AASTU: University For the Industry

Course Title: Industrial Safety And Loss prevention

Course Code: InCh 4514

Taju Sani (PhD)

July 2021 GC
 Objective

At the end of this course students will be able to:

 Describe the general safety requirements for the workplace

and Safety Compliance Agencies

Outline the principles of safety.

Identify common workplace hazards, assess risks and

suggest suitable control strategies.

Develop, maintain and evaluate an organization’s work

safety system.
 CH 1. Workplace Safety

 Introduction to Industrial Safety

 Hazardous Substances

 Principles of workplace safety and health protections.

Safety Management Program

Accident statistics and data sources

Introduction to Safety
 Introduction to Safety
Working in a laboratory can be an exciting experience. It can
also pose many threats and hazards that a traditional classroom
does not. That is why it is important to know your surroundings.
 Introduction to Safety
Safety is the key to reducing injury and illness. There are many
exposures in the laboratory that pose a hazard to your health
A hazardous substance is defined as a material/substance that poses a
physical or health hazard. This includes both chemicals and biological
agents
A Biohazard is defined as any organism that is capable of replication and
is capable of causing disease in human, animal or plant.

There are differences between a physical hazard and a health hazard.

 Introduction to Safety
Health hazard has the following characteristics:

Carcinogen
Toxicity
Irritants
Corrosives
Sensitizers
 Introduction to Safety
Physical hazard has the following characteristics:
Explosive
Flammable
Oxidizer
Pyrophoric
Compressed gas
Combustible liquid
Unstable (Reactive)
 Introduction to Safety
Effects of Hazardous Chemicals

 Immediate (acute)

 Delayed (minutes or hours)

 Long Term (chronic)

 Temporary effects

 Permanent effects
 Introduction to Safety
There are many exposures in the lab that pose a hazard to your health.
Viktor Yushchenko’s (Ukraine) Poisoning by Dioxins

Blood analysis revealed dioxin levels 6000 times normal levels

Introduction to Safety
Intensity of Effects
 Type of chemical
 Exposure (time X amount)
 Physical health
 Age
 Weather (wind, temperature, rain)
 Introduction to Safety

How to Identify Hazardous materials?

 Hazardous materials pose many problems.

 One of the obvious problems is determining what constitutes a

hazardous materials incident

Many agencies are involved with the handling, use, and the problems
associated with hazardous materials. Each of these agencies has identified
hazardous materials as it relates to their realm of service.
 Introduction to Safety
Environmental Health and Safety (EHS) office
 EHS Office plays a large role in overseeing the various
activities that take place on workplace.
 Interpret laws and regulations, and maintain up-to-date
records of current health and safety standards
 The duties range from fire safety and laboratory safety to
training and emergency response.

Occupational Safety and Health Administration (OSHA)

OSHA primarily monitors Hazardous Materials, Hazard
Communication, Bloodborne Pathogens, and Occupational
Exposure to Hazardous Chemicals in Laboratories at ISU.
OSHA is in charge of monitoring work conditions and
eliminating physical and health hazards at the work place.
 Introduction to Safety
Centers for Disease Control and Prevention (CDC)
In charge of laboratories that use or contain infectious agents.
They are focused on protecting personnel and the laboratory
environment from exposure to infectious agents. They are also
aiming at preventative measures by adhering to strict containment.

Environmental Protection Agency (EPA)

The EPA is in charge of the wastes that Industries
generates and stores. Many hazardous wastes are used in
Industries as well as research laboratories, and they pose
a threat to humans, animals, plants, and the environment.
There are also biohazardous wastes that are regulated and
must be properly decontaminated and disposed of.
Safety is the key to reducing injury and illness
 Lab Safety
 Read lab instructions ahead of time
 Always follow lab procedures exactly
 Never do an unauthorized experiment
 Eye Safety
Wear safety goggles when working with chemicals, flames,
or heating devices or if possibility of flying debris
 Proper Attire

o Foot wear that completely

covers the foot is required  Keep all long hair tied back
 Do not wear loose clothing
that could catch on fire
 Hand Safety
• If a chemical spills on your skin, notify Safety
officer and rinse with water for 15 minutes
• Wash hands after every lab

• Handle glassware, sharp tools

and heated containers carefully
 Safety Training
Main goal: Preventing Hazards and Increasing Awareness
Safety Training is required by regulation and law and has high
regard for Preventing hazards and increasing awareness.

It is important to have proper Safety Training as the employee, are

aware of the potential dangers that may threaten your health/life.

By creating awareness it enables us to act safely, that is

protected against physical, social, financial, or other types of
failure, damage, accidents, harm or any other event (incident)
which could be considered non-desirable
 Incident: unplanned/unwanted event that disrupts the work process
& has a potential to cause injury, or damage to persons or property.

Close call incidents do not often result in injuries.

However, ignoring a close call means you could be
paving the way for a serious injury to happen.

A 50Kg carton falls off the top shelf of a 4m high rack and lands near a worker.

A process Industry Chemist starts to turn on the wrong control, & creating a
hazardous mix of chemicals. He catches his error in time, & no harm is done

Being aware of near misses can also help prevent accidents.

 A carpenter's assistant picks up a power drill and gets a slight
electric shock. He quickly drops the tool, suffering no injury.
At this point, he has an important choice to make.

If he just forgets the incident, the next person to pick up the

tool may have damp hands bound to get a severe shock.

 You must report all close calls so they can be investigated and
the hazard removed before someone does get hurt.

If you have a near miss, consider yourself lucky on two counts: You
didn't get hurt, and you have the chance to prevent a future accident.
 Accident is an unplanned, unwanted, but controllable event
which disrupts the work process and causes injury to people.

Near-miss Minor injury Major injury Death

 Unsafe Acts VS unsafe Condition??

Unsafe Acts: conduct that unnecessarily increases the likelihood of injury

For example: All safety rule and procedure violations are unsafe acts
All unsafe acts should be corrected immediately

Unsafe condition: a situation, not directly caused by the action or

inaction of one or more employees, in an area that may lead to an
incident or injury if uncorrected
Unsafe conditions are normally beyond the direct control of employees
in the area where the condition is observed
 Process Safety Triangle
It is Used to illustrate the different actions that can lead to an accident.
One of the main purposes of the process safety triangle (Incident Pyramid)
is the illustration of how unsafe acts can lead to a major incident.

A “proactive” approach focuses on these categories

 Process Safety Triangle
It is also used to visualize the different layers of protection and help
redesign systems to ensure better preventative practices.

It has a bottom up flow where each layer can be thought of as a

preventative measure to the layer above it.

Leading metrics, which categorize the bottom level unsafe acts are
preventative actions taken to avoid an incident from occurring.

Lagging metrics, which categorize near misses and the levels above it
are events that happen in a process that are reported for the
improvement of the safety of the process.

The wider the base of your Incident Pyramid is the wider the top level is
 Process Safety Triangle
An example of a process safety triangle
Incident Pyramid:
with an estimation of each reported type of action on the triangle.

1 Serious/Disabling/Fatalities

10 Medical Aid Case

Property Loss/1st Aid

30 Treatment

600 Near Misses

Unsafe Behaviors/Conditions
10,000
 Are You Safe Or Just Lucky?

Be committed in preventing accidents through safe work practices ...not by luck.

Safety/ loss prevention: the prevention of accidents using

appropriate technologies
to identify the Hazards & Eliminate before an accident occurs.
 Hazardous Overview
Where are the Hazards?
All workplace hazards exist in five general areas.
1.Materials:- including raw materials (wood, metal, etc) to be manufactured
into finished goods & toxic chemicals used at various stages of the process.
2. Equipment:- includes machinery, vehicles, tools, and devices may not
be properly guarded, or in poor working order
3.Environment:- extreme noise, temperature, atmospheres, biological
workstation design, Floors may be slippery and aisles cluttered.
Guardrails, ladders, or floor hole covers may be missing or damaged.
4. People:- anyone in the workplace.
Employees might be fatigued, distracted in some way, or otherwise lack the
mental/physical capacity to accomplish work safely.
5. System:- flawed policies, programs, plans, processes, procedures,
and practices
 Types of Hazard
At workplace Hazards are categorized as Chemical,
Physical, Noise, Ergonomic, Biological & Psyscosocial
Chemical Hazards
 Chemicals can affect skin by contact.
 Chemicals can also enter our body either through the
inhalation or digestive system if air is contaminated with
chemicals, vapor, mist or dust.
 The accumulation of chemicals in or on our body will cause
acute (immediate) effect or chronic (long-term) effect.

Physical Hazards
 Physical hazard will cause injury risks on our body.
 This category includes the hazards from working in confined spaces,
being hit by flying objects, caught in explosions, hurt by collapsing
machinery, falling from heights and tripping on obstacles.
 Types of Hazard

Noise Hazards
 Excessive noise can disrupt concentration, interfere with
communication and result in loss of hearing.
 High impact noises are particularly damaging.
 Noise can mask out signals & affecting communication with others

Biological Hazards (Biohazards)

 Biohazards refer to biological substances that pose a harm to the
health of living organisms.
 Sources of biological hazards may include insects, bacteria,
fungi, plants, worms, animals and viruses.
 These sources can cause a variety of health effects ranging from
skin irritation and allergies to infections, cancer and so on.
 Types of Hazard

Ergonomic Hazards
 Ergonomic hazards refer to workplace conditions that pose the risk
of injury to the musculoskeletal system of the worker.
 These injuries can be caused by performing repetitive and forceful
movements and awkward postures that arise from improper work
methods and improperly designed workstations, tools, & equipment.

Psychosocial Hazards
Working outside the country without family members.
Psychosocial Hazards
 Examples of Occupational Hazards to Human Health

Type of Hazard Example Health Effect Example

Noise-induced hearing loss,

Physical Noise, local vibration
traumatic vasospastic disease
Various chemicals: Intoxications, cancers, allergies,
Chemical
Solvents, heavy metals nervous system damage

Biological Bacteria, fungi, viruses Infectious, allergies

Muskulosceletal injuries, mental

Repetitive work,
Ergonomic stress, lowered productivity &
work-rest schedule
work quality

Organizational stress Work-dissatisfaction, burnout,

Psychosocial
conflict depression
 Safety is intended to bring about condition free from Risk of
injury or threat to our health and well-being.

Risk: probability x consequences of an undesired event occurring

It is a measure of human injury, environmental damage, or economic loss in

terms of the incident likelihood and the magnitude of the loss or injury.
Risk also defined as a measure of the probability that harm
will occur under defined conditions of exposure to a chemical

R = f (H x E) = f (H x D x t)
Where R=Risk, f=function, H=Hazard, E= Exposure, D=Dose, t=time.

 Thus, chemicals which pose only a small hazard but to which

there is frequent or excessive exposure may pose as much risk
as chemicals which have a high degree of hazard but to which
only limited exposure occurs

Reducing risk is based on reducing exposure

Safety management Program
safe place of:work
safe plant and equipment
safe systems of work
 Early Safety management program: were based on “Three
E’s of Safety: Engineering, Education, and Enforcement

Engineering: Involve making design improvement to both Product

and Process

Education: Ensures that Employees know how to work Safety, why

is important to do so, & that safety is expected by management.

Enforcement: Involves making sure that Employees abide by safety

policies, rules, regulations, proctices, & procedures.

Nowadays, Safety management begins with Policy and uses tools such as Local
law & Risk Assessment to establish control of the hazards & risks of work
 Safety management places the following duties on
the employer, and staff members
to take reasonable care
to co-operate with the employer
not to interfere with safety arrangements

The Health and Safety Act 1974 states that:

 All employers must ensure the health, safety and welfare
of their employees – as far as is reasonable and practical.
 There must be a safe working environment
 There must be adequate facilities (toilets etc.)
 The equipment must be safe and maintained
 All items must be stored safely and transported safely
 Safety clothing must be provided where appropriate
 Clear information on health and safety issues and training
 Safety management Program

A successful safety program requires several ingredients:

System
Attitude
Fundamentals
Experience
Time
You
 Cont…

System: the program needs a system in order to:

1. 1. Record what needs to be done, have an outstanding safety program,

2. Do what needs to be done, and

3. Record that the required tasks are done.

Fundamentals: the participants must understand & use

the chemical process safety in the design,
construction, and operation of their plants.

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 Cont…
Attitude: Safety is a Matter of Attitude

Negative attitudes promote:

 Carelessness
 Recklessness
 Overconfidence

Positive safety attitudes promote:

 Openness to new ideas
 Alertness
 Planning ahead
 Cont…
The participants must have a positive attitude.

This includes the willingness to do some of the thankless work

that is required for success.

Experience: Everyone must learn from the history or be

doomed to repeat it.

It is especially recommended that employees:

1. read and understand case histories of past accidents

1. ask people in their own & other organizations for their

experience and advice.
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 Cont…
Time: Everyone should recognize that safety takes time.

This includes time to study, to do the work, time to record results,

time to share experiences, & time to train or be trained.

You: Everyone (You) should take the responsibility to

contribute to the safety program.

All Employees must:

 Cooperate with safety, security, and emergency personnel.
 Obey environmental health, safety, security rules.

 Complete the required training for your job

 Report injuries, accidents, and incidents & risks

 Report known or suspect hazards & risks

 Do not place yourself or others in unnecessary risk 44

 Safety is the responsibility of Everyone!
For examples in a given Industry:
The employer – overall responsibility for health and safety

The chief executive – responsibility for implementing and managing

the health and safety strategy and policy for the Industry

Line managers – day to day responsibility for themselves, their

employees and others, including members of the public

Employees – responsibility for themselves and others

A safety program must have the commitment from all levels within the
organization.

Safety must be given importance equal to production.

Effectiveness of safety program measures using
Accident statistics

Accident statistics and data sources

 Why Accidents are reported??

In general, the Accidents should be reported because:

I. The law requires some specific types of accidents to be
reported to the Enforcing Authorities.

II. It enables investigations so as to prevent further

accidents.

III. Reports enable the given industry to identify trends.

IV. The Industrial Safety Policy may requires all accidents and
near misses to be reported to the Safety Office or other
concerned body.
 Accident statistics and data sources
Don’t investigate only accidents.
Incidents should also be reported and investigated.

Investigate incidents since they are potential “accidents in progress”.

Criteria for investigating an incident:

What is reasonably the worst outcome, equipment damage, or injury to

the worker? What might the severity of the worst outcome have been?

If it would have resulted in significant property loss or a serious injury,

then the incident should be investigated with the same thoroughness as
an accident investigation.
 Accident statistics and data sources
Accident statistics: important measures of the
effectiveness of safety programs.
 Valuable for determining whether a process is safe or
whether a safety procedure is working effectively.

Many statistical methods are available to characterize accident and

loss performance.
The three common methods are:
I.OSHA incidence rate,
II.Fatal accident rate (FAR), and
III.Fatality rate, or deaths per person per year

Like most statistics they are only averages and do not reflect the
potential for single episodes involving substantial losses.

All three methods report the number of accidents and/or fatalities

for a fixed number of workers during a specified period. 49
 Cont…
I. OSHA incidence rate,
OSHA is responsible for ensuring that workers are provided with a
safe working environment.

OSHA incidence rate is based on cases per 100 worker years. A

worker year is assumed to contain 2000 hours (50 work
weeks/year x 40 hours/week).

The OSHA incidence rate is therefore based on 200,000 hours of

worker exposure to a hazard.

The OSHA incidence rate is calculated from the number of

occupational injuries and illnesses and the total number of
employee hours worked during the applicable period.

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 Cont…
OSHA incidence rate is calculated based on injuries and
illnesses, following equation:

An incidence rate can also be based on lost workdays

instead of injuries and illnesses. For this case

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 Safety Performance by Industry Sector
Injuries & illnesses per 200,000 hours worked (2002)

Services
Finance, insurance & real estate
Wholesale & retail trade
Transportation & public utilities
Petroleum and coal products
Chemicals and allied products
Printing & publishing
Pulp & paper
Textiles & apparel
Food & food products
Transportation equipment
Electronic and electrical equipment
Industrial machinery & equipment
Primary metal industries
Construction
Mining
Agriculture, forestry & fishing
0.0 2.0 4.0 6.0 8.0 10.0 12.0

Source: US Bureau of Labor Statistics (www.bls.gov/iif)

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 When in doubt – ASK!!!

• Do not carry out a new or

unfamiliar procedure until
you have been fully trained
and understand the
precautions necessary for
safe working

• DO NOT GUESS!!

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54
 CH 2. Principles of hazard control, risk
management and system safety.

Control

Assess

Recovery

Identify

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