Industrial Safety Engineering

S7 CE
MODULE 5
Prof. Nima M. Anil

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 Hazard and Risk
❖A hazard is any source of potential damage, harm or adverse health effects on
something or someone.

❖Risk is the chance or probability that a person will be harmed or experience an

adverse health effect if exposed to a hazard. It may also apply to situations
with property or equipment loss, or harmful effects on the environment.

❖Factors that influence the degree or likelihood of risk are:

• The nature of the exposure: how much a person is exposed to a hazardous thing or
condition (e.g., several times a day or once a year),
• How the person is exposed (e.g., breathing in a vapor, skin contact), and
• The severity of the effect
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Types of Hazards
1. Fall of person due to poor workmanship, loss of balance, uneven surface, floor
opening, poor work platform, working at height without using full body harness,
Defective ladder or stair, slippery floor, Loose material in assess etc.

2. Fall of material due to failure of lifting appliances, Tools & tackles, Loose
material Keeping at edge on height or near floor opening, Poor method of
Material lifting & shifting etc.

3. Mechanical hazard (entanglement, contact with sharp edge, Ejection like spark
and small particle emitting during grinding job.)

4. Electrical hazard like Fire, Electrocution, Burn injury, Fall due to electrical
shock.
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Types of Hazards…
5. Fire Hazard due to hot job near flammable material, Inadequate storage
of flammable material metal storage tank, smoking,

6. Physical Hazard like heat, Poor illumination, Cold stress,

7. Environmental hazard like dust, fumes, Gases, NOx, SOx, Noise

8. Ergonomical hazard includes repetitive movement, manual handling,

workplace/job/task design, uncomfortable workstation and poor body
positioning

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Types of Hazards…
9. Chemical hazard like dust, fumes, gases create central nervous system
problem & respiratory problem due to inhalation and create skin problem
when come in its contact.

10. Vehicle movement may cause of hit to person, hit to object or collision
or topples

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Fire
• Fire is a chemical reaction in which combustible material combines with oxygen
when external source of heat is applied.

• Causes of Fire include:

• Hot Job near flammable material.
• Flammable material storage near heat source area or live power cable or direct sun light.
• Loose Electrical Connection.
• Over load- electrical equipment.
• Smoking.
• Poor Bonding of flammable material
• Poor earthing with flammable material storage tank.
• Static electricity.
• Poor Housekeeping. 6
 Types of Fire
• According to the European standard, fire classes are :

❖Class A Fire: Common combustibles as papers, textiles, wood, & PVC etc.

❖Class B Fire: Flammable liquids, and solids which can convert to liquids easily, such as
oils, paints, wax, benzene, gasoline, plastic that can melt, petrol and diesel etc.

❖Class C Fire: Flammable gases, as natural gas, propane, LPG and propane etc. (This
type may be considered as of electricity.)

❖Class D Fire: Combustible or flammable metals, as magnesium, sodium, aluminium

and iron etc.

❖Class F Fire: Cooking media fires, as due to the fats and oils in the cooking,appliances
etc.
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Fire Extinction
Three Principle of Fire Extinction

❖ Cooling: To use water

❖ Smothering: Reduce Level of Oxygen

❖ Starvation: To Reduce Amount of fuel

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Fire Extinction…
❖Cooling
• Cooling can be done with the help of water.

• Water can be applied as a jet as well as in the spray form.

• For a large amount of fire we usually use water in jet form in order to cover
maximum contact area, while the spray form is used for small fires, in order to
absorb more heat from the fire due to the drop large surface area.

• We use water because water requires a large amount of heat to increase its
temperature, to convert to steam and usually will absorb a large amount of heat,
if reacts with, the fuel.

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Fire Extinction…
❖Smothering
• Removal of oxygen can be done by the physical means as well as displacement .

• In physical means, we can prevent oxygen by damping the pan by cloths as well
as foam with the help of foam extinguisher.
• The foam must have different properties such as it must have the ability to flow on the
burning surface and can cut off the oxygen supply.
• It must have some resistance to vapours of the flammable liquids as well as to the heat.

• In displacement method we replaces the oxygen contents with a gas which does
not help combustion such as carbon dioxide, steam, nitrogen gas and also some
other inert gases.

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Fire Extinction…
❖Starvation
• It means that by removing the source, usually the fuel a fire can be
stopped, because without having something to burn the fire cannot be
possibly existed

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Fire Extinguishers and Their Use
SL No. Extinguisher Type of Fire

1 Water (Red) Class A (which involves ordinary combustible

solid such as wood, paper, cloth, plastics, coal,
etc).

2 Dry chemical powder Class B (which involves flammable an

(Blue) combustible liquid such as petrol, oil, paint,
kerosene etc).

3 Foam (cream/whitish Class B (which involves flammable and

yellow) combustible liquid).

4 Carbon Dioxide (Black) Class E (which involves electrical fires)

Water Extinguisher
• Water extinguishers are extinguishers that contain water and compressed gas.

• The water is ejected through the nozzle by a CO2 gas cartridge or by stored
pressure typically nitrogen gas.

• These are used on Class A fires (wood, paper, fabric).

• They are typically 9 to 10 litres capacity and can project a jet of water about 6
meters.

• For the best effect the water stream should be directed at the burning material.

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Dry Chemical Powder extinguisher
• The contents are ejected by a gas cartridge or by stored pressure. They
are used on Class B fires, that is on flammable liquid fires to assist foam in
the combined- agent suppression.

• They are safe to use on live electrical equipment, but are generally not
preferred for this role because of the clean-up afterwards.

• They range in size from 1kg to 11kg, though 9 kg is the most common.

• The 'standard' powder is sodium bicarbonate, but a number of high-

performance powders are also in use.

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Foam extinguisher
• The contents are ejected about 4 to 5 meters by a gas cartridge or by
stored pressure and they are about 9 litres in capacity.

• These are used on Class B fires (liquids such as petrol, paints, oils etc.).

• For the best effect the foam should be applied to fall as lightly as possible
onto the burning material.

• This can be achieved by applying the foam to a rear wall in the case of an
enclosed area, or if in an open space aiming the foam to strike the ground
just short of the fire so that it flows gently over the burning fuel.

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Carbon dioxide extinguisher
• They are used as a first attack on electrical fires. The portable units vary in size
from 2.5 kg to 7 kg.

• CO2 is a colourless, odourless gas, which does not support combustion. It is not
poisonous but is suffocating in large quantities.

• The gas is discharged through a wide 'horn' discharge nozzle and the gas stream
projects for 1 to 2 meters.

• It is applied in a low sweeping motion at the base of the fire, and the possibility
exists for re-ignition after the gas disperses.

• However, it leaves no mess or residue and is therefore preferred for electrical fires
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Fire Extinguisher chart

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Hazard Identification
• Hazard identification is the process in which the hazards of a workplace
are identified within a system, procedure or equipment.

• Hazard identification is a part of risk assessment in which the hazards are

identified for further investigation.

• Once the hazards are identified then proper measures can be taken to
eliminate them by using engineering controls.

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Hazard Identification…

Within an organization, there are several ways by which hazards may be

identified. These include:

1. Workplace inspections

2. Management/ workers discussions

3. Independent audits.

4. Job safety analysis.

5. Hazard and operability studies.

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Workplace Inspections
• Workplace inspections are undertaken with the aim of identifying hazards
and promoting remedial action. Many different individuals and groups within
an organization will at some time be involved in a workplace inspections;
directors, line managers, safety advisers, supervisors and safety
representatives.

• The key aspect is that results of all such inspections should be coordinated
by one person within the factory, whose responsibility should include;
1. Monitoring action taken once the hazard has been notified

2. Informing those persons who reported the hazard as to what action has been taken.
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Management/ Worker Discussions

• Management/worker discussion can also be useful in the identification of

hazards.

• Formal discussions take place during meetings of the safety committee with
informal discussions occurring during on-the-job contact or in conversations
between supervisor and worker.

• The concept of "incident recall" is an example of management/worker

discussion

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Independent Audit
• Independent audit can also be used to identity hazards.

• The term independent here refers to those who are not employed of the
organization, but who from time to time undertake either general or specific
workplace audit or inspection. Such independent persons may include
• Engineer surveyors
• Employers' liability surveyors
• Claims investigators
• Insurance brokers personnel
• Outside consultants
• Health and safety executive
• Job Safety Analysis 22
 Job Safety Analysis
• A Job Safety Analysis (JSA) is one of the risk assessment tools used to identify
and control workplace hazards.

• A JSA is a documented risk assessment developed when company policy

directs people to do so.

• The JSA should be created by the work group performing the task.

• Four basic stages in conducting a JSA are:

1. Selecting the job to be analysed
2. Breaking the job down into a sequence of steps
3. Identifying potential hazards
4. Determining preventive measures to overcome these hazards
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Job Safety Analysis…

• Types of JSA

1. Physical Job safety analysis

• JSA which deals with mechanical failure, falling, skidding etc., are classified thus.

2. Chemical Job safety analysis

• JSA which deals with chemicals like flammables, combustibles, explosives etc., are
classified thus.

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 Hazard and Operability Study

• It is a technique of hazard identification (and evaluation) that has been

developed in the chemical and process industries.

• The technique essentially involves a multidisciplinary team of chemists

engineer, safety advisors, production management, designers etc, critically
examine each aspect of a process at the design stage, in order to eliminate
hazards from the process at that early stage, rather than to find them later
and have to modify the plant to eliminate them.

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Hazard And Operability Study (HAZOP)
• A hazard and operability study (HAZOP) is a structured and systematic
examination of a planned or existing process or operation in order to
identify and evaluate problems that may represent risks to personnel or
equipment, or prevent efficient operation.

• It is carried out by a suitably experienced multi-disciplinary team (HAZOP

team) during a set of meetings.

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Hazard And Operability Study (HAZOP)…

• A brainstorming technique

• A qualitative risk assessment tool

• An inductive risk assessment tool, meaning that it is a "bottom-up" risk

identification approach, where success relies on the ability of subject
matter experts (SMEs) to predict deviations based on past experiences
and general subject matter expertise.

• A HAZOP study is a team effort. A minimum team size of 4-5 is

recommended.

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Hazard And Operability Study (HAZOP)…
HAZOP is best suited for assessing hazards in facilities, equipment, and processes

• and is capable of assessing systems from multiple perspectives:

❖Design
• Assessing system design capability to meet user specifications an safety standards
• Identifying weaknesses in systems

❖Physical and operational environments

• Assessing environment to ensure system is appropriately situated supported, serviced, contained, etc.

❖Operational and procedural controls

• Assessing engineered controls (ex: automation), sequences of operations, procedural controls (ex: human
interactions) etc.
• Assessing different operational modes – start-up, standby, normal operation, steady & unsteady states,
normal shutdown, emergencyshutdown, etc.
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 Hazard And Operability Study (HAZOP)…
Advantages Disadvantages
• Helpful when confronting hazards that are • No means to assess hazards involving
difficult to quantify interactions between different parts of a system
• Hazards rooted in human performance and or process
behaviours
• No risk ranking or prioritization capability
• Hazards that are difficult to detect, analyse,
isolate, count, predict, etc. • Teams may optionally build-in such capability as
required
• Built-in brainstorming methodology
• No means to assess effectiveness of existing or
• Systematic & comprehensive methodology
proposed controls (safeguards)
• More simple and intuitive than other commonly
• May need to interface HAZOP with other risk
used risk management tools
management tools (ex: HACCP) for this purpose

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HAZOP Methodology

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HAZOP Methodology…
1. Definition Phase

• The Definition Phase typically begins with preliminary identification of risk

assessment team members.

• HAZOP is intended to be a cross-functional team effort, and relies on specialists

from various disciplines with appropriate skills and experience who display
intuition and good judgment.

• During the Definition Phase, the risk assessment team must identify the
assessment scope carefully in order to focus effort.

• This includes defining study boundaries and key interfaces as well as key
assumptions that the assessment will be performed under.

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 HAZOP Methodology…
2. Preparation Phase

• The Preparation Phase typically includes the following activities:

• Identifying and locating supporting data and information.

• Identification of the audience and users of the study outputs.

• Project management preparations (ex: scheduling meetings, transcribing

proceedings, etc.)

• Consensus on template format for recording study outputs.

• Consensus on HAZOP guide words to be used during the study.

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HAZOP Methodology…
• HAZOP guide words are key supporting elements in the execution of a
HAZOP analysis.

• The identification of deviations from the design intent is achieved by a

questioning process using predetermined “guide words”.

• The role of the guide word is to stimulate imaginative thinking, to focus the
study and elicit ideas and discussion.

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HAZOP Methodology…

Fig.1 Some common HAZOP guide words.

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HAZOP Methodology…

Fig.2 Example showing how different HAZOP guide words might be used to brainstorm deviations
around detergent control for a cleaning operation

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HAZOP Methodology…
3. Examination Phase

• The Examination Phase begins with identification of all elements (parts or steps) of
the system or process to be examined.

• For example:
• Physical systems may be broken down into smaller parts as necessary
• Processes may be broken down into discrete steps or phases
• Similar parts or steps may be grouped together to facilitate assessment

• The HAZOP guide words are then applied to each of the elements.

• In this fashion a thorough search for deviations is carried out in a systematic

manner.
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HAZOP Methodology…
4. Documentation & Follow-up Phase

• The documentation of HAZOP analyses is often facilitated by utilizing a

template recording form.

• Risk assessment teams may modify the template as necessary based on

factors such as:
• Regulatory requirements
• Need for more explicit risk rating or prioritization (ex: rating deviation probabilities,
severities, and/or detection)
• Company documentation policies
• Needs for traceability or audit readiness
• Other factors 37
HAZOP Template with example

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 Control of Chemical Hazards
• Hazardous chemicals present a number of risks upon the people in the workplace.

• To help mitigate these risks, the hazards associated with dangerous substances must
be controlled in a professional manner.

• The risk of hazardous chemicals can be managed by following the STOREMASTA

methodology. This

• Methodology has four phases:

i. Identify

ii. Assess

iii. Control

iv. Sustain 39
STOREMASTA Methodology.

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 STOREMASTA Methodology…
i. Identify

• Identifying risk is a process that involves identifying situations involving

hazardous chemicals that could potentially harm people.

ii. Assess

• Assessing risk allows you to evaluate what would happen if someone was
exposed to hazardous chemicals.

• A risk assessment will allow you to calculate the magnitude of the risk by
determining the severity and likelihood of an incident occurring.

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STOREMASTA Methodology…
iii. Control

• Once you have identified and assessed the severity of the risks, you will have valuable data
that will allow you to determine the best methods that should be used to control the risk.

iv. Sustain

• Once the controls have been implemented, you must review their effectiveness and set up a
proactive system to sustain their effectiveness.

• This proactive system normally consists of a number of periodically scheduled risks

assessments.

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Hierarchy of Control of Chemical Hazards

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Hierarchy of Control of Chemical Hazards…
❑Elimination

• The risk control measure that has the greatest level of effectiveness is elimination.

• Before any other control measures are considered, elimination must be applied
first.

• Elimination is the method of totally removing a hazard or hazardous practice from

the workplace.

• Some examples of eliminating the use of a hazardous chemical in the workplace

include:
• Eliminating the use of chemical adhesive by using fasteners such as screws or nails.
• Eliminating the use of flammable forklift gas by using electric power forklifts instead of LPG
powered forklifts.
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Hierarchy of Control of Chemical Hazards…

❑Isolation

• Hazardous substances must also be isolated from other incompatible

substances.

• If incompatible substances mix, it can result in violent chemical reactions

that can harm people and property.

• Incompatible hazardous substances can be isolated by storing them in

separate chemical storage cabinets and dangerous goods storage
containers.

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Hierarchy of Control of Chemical Hazards…
❑Engineering Controls

• If isolation cannot be achieved, you can implement a number of engineering

controls to reduce the risk associated with hazardous chemicals.

• Engineering controls are physical in nature and are devices or processes

that eliminate exposure to hazardous chemicals.

• Engineering controls can be used to:

• Minimise the generation of hazardous chemicals

• Suppress or contain chemicals

• Limit the area of contamination in the event of spills

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Hierarchy of Control of Chemical Hazards…

• Engineering controls can include devices such as mechanical ventilation

systems, compliant chemical storage containers or the automation of
processes involving the use of hazardous chemicals.

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Hazardous Properties of Chemicals
• Hazardous characteristics of chemicals include:

➢Ignitability

➢Corrosivity

➢Reactivity

➢Toxicity

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Material Safety Data Sheet (MSDS)
• A Material Safety Data Sheet (MSDS) is a document that gives detailed
information about the nature of a chemical, such as physical and chemical
properties, health, safety, fire, and environmental hazards of a chemical
product.

• also tells how to work safely with a chemical and what to do if there is an
accidental spill.

• In other words, it is a document that contains information on the potential

hazards (health, fire, reactivity and environmental) and how to work safely
with the chemical product.
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Material Safety Data Sheet (MSDS)…
• It is essential starting point for the development of a complete health and
safety program.

• It also contains information on the use, storage, handling and emergency

procedures all related to the hazards of the material.

• They are prepared by the supplier or manufacturer of the material.

• MSDS must contain the same basic kinds of information, such as

1. Chemical Identity: Name of the product.
2. Manufacturer's Information: Name, address, phone number and emergency
phone number of the manufacturer.

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Material Safety Data Sheet (MSDS)…
3. Hazardous Ingredients/Identity Information: List of hazardous chemicals. The OSHA
Permissible Exposure Limit (PEL) for each hazardous ingredient must be listed

4. Physical/Chemical Characteristics: Boiling point, vapor pressure and density, melting

point, evaporation rate, etc.

5. Fire and Explosion Hazard Data: Flash point, flammability limits, ways to extinguish,
special firefighting procedures, unusual fire and explosion hazards.

6. Reactivity Data: How certain materials react with others when mixed or stored together.

7. Health Hazard Data: Health effects (acute= immediate; chronic= long- term), ways the
hazard can enter the body (lungs, skin or mouth), symptoms of exposure, emergency
and first aid procedures.

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Material Safety Data Sheet (MSDS)…
8. Precautions of Safe Handling and Use: What to do in case materials
spill or leak, how to dispose of waste safely, how to handle and store
materials in a safe manner.

9. Control Measures: Ventilation (local, general, etc.), type of

respirator/filter to use, protective gloves, clothing and equipment, etc

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THANK YOU

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