INDUSTRIAL SAFETY AND HEALTH

CKB 30103

TUTORIAL 1

1. The following data is accident statistic of a company.

a. Identify the type of incident name (or consequences); according to OSHA

and NADOPOD regulation 2005) for the following data.
b. Identify type of hazard(s) in each incident.
c. Calculate the OSHA Incident Rate, Fatal Accident Rate, Lost Time Injury
from this accident statistics.
d. Calculate the Fatality rate if total number of employee is 150.

Date of Preliminary Description of Incident

Incident
11/1/2010 Worker was conducting repairs on a milling machine, which was not locked out. The machine started,
crushing the worker leg and caused the bone broke. He was away from work 2 months.

2/2/2010 Four workers injured while jack hammering a septic tank when propane fumes in the tank exploded.
Two employees were from ARCG department, and two worked for DHI Department.

18/4/2010 Worker was heating a valve on the rear of a water truck with a propane torch and an explosion
occurred and experienced third degree burn on his body. He died two days later.

12/4/2010 Worker was conducting checker activities at the unloading area. The driver pulled the tractor trailer
forward, causing the worker to fall down under the path of the trailer wheels and twisted her ankle.
She was relocated to the administration office for 21 working days.

26/5/2010 Worker died after receiving multiple bee stings while working outside an apartment building.

127/6/2010 Worker was working at a grain bin. The grain bin collapsed and caused loses about 200kg grain.

24/7/2010 Worker was performing decking work at a height of 10 feet above ground level and fell through
the decking caused twisted his ankle.

30/7/2010 Worker was performing housekeeping job in the detergent store and found fainted by his coworker;
was rushed to clinic and work as usual on the following day.

4/8/2010 Worker was installing heating and cooling equipment and fell from a ladder. An orthopedic confirmed
joint dislocated and advised him to rest for at least 1 month.

1 2/9/2010 Worker was putting a tarp on a leaky roof when he lost his footing, falling about 60 feet through
a glass skylight. He was examined and confirmed paralyzed.

1 3/12/2010 10 workers were hospitalized for 4 days after consuming meal provided by the company
caterer due to stomach upset.

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 2. State the definition of the following terms:-
a. Hazard
b. Risk
c. Accident

3. Laila, who work as receptionist cum telephone operator has been informed that
she is exposed to ergonomic hazard. Due to her ignorant, she consulted you, as
safety and health officer, about ergonomic hazards. Explain in full detail of
ergonomic hazards and its consequences.

4. The following is the details of safety performance from various industries in year
2011.
a. If total number of workers in manufacturing is 200. Determine FR.
b. The total number of hours work for Professional & technical services is
300,000. Calculate the number of occupational illnesses, if half of OSHA
IR is due to illnesses.
c. Calculate the Lost Time Injury Rate of transport & warehouse, if 75% of
DART is Loss Time Injury Case.
d. Rank the safety performance of various industries according to the OSHA
Incident Rate.

Type of industries OSHA IR DART 2011 Fatal Accident Fatality Rate Occ.
2011 Rate 2011 2011 illnesses
2011
Manufacturing 5.0 1.2 411 43.2
Construction 4.7 1.7 975 9.7 12.2
Utilities 3.5 1.1 37 3.9 35.2
Professional & 5.33 0.3 403 2.8
Technical services
Educational 2.3 0.7 141 0.7 8.9
services
Transport & 5.7 2.5 796 14.9 19.4
warehouse

5. Based on the data in in Q1,complete the related the JKKP forms used in the
NADOPOD 2005.

6. Explain the following term:

a. ALARP.
b. Acceptable risk.
c. Significant risk. How a company will decide the significant risk from
several risk (from low to extreme risk) estimated in a company.

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 7. Construct the Fault Tree Analysis from the following diagram with the top event is
‘water leak through the ceiling’.

8. The Fault Tree Analysis for the top event MOTOR DOES NOT RUN WHEN
SWITCH IS PRESSES for the following diagram as shown below:

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Calculate the probabilities of the top event if given the component failure rate as shown in
the table below.

Component Failure rate

Motor 0.05 / year
Battery 0.10 / year
Connectors 0.5 / year
Switch 0.10 / year
Human error 0.02 / year

9. The chemical reaction involves 2 liquids, A & B, which flow from their respective
storage tanks into the stirred product C reactor. The flow rate of materials A & B
is regulated by control valves A & B, respectively.The liquid phase chemical
reaction that results is highly exothermic & generates considerable quantities of
heat, which must be controlled by cooling water on the jacket of product C
reactor.The reaction of materials A & B to produce product C proceeds rapidly&
product C is drawn off from the bottom of the reactor.Product C flows through
valve C into the product C storage vessel to await shipment. The reactor & each
of the storage tanks have pressure-operated relief valves in case of pressure
buildup during the process operation.Temperature, pressure and level indicator
are provided in the product C reactor for use in controlling process chemistry.
Carry out HAZOP study using appropriate OSHA guide words for the process
parameter FLOW using HAZOP worksheet.

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Appendix

1. OSHA incidence Rate:

Number occupational injuries & Illness x 200,000

Total hours work by all employees during period covered

2. Fatal Accident Rate:

Number of fatalities x 108
Total hours work by all employees during period covered

3. Days Away and Restricted Transfer (DART)

Number of days away and Restricted Transfer x 200,000

Total hours work by all employees during period covered

4. Fatality Rate:[also known as Number of fatalities expected per person per year]

Number of fatalities per year

Total no. of people (per year) in applicable population

5. Lost Time Injury Rate:

Number of loss time injury x 200,000

Total hours work by all employees during period covered

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