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NKB30103 Chapter 4 Hierarchy of Control

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24 views88 pages

NKB30103 Chapter 4 Hierarchy of Control

Uploaded by

Adell
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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INDUSTRIAL SAFETY & HEALTH

CONTROL

1
OBJECTIVES
At the end of this chapter, you will be
able to;
 Define principle of control and hierarchy of control.
 List the techniques apply under principle of control
method and provide the example.
 Define emergency response planning
 Discuss the elements in emergency response
planning.
 List out methods involve in chemical control.
 Define procedures and examples in chemical control

2
CONTROL
CONTROL MEASURES CAN BE
DONE AT:-

MORE EFFECTIVE AT: ________?

3
CONTROL
Hierarchy of Control
1. Elimination
2. Substitution
3. Engineering Control
4. Isolation
5. Administration Control
6. Personal Protective Equipment

4
CONTROL
1. ELIMINATION
Ideal solution.
Permanent solution
Most effective method.
Should always be attempted first

•Through prohibition
•May mean discontinuing dangerous work
practices.
•Removing dangerous substances/equipments.
•Control is done at its source.

5
CONTROL
1.ELIMINATION

EXAMPLE

Completely removing asbestos from workplace.

Prohibition of some hazards or its source being


used, operated or even being in the work area.

Discontinuing noisy machine/process

6
CONTROL
2. PREVENTION OR REDUCTION OF EXPOSURE

THE METHOD CAN BE USED ALONE OR IN COMBINATION


TO PREVENT OR REDUCE EXPOSURE TO RISK. MAY
INCLUDE ENGINEERING CONTROL METHODS

 Substitution
 Engineering Control (modification)
 Isolation or separation
 Enclosure

7
CONTROL
SUBSTITUTION OF MATERIAL, PROCESS OR
EQUIPMENT

Goal: Replacing the hazard with one that lower risk


(and more manageable).

EXAMPLE
•Using a less hazardous chemical.
•Vacuuming rather than sweeping.
•Using hoisting equipment instead of manual handling.

8
CONTROL SUBSTITUTION

Choosing a substitute chemical:

• Less volatile/Highly volatile

• Liquid form/Solid form material [also need to


consider the size of material]

9
CONTROL SUBSTITUTION MATERIAL

Instead Of: Consider:

carbon tetrachloride (causes 1,1,1-trichloroethane,


liver damage, cancer) dichloromethane
benzene (causes cancer) toluene, cyclohexane, ketones

pesticides (causes various "natural" pesticides such as


effects on body) pyrethrins
organic solvents (causes water-detergent solutions
various effects on body)
leaded glazes, paints, versions that do not contain
pigments (causes various lead
effects on body)
sandstone grinding wheels synthetic grinding wheels
(causes severe respiratory such as aluminium oxide
illness due to silica)

10
CONTROL
SUBSTITUTION PROCESS

dip coating materials rather than spray coating to


reduce the inhalation hazard.

11
CONTROL
SUBSTITUTION PROCESS Hoisting Equipment –
Portable scissor lift

Use of trolley to transfer


material instead carry

12
CONTROL
ENGINEERING CONTROL (redesign) of equipment,
work process or work environment through modification to isolate or
enclose the hazards.

Requires thinking about ways work could be done differently to


make work safer.

EXAMPLE
•Rearranging aspects of workplace- inherently safe design
•Modifying exhaust system to reduce noise
•Using scissor lift instead hoisting equipment in carrying goods

13
Engineering Control - inherent safe design
1.Separate pump rooms
from the other unit of
operations, e.g flammable
material storage tank.

14
Engineering Control - inherent safe design
2.Build control rooms away from production units for
hazardous production process.

15
CONTROL
ISOLATION or SEPARATION
Isolating or separating the hazard from the person, or the person
from the hazard.

EXAMPLE
•Enclosing or guarding dangerous equipment
•Placing guards on moving parts of machinery
•Placing barriers around a spill until cleaned up
•Using remote-controlled handling equipment for hazardous processes

16
CONTROL
ISOLATION
Containment

17
CONTROL
ENCLOSURE
• Reduce exposure to fume or vapour, noise or heat by
segregation of workers from the source of harm

• by time or distance
- as in mining where workers retire to a safe distance at
the time of blasting,
- and when such operations take place on shifts when
fewer workers are about.

• More commonly, however, it involves enclosure of the process


so that there is a physical barrier between the source of harm and
the workers.

18
CONSEQUENCES

19
20
21
CONTROL
Devices
Presence Sensing
Photoelectrical (optical)
Radiofrequency (capacitance)
Electromechanical
Pullback
Restraint
Safety Controls
Safety trip control
Pressure-sensitive body bar
Safety tripod
Safety tripwire cable
Two-hand control
Two-hand trip
Gates
Interlocked
Other

22
 Location/Distance
 Potential Feeding and Ejection Methods to Improve Safety for the Operator
 Automatic feed

 Semi-automatic feed

 Automatic ejection

 Semi-automatic ejection

 Robot

 Miscellaneous Aids
 Awareness barriers

 Miscellaneous protective shields

 Hand-feeding tools and holding fixtures

23
CONTROL
ENCLOSURE GUARDS
Radius panel guards for
large turret milling machine
included chip-catch
perimeter pans

25
CONTROL
ENCLOSURE GUARDS

Custom saw guard


Custom made and installed guard
panels and machine access stair

26
CONTROL
3. TEMPORARY, LAST RESORT, OR BACK UP
MEASURES

•LOWEST IN HIEARARCHY OF CONTROL STRATEGIES.


• DEPENDENT ON APPROPRIATE HUMAN BEHAVIOUR TO WORK
ADEQUATELY.
•REQUIRES VERY ROBUST MGMT ENFORCEMENT & COMMITMENT
•TEND TO BE LESS EFFECTIVE
•SHOULD NOT BE RELIED ON AS PRIMARY MEANS OF RISK
CONTROLUNTIL OPTIONS HIGHER UP HIEARARCHY OF CONTROL
STRATEGIES ATTEMPTED AND EXHAUSTED.

28
CONTROL

3. TEMPORARY, LAST RESORT, OR BACK UP


MEASURES

• ADMINISTRATIVE CONTROL
• PERSONAL PROTECTIVE EQUIPMENTS

The higher hierarchy of control must be used first.

29
CONTROL
• ADMINISTRATIVE CONTROL
Reduction of exposure to risk through use of procedures or instruction.
EXAMPLE:
1. Job rotation to reduce exposure to hazards [e.g shift work]
2. Develop satety and health documentation [e.g standard
operating, working Instruction and etc]
3. Implement safe work practices [e.g Safe work permit, Log
Out, Tag Out & etc]
4. Limited entry / time in hazardous areas.
5. Training, refresher training and enforcement.

30
Permit to Work System

31
LOTO

32
LOCKOUT/TAGOUT SYSTEM
LOCKOUT/TAGOUT SYSTEM

 The requirements for locking-out or tagging


out energy resources ;
 It is the energy control program during servicing
and/or maintaining of machines and equipment
 To prevent unexpected activation of machinery or
process equipment during maintenance operation
LOCKOUT/TAGOUT SYSTEM

The employee need to aware ;


 the types of energy sources
 the hazards associated

Types of energy ;
 Electrical energy
 Mechanical energy
 mechanical motion
(e.g conveyor belt, roller, mixer, motor)
LOCKOUT versus TAGOUT
 Why lockout is preferred method ;

 Locks are hard to bypass

 Tags only warn - not as safety device

 Tags may be easily lost or damaged

 Locks speak everyone’s language


LOCKOUT versus TAGOUT

 Situations where tag-out system are an acceptable


choice

 The equipment cannot be physically lockout


 valves can be secured with chains, blocks or wedges
that then can be locked

 As an alternative to lockout
 process like computer driven where total lockout is not
possible
PERFORMANCE REQUIREMENTS FOR
LOCKOUT/TAGOUT DEVICES
 Must be singularly identifiable
- instant recognition
 Must be the only device used
- avoid confusing people
 Must not be used for other purposes
 Must be durable
 Must be standardized
- color, shape, size
PERFORMANCE REQUIREMENTS
FOR LOCKOUT/TAGOUT DEVICES
 Must be substantial
- lock’s or tag’s ability to prevent removal

 Must be identifiable
- Recognition
- Review
- Responsibility
PERFORMANCE REQUIREMENTS FOR
LOCKOUT/TAGOUT DEVICES

PERFORMANCE REQUIREMENTS
FOR LOCKOUT/TAGOUT DEVICES

MESSEGES ON TAGOUT DEVICES
 The message must warn of the danger of accidental
re-energization of the equipment

 DO NOT START
 DO NOT OPEN
 DO NOT CLOSE
 DO NOT ENERGIZE
 DO NOT OPERATE
 DO NOT TOUCH
SHUTDOWN/ISOLATION PROCEDURE
 Notification
- notify all affected personnel

 Shutdown
- push a stop button, open a switch, close a valve
etc.

 Isolation
- engaging the energy isolating device to prevent
any inadvertent energy reactivation
SHUTDOWN/ISOLATION PROCEDURE
SECURING THE POINT OF CONTROL

 The lockout/tagout devices are applied only by the


authorized person(s) doing the work

 The point of attachment ensures that the energy control


devices will remain in the OFF of “safe” position

 Tag-out device used in conjunction with the lockout


device is positioned so that affected personnel are
clearly warned to “keep hands off”
SECURING THE POINT OF CONTROL

 Tag-out devices used on energy isolating


devices capable of being lockout are fastened
at the same point with the lock

 Any tag that can’t be secured directly to any


energy isolating device is located at an
obvious point as close as possible to the
isolation device
TYPE OF ENERGY: ELECTRICAL

Method of Isolating or Method of Securing Point Remarks


Blocking Energy (Lockout/Tagout)

1) Place main electrical 1) Secure by a padlock or a bar and Check for


disconnect switch in padlock, and/or alternate source
the OFF position of power
2) Attach a warning tag and restrict
access into the area to trained
personnel, and/or

3) Post a person to protect against in-


authorized actuation of the switch
TYPE OF ENERGY: ELECTRICAL

Method of Isolating or Method of Securing Point Remarks


Blocking Energy (Lockout/Tagout)

2) Remove segments of 1) Tag circuit module and place in a locked


electrical circuit such as cabinet away from the control center,
printed circuit modules and tag the control center door and/or

2) Attach a warning tag to the module and


restrict access to trained personnel
and/or

3) Have a person remain at the control


center to protect from authorized
installation of a spare or replacement
module
VERIFICATION OF ISOLATION

Verify the energy before starting repair or


maintenance :
 Attempt Start-up
 Test equipment
 Visually inspect
RELEASE FROM LOCKOUT/TAGOUT

 Check work areas for operability

 Check that employees are clear of machines and


equipment

 Remove lockout or tag-out devices


- the employee who applied them should be allowed
to remove them
GROUP LOCKOUT

Require a proper procedures when involve


prolonged maintenance or service job involving a
group of people, different department, etc.
SUMMARY

 Never attempt lockout/tagout procedures unless you


have been trained
 Be sure to identify all potentially hazards
 Never just pull a fuse or use a selector switch
(ON/OFF) as a means of energy isolation
 Be sure all lockout/tagout devices are compatible with
the environment
 Always test the equipment or machines after
lockout/tagout
SUMMARY (continue)

 Never loan or share your lock, combination, or key with


anyone else
 Never attempt to remove lockout/tagout devices placed
by others
 If lockout/tagout procedures remain in effect between
work shifts, never remove your lockout/tagout devices
until your relief has installed his/her own lockout/tagout
device
54
55
56
Signages and safety work practices
documentation

57
CONTROL
• PERSONAL PROTECTIVE EQUIPMENTS
• Worn by people as final barrier between themselves and the
hazard.
•Success dependent on PPE being chosen correctly;
•Worn / worn correctly / used correctly;
•Maintained in good condition.
•Often more expensive in long term when cost of maintenance,
supervision and injuries/diseases taken into account

EXAMPLE:
Ear muffs and ear plugs, respirators, goggles, masks and hard hats.

58
Various types of PPE

59
CONTROL OF CHEMICAL HAZARDS

SUBSTITUTION

ENCLOSURE

ISOLATION

VENTILATION

WET METHOD
60
CONTROL
Controlling airborne
VENTILATION toxic materials

• To control toxic and/or flammable atmospheres by


exhausting or supplying air to either remove hazardous
atmospheres at their source or dilute them to a safe level.

• To prevent the work environment from being too hot,


cold, dry or humid

• To prevent contaminants in the air from getting into the


area where workers breathe {breathing zone}.

61
CONTROL
VENTILATION BASED ON TWO PRINCIPLES:

1. Dilute the contaminant below the target


concentration.
2. Remove the contaminant before workers are
exposed.

Ventilation system composed of fan and ducts.

Fan produce small pressure drop (less than 0.1 psi)


that moves the air.

62
Comparison of pressure

63
CONTROL
VENTILATION

64
CONTROL
VENTILATION TYPES Local Ventilation

Dilution ventilation

VENTILATION

65
CONTROL

Attempts to enclose the material, equipment or


process as much as possible and to withdraw air
from the physical enclosure at a rate sufficient
to assure that the direction of air movement at
all openings is always into the enclosure (e.g.
Fume Hood).
66
CONTROL
LOCAL VENTILATION

67
CONTROL
LOCAL VENTILATION-
HOOD

Several types of hood:

1. An enclosed hood – contains source of contaminant; eg


laboratory hood
2. An exterior hood – continuously draws contaminants
into an exhaust from some distance away.
3. A receiving hood – an exterior hood that uses the
discharge motion of the contaminant for collection.
4. A push-pull hood – uses a stream of air from a supply
to push contaminants toward an exhaust system.

68
CONTROL
Dilution ventilation

•For the contaminant that used in open area in the plant.


•Attempts to control hazardous atmospheres by diluting the
atmosphere to a safe level by either exhausting or supplying
air to the general area.
•Workers are exposed to the diluted amount of contaminant
as it has been diluted by the fresh air supplied.
• Cost of operation for dilution ventilation can be substantial
(high) due to the requirement to provide more airflows.

69
Restriction on dilution Ventilation
1. The contaminant must not be highly toxic.

2. The contaminant must evolved at a uniform rate.

3. Workers must remain a suitable distance from


source to ensure proper dilution of the
contaminant.

4. Scrubbing system must not required to treat the


air before exhaust into environment.

70
CONTROL
VENTILATION

71
CONTROL
VENTILATION
Effectiveness:

• How quickly the hazardous agent is being


released into the air
• How much and how quickly fresh air is
introduced/ coming in
• How the contaminated air is being removed

72
CONTROL
WET METHOD

Alternative method for ventilation. This type of


method is applied to a dusty working environment.

Objectives:

•Minimize the dust released to the surroundings and


atmosphere
•Minimize and eliminate the risk of inhaling the dust

73
CONTROL
WET METHOD

• Spraying water onto the equipment that produces dust in


order to reduce or eliminate the dust emission

• Water will be sprayed gently to the dust so the dust or


particles will be clogged together with water droplets

• Care must be taken to collect and properly dispose of the


wetted material and water containing the material.

74
 Wet processing is extremely effective in
reducing the possibility of dust generation.

 Processes which may be wetted typically


have much lower dust levels than
processes that run entirely dry.

75
CONTROL
WET METHOD

76
CONTROL
WET METHOD

77
EMERGENCY
PLANNING

78
Objectives

1. Prevent fatalities and injuries


2. Reduce damage to buildings, stock
and equipment
3. Accelerate the resumption of normal
operations

79
ELEMENTS OF EMERGENCY PLANNING

1. Identify types of emergencies.


 Fire
 Explosion
 Release / spill of hazardous substances
 Natural events; flood, cyclones,
earthquakes, tsunami
 Bomb threat
 Hijack / Pirates

80
ELEMENTS OF EMERGENCY PLANNING

2. Establish standard operating procedure


(documentation) for all possible type of
emergencies.

 such as for fire fighting procedures and


chemical spill procedures
 Prepare Emergency Escape procedures -
contain all of the necessary actions to be
taken.
 List the resources required i.e people or
facilities.
81
ELEMENTS OF EMERGENCY PLANNING

82
ELEMENTS OF EMERGENCY PLANNING

3. List the resources required i.e people or facilities. List


their roles and responsibilities.
 Establish Emergency Response and
Preparedness.
 Identify the person who will remain to perform
(shut down) critical plant operations before
evacuate
 Establish other teams like search & rescue,
medical duties, fire fighting team, food handling
and etc for those employees who are to perform
them.
 Identify the location for emergency control center.
83
ELEMENTS OF EMERGENCY PLANNING

4. Establish the preferred means for


communication during emergency situation.
 Alarm system – indicate fire, toxic gas
release and etc.
 Incident command system

84
SAMPLE OF ERT ORGANIZATION CHART

85
ELEMENTS OF EMERGENCY PLANNING

5. Prepare and keep Floor plans (Large scale


maps) showing evacuation and service
conduits (such as gas and water lines) at
designated area.
 Must include list an equipment and materials
required to properly respond to an incident,
an indication of their locations and a
description of the procedures for using the
equipment and materials

86
ELEMENTS OF EMERGENCY PLANNING

6. Establish Contact List :


 Detailed lists of personnel including
their home telephone numbers, their
duties and responsibility and contact no
of their next of kins.
 relevant government bodies, hospitals,
ambulance and etc

87
ELEMENTS OF EMERGENCY PLANNING

6. Perform drill at regular basis according to


type of industries – major hazard installation
or non major hazard installation.

88
ELEMENTS OF EMERGENCY PLANNING

6. Prepare post mortem report – for


improvement

89
90

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