE RISK ASSESSMENTS?

“McDonald's coffee case”

$3 million

McDonalds also argued that consumers know

coffee is hot and that its customers want it that
way. The company admitted its customers were
unaware that they could suffer third degree burns
from the coffee and that a statement on the side of
the cup was not a "warning" but a "reminder"
since the location of the writing would not warn
customers of the hazard.
 WHY DO WE HAVE RISK ASSESSMENTS?
26th August 2016
WHY DO WE HAVE RISK ASSESSMENTS?
WHY DO WE HAVE RISK ASSESSMENTS?

 They are needed to assess any

danger that people could be put in
when they are in work places
 Risk assessments are needed so that
the risks of danger happening within
the work places is reduced and
eliminated.
WHY DO WE HAVE RISK ASSESSMENTS?

 They are in order to protect people

within the work places, not only the
person carrying out the practical's
but others around
 They help to set out guidelines to
what you should and shouldn’t do
within a work places for safety
WHAT SHOULD A RISK ASSESSMENT COVER?

 A risk assessment must include the

possible dangers that could occur in
the work places.
 The risk assessment should include
guidelines for protecting people.
5 STEPS OF RISK ASSESSMENT

1. Identifying the hazard:

2. Decide who might be harmed and how
3. Evaluate the risks and decide on the
precautions
4. Record your findings and put them into
place
5. Review you risk assessments and make
amendments if needed
STEP ONE: IDENTIFYING THE HAZARDS

 Identified before the hazards can

cause harm to anyone.
• Firstly you would need to know what
can be classed as hazardous before
identifying hazards
 STEP ONE: IDENTIFYING THE HAZARDS

Look around for any chemicals that may

cause harm and any equipment that may
be faulty or be in a place where it could
get in someone's way.
You would also have to think about any
long term hazards there may be.
STEP TWO: DECIDE WHO MIGHT BE HARMED AND HOW
 Think about the possible health risk or
injury that could be caused to an
individual.
 Take into account any workers that may
have special health and work
requirements
 STEP TWO: DECIDE WHO MIGHT BE HARMED AND
HOW

 Think about new workers that work within

the work places as they may not know the
way the equipment works.
 It needs to be taken into account about
how the work places activities can affect
the public
STEP THREE: EVALUATE THE RISKS AND DECIDE ON
THE PRECAUTIONS

 After spotting the hazard decide on the

actions that would need to be taken
 When this has been done you would
need to do anything reasonable practical
that would eliminate the risks of the
hazard occurring
 STEP THREE: EVALUATE THE RISKS AND DECIDE ON
THE PRECAUTIONS

 If there is no way of eliminating the

hazard happening then a precaution
would need to be taken to control
the risk to the best ability i.e. try and
carry out a less risky activities
 STEP FOUR: RECORD YOUR FINDING AND PUT THEM
INTO PLACE

 Once the results are recovered for

the risk assessment then all staff
within the work places should be
informed
 When writing out a risk assessment
results it needs to be kept simple
and understandable
STEP FOUR: RECORD YOUR FINDING AND PUT THEM
INTO PLACE

 A risk assessment do not need to be

perfect but it needs to show that an
inspection has been carried out
correctly and that precautions are
reasonable leaving the risk to a
minimum
STEP FIVE: REVIEW YOUR RISK ASSESSMENT AND MAKE
AMENDMENTS IF NECESSARY

 Make sure that the risk assessment is

correct, and that all hazards have been
covered and included. make sure that
the people are safe to work within the
work places.
STEP FIVE: REVIEW YOUR RISK ASSESSMENT AND MAKE
AMENDMENTS IF NECESSARY

 If hazards occur later on (after a risk

assessment has been conducted) then
changes will need to be made to that
risk assessment.
RISK ASSESSMENT

Hazard Persons who Property which Risk controls already Risk Assessment Further action
may be harmed may be damaged in place LOW, required to control
MODERATE, risk ***
HIGH, EXTREME
(see table next
page)
Hot sand underfoot Actors and crew n/a All actors and crew to wear When not involved in
on beach shoes at all times HIGH the shoot, actors and
crew to have a shaded
area in which to stand

Behaviour of dog Actors and crew Location Dog will be on leash and Feeding, toilet,
supervised at all times and MODERATE recreation and rest
will not be left unattended. areas to be arranged
for animal away from
location premises

Burns from Actors and crew Location All actors and crew to sit Advise local fire brigade
campfire at least 2 metres from
fire. HIGH
Fire to be set at least 20
metres from property.
Fire extinguishers with
trained operators on set.
HIRARC
Risk Control Hierarchy
1. Elimination – Elimination of a specific hazard or hazardous work process, or
preventing it from entering the workplace, is the most effective method of
control. For example, a salvage firm might decide to stop buying and cutting up
scrapped bulk fuel tanks due to explosion hazards.
2. Substitution of the Hazard- Sometimes doing the same work in a less hazardous
way is possible. For example, a hazardous chemical can be replaced with a less
hazardous one. Controls must protect workers from any new hazards that are
created.
3. Isolation Of Hazard- If a hazard cannot be eliminated or replaced, it can some
times be isolated, contained or otherwise kept away from workers. For example,
an insulated and air-conditioned control room can protect operators from a
toxic chemical.
HIRARC
Risk Control Hierarchy
4. Engineering controls - Include the installation of machine guards of hazardous
equipment.
5. Administrative Controls - Include training and education, job rotation to share
the load created by demanding task, planning, scheduling certain jobs outside
normal working hours to reduce general exposure.
6. Personal Protective Equipment (PPE) - Personal protective equipment (PPE)
and clothing is used when other controls measures are not feasible and where
additional protection is needed. Workers must be trained to use and maintain
equipment properly. The employer and workers must understand the
limitations of the personal protective equipment.
Review Risk Control
Re-evaluate the job descriptions and modify the job hazard analysis
accordingly.