Chapter 1 - Industrial Safety

CLD 20002 Occupational Safety & Health UniKL MICET
MICET
Chapter 1
Industrial Safety
Universiti Kuala Lumpur 1
Malaysian Institute of Chemical and Bioengineering Technology

CLD 20002 Occupational Safety & Health SCET
MICET
Topic Outcomes
It is expected that students will be able to:
Identify the types of hazards
Differentiate the methods to identify hazards
Conduct Process Hazard checklist equipment &
process
Apply the concept of HAZOP study
Construct Event tree & Fault Tree Analysis
Differentiate between Hazard Identification &
Risk Assessment
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Content
1.0 Industrial Safety
1.1 Introduction to safety at work.
1.2 Working definition.
1.3 Hazard identification method.
1.4 Hazard Operability Study (HAZOP)
1.5 Biohazard
1.6 Introduction to Risk Assessment
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1.0 Industrial Safety
Terminology at glance!
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What is hazard?
any sources, situations or acts of
potential
damage (i.e property,
workplace, environment),
harm, injury or
adverse health effects
..on something or someone under
certain conditions at work.
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What is a adverse health effects?
"any change in body

function or the
structures of cells that
can lead to disease or
health problems.
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What is a adverse health effects?

Adverse health effects include:
bodily injury,
disease,
change in the way the body functions, grows, or
develops,
effects on children, grandchildren, etc. (inheritable
genetic effects)
decrease in life span,
change in mental condition resulting from stress,
traumatic experiences, exposure to solvents, and so on,
and
effects on the ability to accommodate additional
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What is a risk?
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.
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What is a risk factors?

Factors that influence the degree of risk
include:
how much a person is exposed to
a hazardous thing or condition,
how the person is exposed (e.g.,
breathing in a vapour, skin contact),
how severe are the effects under
the conditions of exposure.
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Accident :
Unplanned event or sequence of

events that has undesirable
consequences that could lead to
health effects, economical losses
and public relation losses.
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What
Happened?
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1.1 Introduction to safety at

work
LIST INDUSTRIAL ACCIDENT
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Case 1
Flixborough (Nypro UK) Explosion 1st June 1974
Nypro Limited
Cyclohexane as raw material, Plant capacity
70,000 ton/year cyprolactam*, 6 reactors
Effect to human being

28 death
36 injured
Damage 1821 houses and 167 shop lots
55 public were injured.
*raw source for Nylon production

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Flixborough Explosion Accident Summary
On 27 March 1974, it was discovered that a

vertical crack in reactor No.5 was leaking
cyclohexane.
The plant was shutdown and investigation
identified a serious problem with the reactor No.5
The decision was taken to remove it and install a
bypass assembly to connect reactors No.4 and
No.6 so that the plant could continue production.
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Flixborough Explosion Accident Summary
Late afternoon, 1 June 1974, a 20 inch bypass

system ruptured, which may have been caused by a
fire on a nearby 8 inch pipe.
This resulted in the escape of a large quantity of
cyclohexane.
The cyclohexane formed a flammable mixture and
subsequently found a source of ignition.
At about 16:53 hours there was a massive vapour
cloud explosion which caused extensive damage and
started numerous fires on the site.
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Flixborough Explosion Failings in technical
measures
1. A plant modification occurred without a full
assessment of the potential consequences. Only
limited calculations were undertaken on the
integrity of the bypass line. No calculations were
undertaken for the dog-legged shaped line or for
the bellows. No drawing of the proposed
modification was produced.
Plant Modification / Change Procedures: HAZOP*
Design Codes - Pipework: use of flexible pipes
*Hazard Operability Study

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measures
2. No pressure testing was carried out on the
installed pipework modification.
Maintenance Procedures: recommissioning
3. Those concerned with the design,
construction and layout of the plant did not
consider the potential for a major disaster
happening instantaneously.
Plant Layout: positioning of occupied buildings
Control Room Design: structural design to withstand
major hazards events
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measures
4. The incident happened during start up when
critical decisions were made under operational
stress. In particular the shortage of nitrogen for
inerting would tend to inhibit the venting of off-
gas as a method of pressure control/reduction.
Operating Procedures: number of critical decisions to be made
Inerting: reliability/back-up/proof testing
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Case 2
Union Carbide India Ltd, Bhopal, India. 3rd
December 1984
Union Carbide Plant, Madhya Pradesh
Pesticide plant.
Methyl Isocyanate(MIC) immediate product
Leakage at MIC storage tank
10,000 death and 20,000 injured within 3 days
Additional 25,000 death by 1994
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Bhopal Leakage Accident Summary
At 23.00 hrs on 2 December 1984, an

operator noticed the pressure inside the
storage tank to be higher than normal but
not outside the working pressure of the tank.
At the same time a MIC leak was reported
near the vent gas scrubber (VGS).
At 00.15hrs a MIC release in the process
area was reported.
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The pressure inside the storage tank was

rising rapidly so the operator went outside to
the tank.
Rumbling sounds were heard from the tank
and a screeching noise from the safety valve.
Radiated heat could also be felt from the
tank.
Attempts were made to switch on the vent
gas scrubber but this was not in operational
mode.
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In the early hours of 3 December 1984 a relief valve on a
storage tank containing highly toxic MIC lifted.
A cloud of MIC gas was released which drifted onto nearby
housing.
Approximately 2,000 people died within a short period and
tens of thousands were injured, overwhelming the
emergency services.
This was further compounded by the fact that the
hospitals were unaware as to which gas was involved or what
its effects were.
The exact numbers of dead and injured are uncertain, as
people have continued to die of the effects over a period of
years.
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Bhopal Leakage Failings in technical measures
1. The flare system was a critical element within

the plants protection system. However, this fact
was not recognised as it was out of commission
for some three months prior to the accident.
Plant Modification / Change Procedures: HAZOP, identification of
safety critical elements
2. Hazards associated with runaway reactions in a
chemical reactor are generally understood.
However, such an occurrence within a storage
tank had received little research.
Reaction / Product Testing: laboratory testing

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3. The ingress of water caused an exothermic

reaction with the process fluid. The exact point
of ingress is uncertain though poor modification
/maintenance practices may have contributed.
Design Codes - Plant: ingress of unwanted material
Maintenance Procedures: training and competence levels
Plant Modification / Change Procedures: HAZOP

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4. The decommissioning of the refrigeration system

was one plant modification that contributed to
the accident. Without this system the
temperature within the tank was higher than the
design temperature of 0C.
Plant Modification / Change Procedures: HAZOP, decommissioning
procedures

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4. The emergency response from the company to

the incident and from the local authority
suggests that the emergency plan was
ineffective. During the emergency operators
hesitated when to use the siren system. No
information was available regarding the
hazardous nature of MIC and what medical
actions should be taken.
Emergency Response / Spill Control: site emergency plan,
emergency operating procedures/training
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Case 3
Skikda, Algeria Explosion
19th January 2004
explosion at LNG plant (6 trains)
Damage almost the whole plant facilities
27 death
72 injured
7 missing
Effect to surrounding area
Damaged of Power station
Refinery on fire and need to be close.
Before
CLD 20002 Occupational Safety & Health After SCET
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Case 4
Port Kembla, NSW, Australia
28th January 2004

Ethanol storage tank on fire (7
million litre)
1 injured
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Case 5
Cianjhen and Lingya districts of
Kaohsiung, Taiwan
31st July 2014, 8.46 pm
Gas pipeline exploded
31 death
309 injured
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Taiwan Kaohsiung Gas Pipeline Explosions

31st July 2014
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Case 6
Dust Explosion at Imperial Sugar in Port
Wentworth Georgia, United States.
07th February 2008

The explosion was fuelled by massive
accumulations of combustible sugar dust
throughout the packaging building
14 death
38 injured
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Case 7
Explosion at West Fertilizer Company in
West Texas
17th April 2013

An ammonium nitrate explosion
14 death
160 injured
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Case 8
Chemical Tanker Ablaze & Explodes Off in
Labuan, Malaysia
26th July 2012

A lighting stroked caused fire & explosion
1 death
4 missing
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1.1 Introduction to safety at

work
WORK ACCIDENT PHOTOS
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1.2 Working Identification
SAFETY & HEALTH

TERMS AND DEFINITION
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The prevention 1. Hazard
APPROPRIATE TECHNOLOGIES
LOSS PREVENTION
of accidents Identification
through the use
of 2. Technical
appropriate Evaluation
Safety technologies
3. Design of
new engineering
to identify the features to
hazards of a prevent loss
plant/
workplace
and
eliminate them
before an
accident occurs
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DEFINITION
Hazard :
source, situation or act with a potential for
harm in terms of human injury or ill health,
damage to property, damage to the
workplace environment, or combination of
these
May also
known as
A chemical or physical condition
that has the potential to cause
damage to people, property or
the environment
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The harm that results FIRST AID

from an uncontrolled
hazard
is called
CONSEQUENCES ACCIDENTS Fatality

/OUTCOME/ (MAJOR Major accident
INCIDENT/ /MINOR)
Minor Accident
CASES
NEARMISSES
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Example of Hazards and Their Effects

Example of Harm
Workplace Hazard Example of Hazard
Caused
Thing Knife Cut
Substance Benzene Leukemia
Material Asbestos Mesothelioma
Source of Energy Electricity Shock electrocution
Condition Wet floor Slips, falls
Process Welding Metal fume fever
Practice Hard rock mining Silicosis
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HAZARD TYPES
Three are few different types of
hazards : Environmental
Physical Hazard.
Chemical Hazard.
Biological Hazard.
Ergonomic
Mechanical
Electrical
Psychosocial
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Failure to Identify Hazards

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Working at Heights
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Worker could fall and sustain injury.

Hoisting Equipment
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Load could shift or fall.

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Frayed Connections
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Corrosion.
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PHYSICAL HAZARD
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Physical Hazards
Slippery floor
Protruding object
Falling object
Moving equipment
Poor housekeeping
Sharp object
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CHEMICAL HAZARD
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Chemical Hazards
Toxic
Chemicals that Chemicals that
show violent hazardous to
Hydrochloric acid reactions health and may
cause death
Hydrofluoric acid Include explosive,
Effects are either
Potassium water-reactivity chronic or acute
hydroxide chemical, air- Enter biological by
sensitive chemical digestion,
Sodium hydroxide
and unstable inhalation & skin
mixture absorption
Acid/Bases Eliminated from
Reactive organism;
excretion,
Flammable detoxification and
storage
Explosive
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BIOLOGICAL HAZARD
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Biological Hazard
Bacteria
Virus
Fungi
Poisonous animal
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MECHANICAL HAZARD
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Mechanical Hazards
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Pressing
Crushing
Pulling
Entanglement
Cutting
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ENVIRONMENTAL &
RADIOACTIVE HAZARDS
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Environmental & Radioactive Hazards
Radioactive:
UV A,UV B, Gamma Ray & etc.
Environmental:
Heat, cold, contaminated air
etc.
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PSYCHOSOCIAL HAZARD
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Psychosocial Hazards
Sexual Harrassment
Stress
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ERGONOMIC HAZARDS
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Ergonomic Hazards
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Ergonomic hazards refer to workplace

conditions that pose the risk of injury
to the musculoskeletal system of the
worker.
Examples of musculoskeletal injuries
include tennis elbow (an inflammation
of a tendon in the elbow) and carpal
tunnel syndrome (a condition affecting
the hand and wrist).
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Ergonomic Hazards
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Ergonomic hazards include

repetitive and forceful movements,
vibration,
temperature extremes, glare (light
illumination) and
awkward postures that arise from
improper work methods and improperly
designed workstations, tools, and
equipment.
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Ergonomic Hazards
Glare
Awkward
Posture
Manual
Handling
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Awkward posture (uncomfortable position)
Bad sitting posture Good sitting posture
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Terms and definition
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Terms and definition

First Aid
Any one-time treatment and any
follow-up visit for the purpose
of observation of minor
scratches, cuts, burns, splinters
Do not require medical care.
Consider non recordable case.

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Occupational Injury
Any injury (including

fatality) results from a work
accident/single exposure
involving a single accident in
the working environment
Recordable case.
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Occupational Injury
Examples are:
Thermal and chemical burns
Cuts, abrasions and punctures
Fractures or crushing injuries
Respiratory irritations
Instantaneous hearing loss
Amputations
Sprains or strains
Broken bones
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OCCUPATION ILLNESS
Any abnormal condition or disorder
(other than an injury) that resulted from
a work-related exposure to a biological,
chemical or physical agent.
These include both acute and chronic
illnesses or diseases that may be caused
by inhalation, absorption, ingestion or
direct contact.
Recordable case
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Occupational Illness
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CATEGORIES EXAMPLES
Lung diseases Silicosis, asbestosis, pneumoconiosis, or
other similar disorder
Physical Heatstroke, sunstroke, heat exhaustion,
disorders freezing, frostbite and other environmental
effects; radiation exposure; and effects
form non-ionizing radiation sources such as
welding flashes, UV rays, microwaves and
sunburn
Other Anthrax, infectious hepatitis, tumors, food
poisoning, and gradual hearing loss
Skin diseases Dermatitis, eczema or rash that is caused
by plants, oil, acne, chromic ulcers, chemical
contact, or inflammation.
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Occupational Illness
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CATEGORIES EXAMPLES
Poisoning Exposure to lead, mercury,
cadmium, arsenic or other heavy
metals; inhalation of carbon
monoxide, hydrogen sulfide or
other gases; exposure to benzene
compounds, carbon tetrachloride,
or other organic solvents; exposure
to toxic levels of insecticide
sprays; and exposure to other
chemicals such as formaldehyde,
plastics or other resins.
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FATALITY CASES
Injuries or illnesses that

results in death, regardless
of the time between the
injury and death or the
length of the illness.
Recordable case
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Nonfatal Cases Without Lost

Workdays
Cases of occupational injury / illness
which did not involve fatalities/lost
workdays but did results;
Transferto another job/termination
Medical treatment other than first aid
Diagnosis of occupational illness
Loss of consciousness
Restriction of work or motion
Recordable case
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Lost Workdays
Days which the employee
would have worked but could
not because of occupational
injury/illness
Not include the day of injury
or onset of illness
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Recordable Cases
Occupational injury / illness,
including deaths (fatality cases)
Not recordable are first aid
cases which involve one time
treatment & subsequent
observation of minor scratched,
cuts, burns
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Work Related Accident- Definition

WORK RELATED ACCIDENT Work
relationship is established with the injury
or illness results from an event or
exposure in the work environment.
The work environment is normally
considered the company premises, or
another location where the employee is
present as a condition of employment (i.e.
a construction site, or customer location).
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Work Related Accident- Definition
Driving to or from work is not

normally considered work-
related, unless the company
requires the employee to drive
or be transported to a specific
location for a specific business
purpose.
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MORE TERMS AND DEFINITION

IN Table 1-2
PAGE 6
CROWL AND LOUVAR
CHEMICAL PROCESS SAFETY
(FUNDAMENTALS WITH APPLICATION)
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Accident Statistics for

some industries
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Accident Statistics for some

industries
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Fatality Statistics
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Accident and Loss

Statistics
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Accident and Loss Statistics

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Measures of effectiveness of safety

programs
Statistical methods : characterize
accident and loss performance.
Systems:
OSHA Incidence Rate (OSHA IR)
Fatal Accident Rate (FAR)
Fatality Rate
report the number of accidents and/or fatalities
for a fixed number of workers during a specified
period. 98
OSHA Incidence Rate

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Based on cases per 100 worker years

A worker year = 2000 hours
(50 work weeks/year x 40 hours/week)
Provides information on all types of
work related injuries and illnesses,
including fatalities
The OSHA incidence rate is based on
200,000 hours of worker exposure to a
hazard [2000hr x 100 worker years]
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OSHA* = Number of injuries & illness x 200,000

total hours worked by all employees during
period covered
* OSHA INCIDENCE RATE [BASED INJURIES &

ILLNESS]
** sometimes used to calculate based on lost
workdays
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For example: MICET
A company has 17 full-time employees and 3 part-

time employees that each work 20 hours per week.
This equates to 28,400 labor hours each year. If the
company experienced 2 recordable injuries, then the
OSHA Incidence Rate is:
OSHA IR = (2 x 200,000) /28,400

= 14.08
What is now known is that for every 100
employees, 14.08 employees have been involved in
a recordable injury or illness.
OSHA Incidence Rate

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Problem 1:
How many injuries occurred in
a chemical industry if the
OSHA incidence rate is 0.49?
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NOTE
Please note that smaller companies that
experience recordable incidents will most likely
have high incident rates, or the incident rates
will fluctuate significantly from year to year.
This is because of the small number of
employees (and hence the lower number of
labor hours worked) at the company.
Calculations are more meaningful at larger
companies that have a higher labor hour count.
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Lost Time Case Rate

The Lost Time Case Rate (LTC) is a similar
calculation, only it uses the number of cases that
contained lost work days. The calculation is made
by multiplying the number of incidents that were
lost time cases by 200,000 and then dividing that
by the employee labor hours at the company.
LTC Rate = Number of Lost Time Cases x 200,000

total hours worked by all employees
during period covered
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Lost Time Case Rate (LTC)

Using the previous company example, assume that
one of the two recordable cases had lost work
days associated with the incident. The calculations
would look like this:
LTC Rate = (1 x 200,000) / 28,400
= 7.04
What is now known is that for every 100
employees, 7.04 employees have suffered lost
time because of a work related injury or illness.
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The same formula can also be used to

calculate the following:-
LOST WORK DAY RATE (LWDR)
LOST TIME INJURY RATE (LTIR)
DAYS AWAY / RESTRICTED JOB

TRANSFER RATE (DART)
Those rates are normally used in big
company.
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British chemical industry
Number of fatalities based on 1000
employees working their entire
lifetime.
[An employee works a total of 50 years]
FAR is based on 108 (100,000,000)

working hours.
[1000 employees x 50 years x 50
work weeks/year x 40 hours/week ]
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FAR = (Number of fatalities x 108)

Total hours worked by all
employees during period covered
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Problem 2:
Calculate FAR if the number of
death per person per year is 4.8 x
10-5 and the employee works 8-hours
shift 300 days per year?
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Problem 3:
A plant employs 1500 full
time workers in a process
with a FAR of 5. How many
industrial related deaths are
expected each year?
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Fatality Rate (FR)

Number of fatalities expected per person
per year
FR = (Number of fatalities per year)
Total number of people

(per year) in applicable
population
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1.3 Hazard Identification Methods
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Identify
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the hazards!
Unsafe Places and / or equipment

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Identify
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the hazards!
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Identify
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the hazards!
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Failure to Identify/Manage Hazards
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FAIL TO CONTROL HAZARDS

Consequences/
Severity
The degree of harm to
people, damage to
property, environment and
reputation.
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Study the consequences.

HAZARDS CONSEQUENCES
Falling objects Body inhuries (heat,
hand, finger etc)
Toxic chemical
Exposure to radioactive
Infected by HIV
Awkward posture
(uncomfortable position)
Fire & explosion 118

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HAZARDS IDENTIFICATION
(HAZID)
the process of recognizing that
hazard exists and defining its
characteristics.
It is essential to identify the hazards
and reduce the risk in advance of an
accident
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There are various approaches to hazard
identification:
1. Experience based reviews/Expert
judgments
2. Review of documentation from vendor
3. Review of legal and other requirements
4. Walkthrough/survey/inspection using
prepared checklist based reviews
5. Job Safety/Hazard Analysis (JS/HA)
No single tool fits all applications 121
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identification:
Experience based reviews / Expert

judgments.
Learning experience from consultants, OJT etc
Review of documentation from vendor
such as machine manual, maintenance list etc
Review of legal and other requirements
Legal document such as:
Occupational Safety and Health Act 1994 (Act 514)
Factories & Machinery Act. 1967 (Act 139)
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identification:
Walkthrough / survey / inspection

using prepared Checklist.
Such as design stage, materials etc
Job Safety /Hazard Analysis
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Observation ; done by experienced or
skilled workers.
a. Process hazards checklist OR
checklist based reviews
b. Hazards and Operability study
(HAZOP)
c. Job Safety /Hazard Analysis
d. Failure Modes and Effects Analysis

(FMEA)
e. What If reviews
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PROCESS HAZARDS CHECKLIST

Design of the checklist depends on the
intent
Used at the preliminary stage of
hazard identification
Effective to identify hazards arising
from:
process design,
plant layout,
storage of chemicals,
electrical system, etc.
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Checklist at design stage

Review characteristic of all
materials raw material,
catalyst,
intermediate products &
final products.
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Check for material type:

e.g. flammability
what is the auto-ignition temperature,
what is the flash point, how can a fire be
extinguish etc
e.g. toxicity
what are the Threshold limit value,
what PPE is needed etc.
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HAZARD IDENTIFICATION, RISK ASSESSMENT & RISK CONTROLS (HIRARC) Form No: ATTACHMENT 2

Signature
Process/Activity Prepared By MICET
Name
Date
Signature
Department/Section Reviewed By Name
Date
Signature
HIRARC NO & REV No Approved By Name
Date
Hazard Identification Risk Assessment
Cond.
Current Control Measures Likeli Futher Control Measures
No Job Steps/Sub-Activities No Of Hazards Consequences Table Severity Risk Level
hood
Asses.
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1.4 Hazards & Operability Studies

(HAZOP)
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Hazards & Operability Studies

To investigate how a plant might
Widely
known &
used
deviate from its design purpose
Consequences of these deviations on
the process are then assessed, and
control measure needed to detect
deviations are established
Brainstorming approach of a
multidisciplinary team consists of 5-
7 people
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Perform by a multi-discipline teams.
Operation personnel; production and
maintenance.
Procurement personnel; production control
(purchasing)
Safety, Health and Environment personnel.
Supplier ( sometimes)
Requires a thorough examination of
process-flow diagrams & piping and
instrumentation diagrams,
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Use of guidewords like no, more, less,
as well as, etc to screen all possible
causes.
Guidewords are applied to various
process parameter like flow,
temperature, pressure, liquid, level,
composition and any other variable
affecting the process
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ADVANTAGES OF HAZOP
1. PFD are examined line by line by

multidiscipline team.
2. Potential problem areas of the
design can be identified to allow
early design modification.
3. Promotes extensive dialogue
between designers and operators;
hence better understanding
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DISADVANTAGES OF HAZOP
1. Excessive time required in review; hence

target time date cannot be achieved.
2. Unmanageable of board documentation,
especially for a complex system
3. Increase in the total capital cost; due to
additional / modification design or
equipment requested by the HAZOP team
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EVENT TREE ANALYSIS

(ETA)
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EVENT TREE ANALYSIS (ETA)

Analysis whereby the consequences
and events are constructed from a
defined primary event.
Initial event and work towards a final
result.
Provides information on how a failure
can occur and the probability of
occurrences.
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EVENT TREE ANALYSIS

Steps in ETA
Identify an initiating event of interest
Identify the safety functions designed

to deal with the initiating event
Construct the Event Tree
Describe the resulting accident event

sequences
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EVENT TREE ANALYSIS

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EVENT TREE ANALYSIS

1 2
safety (Results)
functions
Initiating
event
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Example 2 of Event Tree Analysis
The case of the flat tire on an

automobile. The initiating event in this
case is the flat tire.
There are two safety functions that
can be defined: a spare tire and an
emergency road patrol. Other safety
functions might be included depending
on the particular situation.
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Example 1 of Event Tree Analysis

The event tree is drawn by first identifying the
initiating event, on the left-hand side of the drawing
sheet.
The two safety functions are identified on the top of
the sheet.
A line is drawn from the initiating event to a position
immediately below the first safety function, in this case the
spare tire.
At this point the line branches, the upper branch
representing the success of the safety function and the
lower branch representing the failure of this safety
function.
The lines are continued in this fashion so that
branching occurs below each safety function.
ETA Schematic Flat tire

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Results
Success
Failure
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FAULT TREE ANALYSIS

(FTA)
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FTA - How Does It Work?

Deductive method for identifying
ways in which hazards can lead
accidents
Approach starts with a well-
defined accident or top event
Logic symbols are used to provide
graphical representation
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FAULT TREE ANALYSIS

Steps in FTA
System definitions
Fault tree construction
Qualitative evaluation
Quantitative evaluation
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Consider
FAULT aTREE simple ANALYSIS
systems failure analysis.
Suppose we have a system with a light bulb
that screws into a socket, and
the light bulb illuminates when someone
turns a switch on.
Figure shows a schematic for this system.

One day, we flip the switch and the light bulb
does not come on.
What should we do?
What will be in our mind?
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FAULT TREE ANALYSIS

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FAULT TREE ANALYSIS

Define the problem
The problem here is that the light bulb
does not illuminate.
Define the top event
Top event is light bulb does not illuminate
Construct the FTA

Figure shows it in a command event. Top
undesired events are always shown in a command
event symbol, as they will be commanded to occur
by events in the tree below.
FAULT TREE ANALYSIS

MICET
Intermediate
OR gate Event Undeveloped
Event
Basic
Event
- Required no further
development
The top event, the flat tire,
is broken down into two MICET
immediate contributing
events, road debris and tire The contributing
failure. event, road debris,
is a basic event.
This event, which
The other event,
cannot be broken
tire failure, is
down into other
enclosed in a
events unless
rectangle to
additional
denote it as an
information is
intermediate
provided, is
event.
enclosed in a circle
to denote it as a
basic event.
*manufacturing *heavy usage
defect
*both basic events because additional information is needed for any further definition
MICET
HAZARDS ANALYSIS
What is
technique that focus on job tasks
as a way to identify hazards
before they occur .
What is the focus area .
focus on the relationship between
the worker, the task, the tools and
the environment
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HAZARDS ANALYSIS
Then .
after you identify uncontrolled hazards, you
will take steps to eliminate or reduce them
to an acceptable risk level
Why it is important .
prevent workplace injuries and illness by
looking at your workplace operations,
establishing proper job procedures and
ensuring that all employees are trained
properly
MICET
HAZARDS ANALYSIS
How .
what it is happening (environment)
who or what is happening to (exposure)
what precipitate the hazard (trigger)
to outcome that would occur should it

happen (consequences)
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HAZARDS ANALYSIS
Prioritization
highest injury or illness
Potential cause severe or disabling

injuries or illness
Simple human error could lead to a
severe accident
New to your operation
Complex process
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1.5 BIOLOGICAL HAZARD
162
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BIOLOGICAL HAZARDS
also known as biohazards
refer to biological substances that pose a
threat to the health of living organisms,
primarily that of humans & animals such as:
medical waste, fungi, moulds
microorganism, bacteria, parasites
virus, organic dusts
workers maybe at risk of
viral or bacterial infection.
allergies
respiratory diseases
163
MICET
COMMON OCCUPATIONAL DISEASES

Result from such exposure:
1. HIV/AIDS
2. Hepatitis B & C viruses and other

blood borne pathogens
3. Tuberculosis infections among health
care workers
4. Asthma (expose to organic dusts)
5. Chronic parasitic infections among

agricultural/forestry workers
164
MICET
BIOHAZARDS TRANSMITION
Biohazards can be transmitted

to a person through:
a. Inhalation
b. Injection
c. Ingestion
d. Contact with the skin
165
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BIOHAZARDS CLASSIFICATION
..to decide on what to do to safeguard the
workers from the hazards:
a. Any accident involving biohazards
materials can result in infection
b. When working with biological agents
or materials for which epidemiology*
and etiology** is not known or not
completely understood, it must be
assume that materials present a
biohazards
166
*distribution; ** causes
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Occupational Exposure to BIOHAZARDS

Workers who handling & manipulation of
biological agents:
a. Research Laboratory
technician/scientist
b. Health Care Facilities
laundry/house keeping/health care
staff
c. Agriculture
animals transmissible to human
167

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BIOHAZARDS Control Program
1. Employee Health
pre-placement examination for
new employee.
periodic physical examination as
part of surveillance program
Vaccination
168
MICET
2. Laboratory Safety & Health

employee training.
avoid if possible entering into a
biohazards area
avoid eating, drinking, smoking &
gum chewing in biohazards area
wearing PPE always
169
MICET
3. Biological Safety Cabinet

to protect workers from
exposure to aerosols especially
when there is contact with
biohazards in laundry activities.
170
MICET
4. Animal Care & Handling

periodic examination, disposal
of manure, cleanliness,
collection of medical history
and treatment.
171
MICET
172
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BIOHAZARDS ~ Preventive Methods

Wear appropriate PPE
Never discard syringes, needles or any
apparatus used in testing involve
microorganism
Employ good, sterile techniques when open
any tubes, bottles and culture plates-
minimize contamination
Storage vessels containing biohazard
agents must be labeled to provide
identification of their content
173
MICET
174
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175
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1.6 RISK ASSESSMENT
176
MICET
What is a risk?
Risk is the chance or
probability/likelihood 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.
177
MICET
RISK ASSESSMENT
the overall process of
estimating the
magnitude of risk and
deciding whether or
not the risk is
tolerable/acceptable
178
MICET
RISK ASSESSMENT..cont
Risk assessment is the process where you:
identify hazards,
analyze or evaluate the risk associated
with that hazard, and
determine appropriate ways to eliminate or
control the hazard.
The OSH Answers Risk Assessment has
details on how to conduct an assessment and
establish priorities.
179
MICET
What is Risk Assessment?
Risk consists of 2 dimensions

Probability Consequence
(Likelihood) (Severity)
180
MICET
What is Risk Assessment?

Determination of likelihood x consequence
by:
Describing scenarios involving the
hazard
Analysis of probability of each event
Analysis of consequence of each
event
181
Process of Risk Assessment

MICET
No Activities
1 Identification of the potential harmful hazards

2 Measurement to estimate the consequnces of the
hazards.
3 Estimation of the probability of the occurrence of
each hazards consequence.
4 Quantitative calculation of risks & comparison
with potentially acceptance hazard levels.
5 Characterization of the hazard risks to be
managed, along with the assumptions &
uncertainties.
6 Ranking of the risk hazards for management
decision making.
Basic Risk Assessment Tools &

MICET
Techniques
There are various risk assessment tools
and techniques:
Informal, intuitive techniques based upon:
experienced judgment, checklists, codes and
standards.
Qualitative - scenario-based assessment
using a Risk Matrix.
Quantitative techniques using fault trees,
event trees, failure modes and effects
analysis, consequence analysis.
183
MICET
Probability/Likelihood
We can determine the safety probability based
on the following:
Historical data / Trends
The number of employees exposed and their
competency level
The frequency and duration of exposure;
The proximity of employees to the danger
zone;
184
Probability/Likelihood Rating
MICET
Rating Likelihood (L) Description/Example
5 MOST LIKELY The most likely result of the hazard / event

being realized (once per week)
4 POSSIBLE Has a good chance of occurring and is not

unusual (once per month)
3 CONCEIVABLE Might be occur at sometime in future (once per

year)
2 REMOTE Has not been known to occur after many years

(once per 10 years)
1 INCONCEIVABLE Is practically impossible and has never occurred

(once per 100 years)
185
MICET
Severity / Consequences
The degree of harm

to people, damage to
property, environment
and reputation.
186
MICET
Severity / Consequences
Rating Severity (S) Description/Example
5 CATASTROPHIC Numerous fatalities, irrecoverable property

damage and productivity
4 FATAL Approximately one single fatality major

property damage if hazard is realized
3 SERIOUS Non-fatal injury, permanent disability
2 MINOR Disabling but not permanent injury
1 NEGLIGIBLE Minor abrasion, bruises, cuts, first aid type

injury
187
Risk Levels
MICET
Risk Matrix combines the probability and

consequence of a defined scenario to define a risk
level
Risk matrix is typically divided into FOUR levels of
risk, each with defined approval levels, based on
the risk level before any additional or alternative
risk reduction measures are considered e.g.:
Extreme risk immediate action required
High risk urgent management attention needed
Medium risk management attention as soon as
possible
Low risk longer term action may be required
through process of continuous improvement
188
MICET
What is a Risk Matrix

A risk matrix represents a simple,
straightforward, qualitative or semi-
quantitative template to
determine the magnitude of
potential risks, and
establish a decision-making basis
189
MICET
Risk Assessment
Consequence/
Likelihood (L)/ severity (S) of the
Relative
Risk = probability of X harmful effects of a
occurrences specified hazardous
event occurring
= L S
Relative
Risk X
190
Risk Matrix
MICET
Severity (S)
Likelihood (L) 1 2 3 4 5
5 5 10 15 20 25
4 4 8 12 16 20
3 3 6 9 12 15
2 2 4 6 8 10
1 1 2 3 4 5
High
Medium
191
3Low
Risk Matrix
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RISK DESCRIPTION ACTION
A High risk required immediate action to control

the hazard as detailed in the hierarchy of
15 - 25 HIGH control. Actions taken must be documented on
the risk assessment form including date for
completion.
A Medium risk requires a planned approach to
controlling the hazard and applies temporary
5 - 12 MEDIUM measure if required. Actions taken must be
documented on the risk assessment form
including date for completion
A risk identified as Low may be considered as
acceptable & further reduction may not be
1-4 LOW necessary. However, if the risk can be resolved
quickly & efficiently, control measures should be
implemented and recorded. 192
MICET
Then .
after you identify uncontrolled hazards,
you will take steps to eliminate or reduce
them to an acceptable risk level
Acceptable Risk :
a risk that has been reduced to a level that
can be tolerated by the organization having
regard to its companys policy and legal
obligation
193
Risk Assessment
MICET
All risks must be

reduced RISK
High
As UNACCEPTABLE
Low
Medium REDUCE
FURTHER IF
As POSSIBLE
Reasonably
Low
DESIRABLE
Practicable.
194
MICET
Why it is important .
To prevent workplace injuries and
illness by .
looking at your workplace operations
safely,
establishing proper job procedures
ensuring that all employees are

trained properly
195
MICET
RISK PRIORITIZATION (or Significant Risk)

based on..
highest injury or illness
Potential cause severe or disabling
injuries or illness
Simple human error could lead to a
severe accident
New to your operation
Complex process
196
MICET
What is a Significant Risk?
Answer:
A significant risk is a condition
of work that will likely
adversely affect safety and
health of workers
Significant = priority
197
MICET
Significance Criteria according to business

concerns to decide on significant risk.
Regulatory concerns Impact on international

issues (the Market).
Concerns of
interested parties. Concern of parent
company.
Potential liabilities
resulting from the
Concern of investors,
impact/risk
insurers and financial
Effect on public institutions
image of organisation
198
CLD 20002 Occupational Safety & Health
What do you think?
SCET
MICET
Risk To Coyote?
Risk To Road-Runner?
Cai-yo-tea
199
Risk = Likelihood x Severity

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Industrial Safety
MICET
Industrial Accidents
Type of Probability Potential Potential for
accident of for economic loss
occurrence fatalities
Fire High Low Intermediate
Explosion Intermediate Intermediate High
Toxic Low High Low

release 201
MICET
FIRE
Chemical reaction in which
substance combines with oxidant
and releases energy
Need 3 elements;
fuel,
oxidizers,
ignition source
202
MICET
3 elements for FIRE

Fuel
gasoline, acetone (liquid)
plastic, wood (solids)
propane (gases)
Oxidizers
hydrogen peroxide (liquid)
metal peroxides (solids)
oxygen, fluorine (gases)
Ignition source
spark, flames, static electricity, heat
203
MICET
EXPLOSION
Rapid expansion (mechanical /chemical
reaction) of gases resulting in a rapidly
moving pressure or shock wave
Types of explosions
mechanical explosion
confined explosion
unconfined explosion
boiling liquid expanding vapor explosion
(BLEVE)
dust explosion
204
Estimation of explosion strength

MICET
Blast damage from explosion
r
Ze
m1/ 3TNT
Ze = scaled distance (ft/lb1/3 or m/kg1/3)

r = distance from the explosion
m = mass of TNT [Tri Nitro Toluene]
205
MICET
206
MICET
207
MICET
Problem 1:
A vessel contains 50 lbs of TNT. The vessel

accidentally falls over and ruptured. The
cloud is ignited and an explosion occurs.
Determine the overpressure from this
explosion 100 feet away. What type of
damage is expected?
Given info:
m = 50 lbs (22.73 kg) r = 100 ft (30.48 m)
r
Using Ze formula, Ze
m1/ 3TNT
208
MICET
Problem 2:
a. One kilogram of TNT exploded. Compute the

overpressure at a distance of 30 m from the
explosion. Estimate the injury to people and the
damage to structures 100 m away
b. A reactor contains the equivalent of 10,000 lb of
TNT. If it explodes, estimate the injury to people
and the damage to structures 500 ft away
Given info:
1kg = 2.20 lbs 1ft = 0.3048 m
r
m1/ 3TNT
209
MICET
Problem 3:
Micet Safety Consultant Sdn Bhd rule is to design
occupied control rooms to withstand a 2 metric tons blast
of TNT at 125 ft.
a) Determine the overpressure does this correspond to?
State the types of damage.
b) Recommend the distance (in ft) of a residential area, if
the 2 metric ton of TNT blast the house should
receive no more than minor damage to house
structures?
Given info:
1kg = 2.20 lbs 1ft = 0.3048 m
r
m1/ 3TNT
210
MICET

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Chapter 1 - Industrial Safety

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CLD 20002 Occupational Safety & Health UniKL MICET

Universiti Kuala Lumpur 1

Malaysian Institute of Chemical and Bioengineering Technology

1.0 Industrial Safety

What is a adverse health effects?

"any change in body

What is a adverse health effects?

What is a risk factors?

Unplanned event or sequence of

1.1 Introduction to safety at

LIST INDUSTRIAL ACCIDENT

Effect to human being

*raw source for Nylon production

Flixborough Explosion Accident Summary

On 27 March 1974, it was discovered that a

Flixborough Explosion Accident Summary

Late afternoon, 1 June 1974, a 20 inch bypass

*Hazard Operability Study

Bhopal Leakage Accident Summary

At 23.00 hrs on 2 December 1984, an

Bhopal Leakage Accident Summary

The pressure inside the storage tank was

Bhopal Leakage Accident Summary

Bhopal Leakage Failings in technical measures

1. The flare system was a critical element within

*Hazard Operability Study

Bhopal Leakage Failings in technical measures

3. The ingress of water caused an exothermic

*Hazard Operability Study

Bhopal Leakage Failings in technical measures

4. The decommissioning of the refrigeration system

*Hazard Operability Study

Bhopal Leakage Failings in technical measures

4. The emergency response from the company to

Bhopal Leakage Failings in technical measures

28th January 2004

Taiwan Kaohsiung Gas Pipeline Explosions

07th February 2008

17th April 2013

26th July 2012

1.1 Introduction to safety at

WORK ACCIDENT PHOTOS

1.2 Working Identification

SAFETY & HEALTH

The harm that results FIRST AID

CONSEQUENCES ACCIDENTS Fatality

Example of Hazards and Their Effects

Failure to Identify Hazards

Worker could fall and sustain injury.

Load could shift or fall.

Environmental & Radioactive Hazards

Ergonomic hazards refer to workplace

Ergonomic hazards include

Awkward posture (uncomfortable position)

Bad sitting posture Good sitting posture

Terms and definition

Terms and definition

Consider non recordable case.

Any injury (including