Safety and hazard managment

1. HU-IOT
Chemical Engineering Department
Plant safety and hazard management
(CHEg.5212)
Chapter one
Introduction

2. 1. Introduction
1.1 What is safety?
Safety :-
 accident free operations ,
being protected from any failure, breakage and accidental harm.
Continuing of healthful living without injury.
Safety also refers to the precautions people take to prevent
accident, harm, danger, loss, pollution (air/water/environment).
safety also deals with the improvement in working condition for
better health.
Accident :- is a condition of something going wrong due to various
contradictions.

3. Introduction cont…
 Safety, hazard, and risk are frequently-used terms in chemical
process safety. Their definitions are
Safety or loss prevention: the prevention of accidents through the
use of appropriate technologies to identify the hazards of a
chemical plant and eliminate them before an accident occurs.
Hazard: a chemical or physical condition that has the potential to
cause damage to people, property, or the environment.
Risk: a measure of human injury, environmental damage, or
economic loss in terms of both the incident likelihood and the
magnitude of the loss or injury.

4. 1.2 How accident happened?
Accident occur because of:-
 lack of knowledge
discrepancies (difference, inconsistent)
deviations (from normal conditions or operations)
individual behavior
Unsafe operations
The above all cause accident
 Today safety is an integral part of any industry. Developing any
process industries from concept stage the following stages are
required,
-Designing
-Erection
-Testing
-Operations
-Maintenance
 Neglecting safety actions at any of the above stages can result into
disaster leading to loss of human life and desired plant production.

5. Trends in process industries:
In process industries unsafe conditions reduces:-
-production rate
failure of equipment parts, decline of the efficiency
the equipments
-Quality of the product
-Good working condition for employees
(safe place)
Therefore, it is essential to design and incorporate complete
safety system in all stages (Process plant design
development)

6. Integration of safety, health & environment
 Apart from safety there are two interrelated aspects i.e. Health (well-
being of employee) & environment are also attached equal importance
and considerations.
For instance, if the health of employee is not given due regard, may lead
to accident.
If the industry pollutes the environment around workplace it will
ultimately affect health of employee which may ultimately affect
production.
N.B. Checking the pollution in the industry should be
implemented because in the long run it is not only affect the
performance of the industry but also the life of everybody will
became miserable due to poor health which in turn will affect
safety.

7. 1.3 Overview of industrial safety management
 Safety management :- is an act and science of setting
safety objectives of the industrial company and related
activities of planning, organizing, directing, executing,
supervision, monitoring, improving various functions
to achieve the safety objectives.
Objectives of safety managements
The objectives are
 to prevent accidents, personal injuries and death,
 to minimize unsafe situations and unsafe acts by
personal by applying management techniques.

8. Functions/specific objectives of safety management
Functions of safety
managements
Humanitarian
Morale
Mandatory &
Legal
Organizational
Social
Commercial

9. Functions of safety management cont…
Humanitarian
 providing fast medical treatment and financial
assistance and compensations
 provide healthful environment and surrounding
 continuous following/watching and improvement
Morale
 the reduction of injuries and death by keeping up
the moral of the worker and organizations
Legal
 implementation of acts and rules formulated by
legal, government standards…etc

10. Functions of safety management cont…
Mandatory:- safety function activities
• Safety provisions (or requirements they are
obligatory and absolute)
• Notices /warnings / signs
Organizational
 to reduce DOWNTIME, expenditure on worker
compensations, legal expenditure and improve productivity
and profits.
 Sometimes safety is the question of Survival of the company,
some accidents (disasters) result in closure of the company.
Commercial
 to enhance company’s image and respect,
 Improve public relations there may improve commercial
competitiveness.
Social
 to help society by improving environment, minimizing
pollutants and leading a happy human life.

11. 1.4 Classification of accidents
Accidents can be classified in various ways such as
1.4.1 Classification based on the magnitude of the
danger of life, and property, these are:
1. Minor:- where there is no loss of life
2. Moderate :- where there is injury but no loss of life
and property
3. Major:- where there is loss of life
4. Disaster: - There is extensive loss of property and /or
life.

12. Classification of accidents cont…
1.4.2 Classification based on cause and effects
 Fire and explosions
 Electrical Accidents –shock
 Fire and explosion initiated by spark and short circuiting currents
 Chemical accident and explosion
 Emission of gases, flames, dust, chemical fluids
 Nuclear disaster, radiation of radioactive rays
 Accident with machinery, plant, tools
 Due to human error
 Due to failure of plant accessories
 Due to process hazard (eye injury due to laser, welding light)
 Falling of object on body
 During construction work
 During operation of plant (ex, overhead crane)

13. Classification of accidents cont…
 Falling of person from height (ex, ladder)
 Accident from civil works
 During construction
 During service life of plant
 Human made accidents
 Deliberate damage in parts
 Thefts of critical parts
 Natural disasters
 Flooding
 lightning
 Landslide
 Earthquake and volcano

14. Summary of industrial accidents
Industri
al
Acciden
t
Fire and
explosion
Electrical
Accidents
Accident
from civil
works
Human
made
accidents
Natural
Disasters
Falling of
Object
from height
falling of
object on
body
Accidents
with
machinery ,
plant, tools
Chemical
Accident &
Explosion

15. 1.5 Accident investigation Approaches (Strategies)
 There are three basic approaches/ strategies
1. Pre-Accident Strategy
2. Post-Accident Strategy
3. Collateral Accident Strategy

16. Accident investigation Approaches (Strategies)
cont…
1.5.1 Pre-Accident (Pre-Risk) Accident investigation
• Is the activities taken before the occurrence of an accident
(Prevention methods)
This can be divided in to Two parts
• Safe place strategy
• Safe Person strategy

17. Pre-Accident (Pre-Risk) Accident investigation
cont…
 Safe place Strategy
 Safe Workplace
 Safe Equipments
 Safe Process
 Safe Transportation
Generally Safe Environment
 Safe Person Strategy
This means protecting the workers by giving protective equipments
(PPE, like gloves, helmets,..) or protective facilities, if the working
environment is not safe.
Note: - Usually the safe place strategy is preferable than the safe
person strategy,
-if the place is safe, the safe person strategy is unnecessary

18. Accident investigation Approaches (Strategies)
cont…
1.5.2 Post Accident Strategy
(Also called post risk assessment)
 Is a strategy after the accident had occurred
 The post accident strategy is used as a feedback for the pre-accident
strategy by assuming the cause and effect of the accident occurred.
1.5.3 Collateral Strategy
 Is the action taken after an accident had occurred
 Its carried out by specialized organizations
 Example,
 fire extinguisher servicing agents (Hassen Business group,
Efsec, Petram)
 First aid ,…

19. 1.6 Accident agency
 Accident agency (Cause of industrial accidents)
Agency:- is an object or substance which is responsible for the
occurrence of an accident.
Industrial Engineers found out common agencies
example
 Machines (Pump, compressors, prime movers ….)
 Transportation system (material handling equipments, conveyors,
pipes, overhead cranes)
 In selecting such agencies special emphasis will be given to those
which are unsafe,
In case of machines, the prescription (history of machinery, and spec) is
helpful to avoid accident.
 Example, The normal sound of the equipment should be familiar to
worker.

20. Types of industrial accident (on workers)
 Fall of person (from height)
 Slipping
 Falling, flying, ….of objects
 Worker may be caught b/n two objects
 Electric shock
 Poisoning (exposed in toxic, acidic matter)

21. When and why accident happened?
1. Unsafe act (practice) :- this includes
 Operation without authority
 (when you operate with out authority, you need to inform other
workers)
 Operating at unsafe speed
 (driving too fast, ex, forklift)
 Using unsafe equipments
 Using not properly maintained equipment
 Working on unguarded or dangerous equipments
 Misbehaving at working place
 (laughing and joking with other workers)
 Failure to use personal protective materials
 Unsafe human (personnel) cause
 Concerned with mental/physical characteristics of
personal unsafe act, this includes
 Improper attitude (deliberate violation of safety acts)
 Lack of knowledge /skill
 Physical/ mental defects

22. When and why accident happened? Cont..
 Unsafe mechanical (Physical) causes
(Also called unsafe condition)
Improper guarding :
 Unguarding
 Removing the guards
Defective agencies
 Breakage
 Decayed equipments and places
 Slippery/ smoothness
 Hazardous arrangement
o Process line /layout
o material storages
Improper ventilation
Other mechanical/physical related causes includes
Abuse(misused) of materials - crack and damage
Equipments or materials defected during design

23. When and why accident happened? Cont..
 Unsafe procedure
 Caused by managerial acts
• Unsafe house keeping
 General cleanness of the house
 Waste disposal methods
Generally accident occurred due to
1.Human Error
Due to unsafe practice
Lack of foresight
 wrong attitude …etc
This accident cover about 88 % of the total
industrial accident

24. Cont…
2. Mechanical failure
 due to plant condition, equipment or tool failure
This cover about 10% of the total industrial accident
3. Act of Nature
 Due to whether, flood, lightning …
 This covers only 2% of the accident occurred in most
of the industry.

25. Main cause of accident
 Incorrect design, construction, installation,
testing and commissioning
 Incorrect use of machinery and industrial
facility
 Lack of inspection and maintenance
 Incorrect plant layout ,(improperly set)
 Incorrect functioning of equipments
 Poor maintenance practice
 Lack of skill, instruction and poor supervisions
 Poor working condition
 Incorrect working materials (ex, improper raw
material substitution)

26. 1.7Fundamental of accident prevention
 the prevention techniques are
1. Discover previous/ similar techniques
 From the record of the frequency and magnitude of the
previous accidental data.
 This can be used as a feedback for the latter accident
 Discovering the existing accident through auditing.

27. Fundamental of accident prevention cont…
2.Control of mechanical/ physical causes
 By looking(checking) equipment specification
 Provide guard for hazardous parts
 Perform proper maintenance
 Inspect for defected equipments and correct the
defected once.
 Formulate working procedure
 Provide good house keeping and good ventilation
 Provide personal protective equipments (PPE)
 Specify the more hazardous materials,
equipments, and process for particular operation

28. Fundamental of accident prevention
cont…
3.Control of behavioristic causes:-
 This starts from carrying out job analysis and
training
 Perform supervision
 Discipline at workplace
 Physical examination and proper place of worker
4. Supplementary works
 Provision of poster about safety
 Training and consult for safety and hazard
 Forming a safety committee

29. 1.8 Consequence of industrial accidents
 Production interruption
 Economic and social loss
 Damage and distraction of material
 Distraction of human life
 Damage the moral of the employee

30. Advantage of safety/ accident prevention
 Guaranty /enhance productivity
 Protect the equipment, building, the worker from
accidental damage
 Enhance employee moral
 Encourage more employees due to expansion
 Encourage additional investment for new
organization.

31. Safety and health management responsibilities
 Management bodies (CEO, and departmental Managers)
they are
 Decision makers
 Setting objectives
 Planning, organizing, monitoring and supervision …etc
 They put legal and organizational aspect of labor/worker
protection.
Plant manager: -he is responsible for (safety aspect)
 Actively participate in all safety magt activities and programs
 Enforce all safety norms (Rules and regulations)
 Making adequate supervision against hazard of all type
 Delegate power to various departments to carry out such
measures which will insure safety .

32. Safety and health management responsibilities cont…
Responsibility of engineers:-
 Ensure safe working conditions
 Provide properly maintained tool and equipment
 Design properly and planned work to be performed in a
safe manner
 Assign employees which they are capable of doing safely
 Take immediate steps for safety provision
Responsibility of individuals (Must all)
 Safety to themselves
 Safety to the fellow works
 Protect the company properly
 Protect the public

33. Safety organizations
 An Organization:- is the way in which authority
is distributed to carry out the work
 Organization is a strategy developed by mgt
 The organization structure is built by
considering:
 List of essential activities
 Grouping and assigning activities to the group
 Deciding line of authority delegations
 Co-ordination of activities

34. 1.9 Safety Auditing
 It is the process that identifies unsafe conditions and
unsafe acts in the plants and recommends safety
improvements.
 It is a very effective tool with safety management for
identifying weak spots and planning corrective actions.

35. Types of safety auditing
1. Walk-through safety audit.
2. Intermediate safety audit.
3. Comprehensive safety audit.
These audits are different , but they do not have rigid
boundaries. they have some overlap.

36. 1.9.1 Walk-through safety audit
 It is least expensive safety audit.
 It evaluates the unsafe conditions noticeable to naked eye
During the walk through, many unsafe conditions may be
noticed. These are listed, discusses and commitments for
their dissolving are taken from a line manager/supervisor.

37. Cont…
 During construction phase walk-through safety audits
may be carried out for stores, civil works, and erection
works, commissioning work.
 During operations and maintenance, safety auditors
observe the processes, unsafe acts and unsafe conditions.
 The safety auditors discuss their observation with safety
managers, line managers and line supervisors.

38. Cont…
 Audit report and recommendations are submitted to the
plant manager and safety manager for taking corrective
actions to eliminate unsafe conditions and prevent unsafe
acts.

39. The team for walk through safety audit
includes:
1. Safety manager.
2. Safety consultant.
3. Insurance inspector.
4. Electrical inspector.
5. Manager-Civil/Erection/Commissioning/Operation-
maintenance.
The entire plant and its stores , documents, procedures are
received ,interviews are conducted, observations are
noticed, report is submitted. The report gives
recommendations.

40. 1.9.2 Intermediate safety audit
 It involves more detailed study and review of plant design
and plant operation than a walk through audit.
 Detailed measurements of high-risk zones are conducted.
 Tests may be conducted on unsafe conditions/
equipment.
 It identifies weakness in plant design ,equipment and
subsystems and operation/maintenance procedures and
improvements are also suggested.

41. 1.9.3 Comprehensive Safety Audit
 It is a full scale audit that evaluates the safety factors in the
plant on the basis of:-
Engineering
Analysis
Testing
Measurement
Module analysis.
• Full scale improvements in the plant design, renovations,
operation procedures ,staffing etc. are recommended.

42. Comprehensive audit consist of the following.
 Envelope Audit. this covers civil works, switchyard,
electrical plant auxiliaries, stores, offices, canteen,
ventilation system, security arrangements, lighting etc.
 Function Audit. this covers organizational weakness,
training requirements, clarity of responsibilities and
delegation, documentation, etc.

43. Cont…
 Safety facility Audit. this audit reviews unsafe
conditions of high risk and exiting safety facilities
through safety recommended safety facilities for high
risk, medium risk and low risk zones.
 Recommendation. The unsafe conditions and unsafe
acts are listed. The corrective actions and improvements
are recommended. The unsafe conditions and unsafe acts
observed are subjected to ABC analysis(A=high
risk=moderate risk=low risk) attention is focused on A
and B categories.

44. Cont…
 Managements Response: the safety audit is a powerful
tool available to the management to take actions in the
right direction without hesitation/confusion.

45. TRAINING AND SUPERVISON
 Since safety is a line function ,manager, supervisors and
workers must be trained to identify unsafe acts and
unsafe conditions in their respective working areas.
They must also be given training in emergency
operations, fire protection, basic electrical engineering.
The principles of safety and first aid must be taught.
The dangers of negligence and ignorance must be
emphasized. The attitude of persons must be tuned to
achieved safety.
 The company must have training program for safety
from plant manager down ward up to technicians and
storekeepers.

46. ECONOMIC ASPECTS
 the safety management requires certain investment which are
classified as recurring expenditures and fixed expenditure.
Fixed expenditures: one time expenditures
Safety facilities
First aid facilities
Security facilities
Fire fighting facilities
Secured lighting
Room for safety security office and safety offices
Computer facilities and documentation facilities
HRD facilities, safety awareness boards

47. Cont…
Recurring expenditures: occur often and repeatedly
Salary for safety and security staff.
Royalties to consultants and inspectors
Safety audit expenses
Documentation expenses
Miscellaneous expenses

48. ECONOMIC BENEFITS
 Safety managements results in the following:
1. Reduced accidents
2. Reduced down time of plant and equipment
3. Reduced compensation to victims of accidents
4. Improved personnel relations between management and workers.
Reduced strike.
 More than above the lives of people are saved and the property is
saved against destruction.

49. ANNUAL REPORTS
 The safety mangers should give annual report to
managements.the annual reports may cover the
following:
1. Summary of safety activities during the previous year.
2. The list of accidents during the previous year and
causes and corrective actions.
3. Improvement in safety system during previous year and
their benefits.
4. Budget estimates for next year as aginst expenditure in
previous year.
Improtant aspects about high risk zones and essential
precautions to be taken.

50. INSURANCE COVERAGE OF INDUSTRIAL
PALNT PERSONNEL
 Risks of loss due to accidents, fire, thefts exist during construction
and routine operation maintenance phases of the industrial
plant/substation/electrical plant and equipment. The financial risk is
covered by taking appropriate insurance policy. If equipment gets
damaged or stolen, insurance company provides the financial
compensations against settled insurance claims. New equipment can
be purchased and installed to resume the operation of plant.
 For industrial projects and plants the following stages of project may
be covered in a single policy or a series of policies as under:

51. Cont…
1. Civil work policy to cover only civil works, buildings, bridges.
2. Transit insurance policy.
3. Storage cum erection policy. For entire construction period: such as
a policy may covers: civil works, stores, equipment during
-storage;-erection;-testing;-commissioning
4.Plant and equipment operation policy during regular operation and
maintenance .

52. STAGES IN PLANT LIFE AND UNSAFE-
CONDITION FACTOR
 Stage I :construction stage
 Stage II : installation and commissioning stage
 Stage III : operation and maintenance stage
 Stages IV : replacement and phasing out stage

53. Thank you for your Attention!!!
End of Chapter 1