CHAPTER 5

HAZARD IDENTIFICATION, RISK ASSESSMENT AND CONTROL

EMM5616 Environmental, Safety and Health Mgt. Assoc.Prof.Dr. Rosnah Mohd.Yusuff

Definitions
Hazard anything that have potential to cause harm (chemicals, electricity, vibration, noise) Risk chance or likelihood of harm actually being done Danger relative exposure to a hazard (little danger due to control measure) The concept modify the workplace to suit the people - Identifying the hazards - Assessing the risk - Controlling the risk - Review the steps (PDCA) new technology, standards, legislation, ISO
EMM5616 Environmental, Safety and Health Mgt. Assoc.Prof.Dr. Rosnah Mohd.Yusuff

Identification of Hazards
Critical appraisal of all activities Complete understanding of working situation Methods of identifying hazards: - Previewing legislation and codes practice - NIOSH/DOSH published information - Review relevant Malaysian and international standards - Review industry or trade association guidance

EMM5616 Environmental, Safety and Health Mgt. Assoc.Prof.Dr. Rosnah Mohd.Yusuff

- Review other published information - Develop a hazard checklist - Conduct walk through survey/audits - Review information from designers or manufacturers - Asses adequacy of training or knowledge required - Analyse unsafe act, injury data and accident - Analyse work processes - Job safety analysis - Consulting with employees, employees complaints - Observation - MSDS/CSDS or product label - Advice from specialist
EMM5616 Environmental, Safety and Health Mgt. Assoc.Prof.Dr. Rosnah Mohd.Yusuff

 Hazard inherent at the workplace (mechanical hazard, toxic properties, noise) Hazard Identification hazard sources, form in which hazard occurs, work place, persons exposed

EMM5616 Environmental, Safety and Health Mgt. Assoc.Prof.Dr. Rosnah Mohd.Yusuff

The Risk Assessment Process

How many people are exposed and for how long Assess the likelihood and consequence and produce a qualitative risk table Likelihood of a hazard event: - Very likely could happen frequently - Likely could happen occasionally - Unlikely could happen, but only rare - High unlikely could happen, but probably never will
EMM5616 Environmental, Safety and Health Mgt. Assoc.Prof.Dr. Rosnah Mohd.Yusuff

 Consequences of a hazard event:

Fatality Major injuries (irreversible) Minor injuries (reversible) First aid injuries Property damage Environmental damage

EMM5616 Environmental, Safety and Health Mgt. Assoc.Prof.Dr. Rosnah Mohd.Yusuff

Qualitative Risk Table

Consequence Very likely Fatality Major injuries Minor injuries First aid Property damage Environmental damage
EMM5616 Environmental, Safety and Health Mgt. Assoc.Prof.Dr. Rosnah Mohd.Yusuff

Likelihood Likely High Unlikely High High unlikely Medium

High

Low High

Most serious (high risk), least serious (low risk), medium risk Tackle anything with high risk

Individual exercise 1. Identify all hazards at your workplace 2. Construct a qualitative risk table for the most hazardous process 3. Describe the control measures taken at present
EMM5616 Environmental, Safety and Health Mgt. Assoc.Prof.Dr. Rosnah Mohd.Yusuff

Risk Control
Information from Codes of practice Industry or trade association (FMM) Specialists MSDS/CSDS Manufacturers and suppliers Most effective - Elimination removing the hazard or work practice
EMM5616 Environmental, Safety and Health Mgt. Assoc.Prof.Dr. Rosnah Mohd.Yusuff

Fairly effective - Substitution replacing hazard with a less hazardous one - Isolation isolating the hazard from the people or vice versa (barrier, screen, control room) - Engineering control modification to machine, providing guard to machinery

EMM5616 Environmental, Safety and Health Mgt. Assoc.Prof.Dr. Rosnah Mohd.Yusuff

Least effective - Administrative control time limit, SOP, safety rules - PPE last resort, suitability, limitation Use more than one control measures Maintained safety devices, PPE Develop and maintained reporting and recording system Permit-to-work system for high risk activities

EMM5616 Environmental, Safety and Health Mgt. Assoc.Prof.Dr. Rosnah Mohd.Yusuff

Sophisticated Risk Identification and assessment (systems engineering) Consideration of OSH during design and planning Consider all possibilities Probability of future events can only be guessed

EMM5616 Environmental, Safety and Health Mgt. Assoc.Prof.Dr. Rosnah Mohd.Yusuff

Hazard Identification
1. HAZOP Hazard and operability studies New design or process Developed in the chemical industries Structured, multi disciplinary brain storming session involving chemists, engineers, production, safety, designers etc 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

EMM5616 Environmental, Safety and Health Mgt. Assoc.Prof.Dr. Rosnah Mohd.Yusuff

Focus on fire, explosion, toxic release, offensive odour and environment Establish purpose, objectives and scope End product hazard identification

2. Failure Mode and Effect Analysis (FMEA) Evacuate kinds of failure that could happen and their effect in terms of maximum potential loss Part of HAZOP study

EMM5616 Environmental, Safety and Health Mgt. Assoc.Prof.Dr. Rosnah Mohd.Yusuff

 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
System Component Failure mode Failure effects

Scrubber

Water pump

Inadequately Water Flow

Environmental Pollution

EMM5616 Environmental, Safety and Health Mgt. Assoc.Prof.Dr. Rosnah Mohd.Yusuff

Quantitative Risk Assessment

Uses numerical values for likelihood and consequences Restricted to sensitive components of major hazard installation

1. 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
EMM5616 Environmental, Safety and Health Mgt. Assoc.Prof.Dr. Rosnah Mohd.Yusuff

 Work backwards to find the initiating event or combinations of events Probability of disaster can be calculated, use reliability analysis Based principle of multi casuality that traces all branches of event Obtain data on components from manufacturers

EMM5616 Environmental, Safety and Health Mgt. Assoc.Prof.Dr. Rosnah Mohd.Yusuff

No Flow

Pump Failure

Control Valve (c) failure to regulate Flow of water through pump

Failure Pump (A)

Failure Automatic Stand by Pump (B)

Fault Tree Analysis

EMM5616 Environmental, Safety and Health Mgt. Assoc.Prof.Dr. Rosnah Mohd.Yusuff

2. HAZAN Hazard analysis undertaken to ascertain the magnitude of potential problem and its potential harm Then examine the actual consequences, worst possible and express in quantifiable terms Analyze the safety of major hazard installation: - Which toxic, flammable, reactive or explosive substances constitute a major hazard. - Which failures could cause abnormal conditions leading to accident
EMM5616 Environmental, Safety and Health Mgt. Assoc.Prof.Dr. Rosnah Mohd.Yusuff

- Consequences of accident for workers, the public, environment - Prevention of accident - Accident mitigation Analysis should indicate: - Worst events considered - 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

EMM5616 Environmental, Safety and Health Mgt. Assoc.Prof.Dr. Rosnah Mohd.Yusuff

3. Human Error Analysis Add considerations of human performance to the hazard evaluation process Factored human factors into reliability analysis Errors in man-machine interaction Technique for Human Error Prediction (THERP): - Identification of human activities which create a hazard - Estimation of failure rates - Effect of human failures on the system

EMM5616 Environmental, Safety and Health Mgt. Assoc.Prof.Dr. Rosnah Mohd.Yusuff

 THERP is an input to FTA THERP can estimate failure rates of routine performance

EMM5616 Environmental, Safety and Health Mgt. Assoc.Prof.Dr. Rosnah Mohd.Yusuff

Job Safety Analysis (JSA)

Method of hazard identification and formulate safe work procedures Basic for job training Priority of jobs for JSA:
Accident frequency and severity Newly established or infrequently performed jobs

EMM5616 Environmental, Safety and Health Mgt. Assoc.Prof.Dr. Rosnah Mohd.Yusuff

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

EMM5616 Environmental, Safety and Health Mgt. Assoc.Prof.Dr. Rosnah Mohd.Yusuff

Example of narrative style format for changing car tyres:

1. Park vehicle a. Drive vehicle off the road to an area well clear of traffic, even if it requires driving with a flat tyre, Turn on the hazard warning lights to alert passing drivers, so that they will not hit you b. Choose a firm, level area so that you can jack up the vehicle without moving c. 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

EMM5616 Environmental, Safety and Health Mgt. Assoc.Prof.Dr. Rosnah Mohd.Yusuff

2. Remove spare and tool kit a. 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

EMM5616 Environmental, Safety and Health Mgt. Assoc.Prof.Dr. Rosnah Mohd.Yusuff

Safe Systems of Work

Formal procedure from systematic of tasks to ensure hazards are eliminated Examples where safe system will be required: - Cleaning and maintenance - Changes to normal procedures, methods or materials - Working alone or away from the work place - Breakdowns or emergencies - Control of the activities of contractors - Vehicle loading, unloading and movements
EMM5616 Environmental, Safety and Health Mgt. Assoc.Prof.Dr. Rosnah Mohd.Yusuff

Basic steps for producing safety system: - Assessment of the task - Hazard identification, risk assessment and control - Identification of safe methods - Implementing the system - Monitoring the system

EMM5616 Environmental, Safety and Health Mgt. Assoc.Prof.Dr. Rosnah Mohd.Yusuff

Task Assessment
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

EMM5616 Environmental, Safety and Health Mgt. Assoc.Prof.Dr. Rosnah Mohd.Yusuff

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, tagout, tests etc

EMM5616 Environmental, Safety and Health Mgt. Assoc.Prof.Dr. Rosnah Mohd.Yusuff

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

EMM5616 Environmental, Safety and Health Mgt. Assoc.Prof.Dr. Rosnah Mohd.Yusuff

Monitoring the System

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

EMM5616 Environmental, Safety and Health Mgt. Assoc.Prof.Dr. Rosnah Mohd.Yusuff

Permit-to-work
Formal, written authority to a tradesperson to carry out maintenance 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 Maintenance is not routine and under pressure from production Permanent record of precautions for maintenance
EMM5616 Environmental, Safety and Health Mgt. Assoc.Prof.Dr. Rosnah Mohd.Yusuff

 Give protection to a tradesperson Sign off by tradesperson when the job is completed and person who accept the plant back People given the authority to issue permit to work - Have intimate knowledge of the plant and hazard - Have demonstrated a responsible attitude to safety - Prepare to admit ignorance and consult if in doubt - Mature and senior enough to resolve conflicts - Can obtain the tradesperson confidence - From operating or production staff

EMM5616 Environmental, Safety and Health Mgt. Assoc.Prof.Dr. Rosnah Mohd.Yusuff

Level authorization Standard ordinary permits 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

EMM5616 Environmental, Safety and Health Mgt. Assoc.Prof.Dr. Rosnah Mohd.Yusuff

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

EMM5616 Environmental, Safety and Health Mgt. Assoc.Prof.Dr. Rosnah Mohd.Yusuff

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

EMM5616 Environmental, Safety and Health Mgt. Assoc.Prof.Dr. Rosnah Mohd.Yusuff

Inspections
Implement inspection procedure checklist prepared Involve from line supervisors identify hazards and implement remedial action Safety and Health Committee to conduct quarterly inspection Types of inspection:
Statutory compliance with legislation Safety and Health Office, executive Safety and Health Committee Scheduled, planned inspections

EMM5616 Environmental, Safety and Health Mgt. Assoc.Prof.Dr. Rosnah Mohd.Yusuff

 Require knowledge of plant and facilities, regulations and standards Result of inspection list of actions, who is responsible and time frame Record all preventive actions, who is responsible and time frame Record all preventive actions, follow up and assess effectiveness

EMM5616 Environmental, Safety and Health Mgt. Assoc.Prof.Dr. Rosnah Mohd.Yusuff

Checklist
Use checklist for inspection and audit Well designed checklist: - Ensure items are not overlooked - Enable a standardized approach - Underpin a system of accountability for performance assessment How the checklist is to be applied and the content Tailored to the specific needs of the organization and allow a systematic walkthrough
EMM5616 Environmental, Safety and Health Mgt. Assoc.Prof.Dr. Rosnah Mohd.Yusuff

Example of safety checklist

ABC Manufacturing Safety Checklist Department: Date: Name: HOUSEKEEPING CHECK EMERGENCY CHECK

Foyer Floor surface Escalator Stairways Safety sign Car parking

Exit Fire escape route Fire alarm Assembly point Written procedures Fire extinguisher

EMM5616 Environmental, Safety and Health Mgt. Assoc.Prof.Dr. Rosnah Mohd.Yusuff

AUDITS
Full examination and report status Proactive approach, risks are within control and policy is achieved Example of specific aspect fire protection, electrical safety Full blown comprehensive audit or mini audit
EMM5616 Environmental, Safety and Health Mgt. Assoc.Prof.Dr. Rosnah Mohd.Yusuff

Workplace Audit
Audit item vary with location Examples: - Fire fighting facilities - Slip and trip hazards, floor surface - Ladders and stairways - Safety apparatus - Manual handling - Lighting - Warning signs - Emergency arrangements - Accessibility for maintenance and emergency - Management of hazardous substances
EMM5616 Environmental, Safety and Health Mgt. Assoc.Prof.Dr. Rosnah Mohd.Yusuff

Procedures audit
Procedures audit Identification of what procedures exist Evaluation of procedures:
Are they in place Are people aware of them Are they being complied with? Are they adequate?

Use checklist and WHAT IF technique

EMM5616 Environmental, Safety and Health Mgt. Assoc.Prof.Dr. Rosnah Mohd.Yusuff

 Example of safety procedures audit: - operating procedures correct, up-to-date - safety equipment check performance, identification - permit system procedures, application - housekeeping and orderliness - contigency plan procedures, equipment, preparedness - training content, method, level - Incident investigation - Contractors training, procedures
EMM5616 Environmental, Safety and Health Mgt. Assoc.Prof.Dr. Rosnah Mohd.Yusuff

Safe Workplace Plan

Complied with all relevant regulations Factories and Machinery Act 1967, Occupational Safety and Health Act 1994, Environmental Quality Act 1974, Bomba etc Review all accidents and determine prevention strategies Documented procedure for recording and reporting accidents OSH consideration incorporates into design, purchase, material, product etc Regular workplace inspection Identify hazard, assess and control risk OSH related specific employee data skills, experience, training, exposure to hazard, health monitoring records
EMM5616 Environmental, Safety and Health Mgt. Assoc.Prof.Dr. Rosnah Mohd.Yusuff