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222EME 106-INDUSTRIAL
SAFETY IN ENGINEERING
MTECH-INTERDISCIPLINARY
ELECTIVE
Module: 2
INDRAJITH I B
RIE23CESE02
SE
RIET

HAZARD AND ACCIDENT
❖Hazard is something which has the potential to cause
harm to people, equipment and environment
❖ Accident is an unexpected and unwanted occurrence
which could result to injury to persons, damage to
equipment, materials or environment
❖Hence hazard can be something which has to be avoided
inorder to prevent accident
2

HAZARD CONTROL
❖It focus on :
• The steps necessary to protect workers from exposure to
a substance or system
• The training and the procedures required to monitor
worker exposure and their health to hazards
❖Hazard control should :
• Outline which methods are being used to control the
exposure
• How these controls will be monitored for effectiveness4

Where are controls used?
mes from")
travels")
❖Controls are usually placed:
• At the source (where the hazard "co
• Along the path (where the hazard "
• At the worker
❖The best strategy is to control the hazard at its source.
Control at the source and control along the path are
sometimes also known as engineering controls.
4

SELECTION OF CONTROL
METHODS
❖Selecting an appropriate control method is not always
easy. It often involves doing a risk assessment to evaluate
and prioritize the hazards and risks
❖Choosing a control method may involve:
• Evaluating and selecting temporary and permanent
controls
• Implementing temporary measures until permanent
(engineering) controls can be put in place
• Implementing permanent controls when reasonably
practical 5

MAIN WAYS TO CONTROL
HAZARD
Main ways to control a hazard include:
❖ Elimination
❖ Substitution
❖ Engineering Controls
❖ Administrative Controls
❖ Personal Protective Equipment
6

MAIN WAYS TO CONTROL
HAZARD(cont..)
Main ways to control a hazard include:
7
❖ Elimination: Remove the hazard from the workplace
❖ Substitution: Replace the hazard with a less hazardous one
❖ Engineering Controls: They reduce exposure by preventing
hazards from coming into contact with workers
❖ Administrative Controls: They change the way work is done
or give workers more information by providing workers with
relevant procedures, training, or warnings

MAIN WAYS TO CONTROLA
HAZARD(cont..)
❖ Personal Protective Equipment: These includes
clothing and devices to protect workers
• PPE needs constant effort and attention (including
proper use and training) from workers. Higher-level
controls aren‟t always feasible, and PPE might be
needed in conjunction with other control measures
8

HAZARD CONTROL PROCESS
❖Assess or identifying workplace hazard:It is
accomplished through the use of variety of methods
including observation, periodic surveys and inspections
❖Analyzing the workplace: Beyond initial
identification, analysis takes a much closer look to
determine the nature and impact of specific hazardous
conditions or unsafe work practices
❖Developing solutions: Once hazards are
identified,analyzed and understood, effective problem
solving techniques are used to determine the solutions to
those hazards 11

HAZARD CONTROL PROCESS
❖ Recommendations: Once solutions are found, it
becomes important to offer effective reccomedations
❖ Taking action:After recommendations have been
approved,carefully plan and implement with necessary
improvements
❖ Evaluation of results:To ensure changes are
effective,long term,continous evaluation through
monitoring and feedback are necessary to revise and
improve the changes made
12

IMPORTANCE OF MONITORING
AND REVIEWING HAZARD
CONTROL
❖It is important to monitor both the hazard and the control
method to make sure that the control is working
effectively and that exposure to the hazard is reduced or
eliminated
❖Some tools include physical inspection, testing, exposure
assessment, observations, injury and illness tracking,
incident investigations reports, employee feedback,
occupational health assessment,etc
13

TOOLS USED FOR
MONITORING AND
REVIEWING
❖ Some tools include :
• Physical inspection
• Testing
• Exposure assessment
• Observations
• Injury and illness tracking
• Incident investigations reports
• Employee feedback
• Occupational health assessment
14

ACCIDENT CAUSATION
AND CLASSIFICATION
OF ACCIDENTS

17
CAUSATION OF ACCIDENTS
UNSAFE ACTS
• The unsafe act is a violation of an accepted safe procedure which could
permit the occurrence of accidents.
• 80% of all accidents are then results of unsafe acts by people.
• Ex: Over speeding, Working without authority, chance taking etc.
ACCIDE
NTS
UNSAFE
ACTS
UNSAFE
CONDITIONS

18
CAUSATION OF ACCIDENTS
(contd…)
UNSAFE CONDITIONS
• The unsafe condition is a hazardous physical condition or circumstance
which could directly permit the occurrence of accidents.
• A study attribute 20% of all accidents on duty to unsafe working conditions.
• Physical or Mechanical defects.
• Ex: poor guarding, Defective conditions, poor Layout, Defective tool etc

19
PREVENTION OF ACCIDENTS
• Think about how to do the task safely
prior to engaging in the work.
• Warn co-worker of hazardous.
• Comply with all work rules and
To prevent Unsafe Act To prevent Unsafe conditions
procedures
• Don‟t rush your work or take
shortcuts.
• Use all equipment tools and materials
in appropriate and intended manner.
• Use proper lifting techniques
• Use personal protective equipment
• Supervisor should be vigilant
• Think about how to do the task safely
prior to engaging in the work.
• Inspect all the equipment, tools and
material before use.
• Ensure that enough space is available
to do the work.
• Report the unsafe condition
immediately once it is found out.
• Use all equipment tools and materials
in appropriate and intended manner.

19
THEORIES OF ACCIDENT
CAUSATION
Widely known theories of accident causations are:
1. Domino Theory
2. Human Factor Theory
3. Accident/Incident Theory
4. Epidemiological Theory
5. Swiss cheese Theory
6. System Theory
7. Combination Theory
8. Behaviour Theory

20
1. DOMINO THEORY OF ACCIDENT
CAUSATION
Herbert W. Heinrich, an early pioneer of accident prevention and
industrial safety.
• He studied 75,000 industrial accidents.
• 88% of IndustrialAccidents are caused by unsafe acts committed by
fellow workers.
• 10% of industrial accidents are caused by unsafe conditions.
• 2% of industrial accidents are unavoidable.

21
CAUSATION (contd…)
Heinrich' axioms of industrial safety
1. Injuries result from a completed series of factors, one of which is the
accident itself.
2. An accident can occur only as the result of an unsafe act by a person and/or
a physical or mechanical hazard.
3. Most accidents are the result of unsafe behaviour by people.
4. An unsafe act by a person or an unsafe condition does not always
immediately result in an accident/injury.
5. The reasons why people commit unsafe acts can serve as helpful guides in
selecting corrective actions.
1.DOMINO THEORY OF ACCIDENT

22
6. The severity of an accident is largely fortuitous, and the accident that
caused it is largely preventable.
7. The best accident prevention techniques are analogous with the best
quality and productivity techniques.
8. Management should assume responsibility for safety because it is in the
best position to get results.
9. The supervisor is the key person in the prevention of industrial
accidents.
10. In addition to the direct costs of an accident, there are also hidden or
indirect costs.

5. Injury: Typical injuries include lacerations and fractures
23
Five factors in the sequence of events leading up to an accident:
1. Ancestry and social environment: Negative character traits can be
inherited (ancestry) or acquired as a result of social environment.
2. Fault of person: Negative character traits are why people behave in an
unsafe manner
3. Unsafe act mechanical or physical hazard: Unsafe acts and mechanical
or physical hazards are the direct causes of accidents
4. Accident: Accidents that result in injury are caused by failing or being
hit by moving objects.

(1) Injuries are caused by the
action of preceding factors
Fig 1. Injury caused by preceding events
accidents and injuries
24
(2) Removal of the central
factor
hazardous
(unsafe act/
condition )
negates the action of the
preceding factors and, in
so doing, prevents
1. DOMINO THEORY OF ACCIDENT CAUSATION
Fig 2. Domino theory

26
2.HUMAN FACTORS THEORY
• The human factors theory of accident causation attributes accidents to
a chain of events ultimately caused by human error.
• It consists of the following three broad factors that lead to human
error:

26
3. ACCIDENT/INCIDENT THEORY
• The accident/incident theory is an extension of the human factors theory
sometimes referred to as the Petersen accident/incident theory.
• Petersen introduced such new elements as ergonomic traps, the decision
to err, and systems failures, while retaining much of the human factors
theory.
• In this model, overload, ergonomic traps, or a decision to err lead to
human error.

27
Following are just some of the different ways that systems can fail, according
to Petersen‟s theory:
• Management does not establish a comprehensive safety policy.
• Responsibility and authority with regard to safety are not clearly defined.
• Safety procedures such as measurement, inspection, correction, and
investigation ignored or given insufficient attention.
• Employees do not receive proper orientation.
• Employees are not given sufficient safety training
3. ACCIDENT/INCIDENT THEORY (contd)…

• Other significant impersonal risk factors are:
29
management and supervision, job satisfaction etc.
4. EPIDEMIOLOGICAL THEORY OF ACCIDENT
CAUSATION
• Epidemiology is the study of causal relationships between
environmental factors and disease.
• The epidemiological theory holds that the models used for studying and
determining these relationships can also be used to study causal
relationships between environmental factors and accidents or diseases.
• The key components are personal factors like: age, experience, training,
education, emotional stability, impulsiveness, risk taking behavior etc.
working condition,

29
5. SWISS CHEESE THEORY
• James Reason proposed the image of “Swiss cheese” to explain the occurrence
of accidents.
• According to this theory, in a complex system, hazards are prevented from
causing accidents by a series of safety barriers. Each barrier has unintended
weaknesses, or holes – hence the similarity with Swiss cheese.
• These weaknesses are inconstant – i.e, the holes open and close at random.
• When by chance all holes are aligned, the hazard results in accident and causes
injury

5. SWISS CHEESE THEORY
30
Fig. 3 Swiss cheese theory

31
6. SYSTEMS THEORY OF ACCIDENT
CAUSATION
• A system is a group of regularly interacting and interrelated components that
together form a unified whole.
• This definition is the basis for the systems theory of accident causation.
• This theory views a situation in which an accident may occur as a system
comprised of the following components: person (host), machine (agency), and
environment.
• The likelihood of an accident occurring is determined by how these components
interact.
• Changes in the patterns of interaction can increase or reduce the probability of
an accident.

32
CAUSATION (contd)…
• The primary components of the systems model are the person/ machine/
environment, information, decisions, risks, and the task to be performed.
• As a person interacts with a machine within an environment, three
activities take place between the system and the task to be performed.
• Based on the information that has been collected by observing and
mentally noting the current circumstances, the person weighs the risks and
decides whether to perform the task under existing circumstances.
• The environment in which the machine operator is working is unusually
hectic, and the pressure to complete an order that is already behind
schedule is intense.

1
2 3 4
5
(contd)…
• These factors are stressors that can cloud the judgment of those
collecting information, weighing risks, and making the decision.
• When stressors are introduced between points 1 and 5 in the below
figure, the likelihood of an accident increases.
Feed Back loop
33
6. SYSTEMS THEORY OF ACCIDENT CAUSATION
Fig. 4 System theory

34
CAUSATION (contd)…
For this reason, five factors should be considered before beginning the
process of collecting information, weighing risks, and making a decision:
• Job requirements
• The workers‟abilities and limitations
• The gain if the task is successfully accomplished
• The loss if the task is attempted but fails
• he loss if the task is not attempted
These factors can help a person achieve the proper perspective before
performing the above mentioned tasks.

35
7. COMBINATION THEORY OF ACCIDENT
CAUSATION
• For some accidents, a given model may be very accurate. For others, it
may be less so.
• Often the cause of an accident cannot be adequately explained by just
one model or theory.
• According to the combination theory, the actual cause may combine
parts of several different models.
• According to the combination theory of accident causation there is no
model or theory that can explain all accidents. Factors from two or more
models may be part of the cause.

36
8. BEHAVIOURAL THEORY OF ACCIDENT
CAUSATION
• The behaviour theory of accident causation and prevention is often
referred to as behaviour - based safety (BBS)
• BBS has both proponents and critics.
• One of the most prominent proponents of BBS is E. Scott Geller, a
senior partner of Safety Performance Solutions, Inc., and a professor of
psychology.
• It is appropriate that Geller is a professional psychologist because BBS
is the application of behavioural theories from the field of psychology to
the field of occupational safety.

37
(contd…)
According to Geller, there are seven basic principles of BBS:
1. Intervention that is focused on employee behaviour;
2. Identification of external factors that will help understand and improve employee
behaviour (from the perspective of safety in the workplace).
3. Direct behaviour with activators or events antecedent to the desired behaviour, and
motivation of the employee to behave as desired with incentives and rewards that will
follow the desired behaviour;
4. Focus on the positive consequences that will result from the desired behaviour as a way
to motivate employees;
5. Application of the scientific method to improve attempts at behaviour interventions;
6. Use of theory to integrate information rather than to limit possibilities; and
7. Planned interventions with the feelings and attitudes of the individual employee in mind.
8. BEHAVIOURAL THEORY OF ACCIDENT CAUSATION

38
1. Slips, Trips And Falls
• Slips and trips can result to falls, they are among the most frequent type
of reported injuries and have so far averaged approximately 25 percent
of reported claims yearly.
• It has been reported that on average, approximately 50 people die each
year from a slip, trip or fall and many more are injured.
• Slips can occur due to slippery floor, leaks, from materials and debris
left in walkways, uneven floor or working surfaces, protruding nails
and boards, bunched floor mats or uneven carpeting, holes or
depressions in working surfaces, and also step-risers on stairs that are
not uniform in height, etc
TYPES OF ACCIDENTS IN THE
WORKPLACE

39
2. Caught in or between hazard
• It is categorized by cave-ins, being pulled into or caught
in machinery and equipment or being compressed or crushed between
rolling, sliding or shifting objects.
3. Struck by moving Machinery
• Struck by a vehicle or heavy equipment while in motion or any object
that rolls, moves, slides. rotates, etc.
WORKPLACE (contd)…

40
4. Transportation and Vehicle-Related Accidents:
• This covers mainly struck by and crushed accidents.
5. Fire and Explosions:
• This is the type of accidents that involves gas and other fire/explosion generating
substances.
6. Overexertion and Repetitive Stress Injuries:
• A repetitive strain injury (RSI), sometimes referred to as repetitive stress injury, is a
gradual buildup of damage to muscles, tendons, and nerves from repetitive motions.
RSIs are common and may be caused by different types of activities.
7. Falling Object Accident:
• These are accident which involves falling object, i.e, equipment and materials
falling from height on to an employee.

8. Machine Entanglement:
• This occurs where materials such as long hairs, loose clothing, ties etc,
get caught in a rotating part and draw the person into the machine.
9. Assault or workplace violence:
• This is defined as any act in which a person is abused, threatened,
intimidated or assaulted in his or her employment.
10. Chemical spillage:
• This occurs when there is unplanned and unintended release of toxic
liquid into the environment.
11. Electrical accident:
• This is the type of accident involving unsafe use of electrical
equipment. It could result to electric shock, electric burns or
42
electrocution.
TYPES OF ACCIDENTS IN THE WORKPLACE
(contd)…

43
12. Confine space accident:
• These are accidents peculiar to confine space entry like slip, trips and
fall, suffocation, explosion, fire, etc.
12. Structural collapse:
• This type of accident occurs when a structure, permanent or temporary
collapses and fall on workers thereby injuring them. It could happen
during the demolition or dismantling process that is not well planned.

CONTENTS
45
1. Accident proneness
2. Cost of accidents

1. ACCIDENT PRONENESS
46
„Accident proneness is the continuing
tendency of a person to have accidents
as a result of his/her stable and
persisting characteristics‟
T.W. Harrell

ACCIDENT
PRONENESS
✓ Accident proneness, also known as
clamsiness, is the conception that
some people might have
predispostion or that they might be
more likely to suffer accidents, such
as industrial injuries, car crash, etc
than other people
✓ In other words, accidents prone
refers to anyone who seems to be
more susceptible to accidents and
injuries than others. This may be
clums
due to disability or merely
iness 47
A
B

ACCIDENT
PRONENESS
✓ Accident proneness is a condition in
which a “human being is mentally
inclined, strongly disposed,
attitudinally addicted or personally
destined to become continually
involved in an on going and never-
ending series of accidents or
injuries”
✓ Thus, some people may be more
in accidents than
words, they are
often involved
others. In other
„accident-prone”
A
B
47

ACCIDENT
PRONENESS
✓ If two individuals (suppose A and B)
are working on similar machines
under identical circumstances, one
may commit more accidents than the
other. The later employee will be
called an “Accident-prone
operator”
A
B
48

ACCIDENT PRONENESS
-3 KEYS
✓ A team of british researchers identified 3 key
personality traits of people who are not accidents
prone which are as follows;
➢ Openness : This is the tendency to learn
from experience and to be open to suggestions from
others, but too much openness can increase
accident risk
➢ Dependability : This is the tendency to be
conscientious and socially responsible
➢ Agreeableness : This is the tendency to be
aggressive or self controlled
A
B
49

2. COST OF ACCIDENTS
The cost of an accident in the
workplace has been defined as “effects
on the costs […] of a company that
would not have been borne if the
injury/accident had not taken place”
“ They cost more than you might
think”
50

COST OFACCIDENTS
Incidents after an accidents are like;
• Workers who witnessed the scene are
too shaken up to resume their duties
• Prodn. stopped untill the damaged eqpt.
is cleaned/replaced with new machinery
• Replacement of the injured worker
• Supervisor filled out a lengthy accident
report and several regulatory forms
• The business owner prepared for
possible litigation
What are the cost implications of these
interrelated events?? 51

COST OFACCIDENTS
Cost of accident mainly of two
type;
1. Direct cost
2. Indirect cost
Total cost = Direct cost +
Indirect cost
52

COST OFACCIDENTS
➢ Direct cost : The direct cost of accidents, as
represented by compensation payments, first aid,
medical and surgical expenses, plus legal fees and
overhead, may be approximately portrayed by
compensation insurance rates or premiums
➢ Indirect cost :Indirect costs are less considered, but
they are just as essential and, in general, more
expensive.
Indirect cost = Direct cost x 5
ie, compensation payments consists only one-fifth of
the total employer accident cost
53

COST OFACCIDENTS
Direct cost of Accidents involves;
• Medical cost : Doctor‟s fee, hospital charges etc
• Man days wages lost
• Loss of property : machinery, equipment, job, etc
• Compensations
• Wages for lost time of uninjured co-workers
• Workers adjacent to the accident scene who stop
their work to watch or offer assistance or talk
about the accident need to be considered when
assessing the financial impact of accidents
54

COST OFACCIDENTS
Direct cost of Accidents involves;
• Repairs of damaged equipments which includes
the time of order, deliver, and test the new
machine following the accident
• Recruiting and training temporary or permanent
workers and all the costs incurred by
administrative personnel
• Supervisor‟s diverted activity. Supervisor wages
for time attending to the accident
• Overtime, extra costs of employee overtime to
makeup lost production frequently occur after a
workplace accident
55

COST OFACCIDENTS
Indirect cost of Accidents
involves;
• Administrative cost
• Decreased output
• Breakdown/maint.
• Working hrs lost
• Retraining cost
• Loss of morale
56

Representation of accident costs
58
Visible
costs
Invisible
costs
➢ Loss or damage to equipments
➢ Loss of production
➢ Legal cost. Insurance
➢ Loss of lives & limbs
➢ Medical cost & compenstaion
➢ Cost of mandays lost of injured
❖ Production loss
❖ Loss of goodwill
❖ Lowered employees moral
❖ Loss of public confidence and revenue
❖ Loss of earning power of injured
❖ Failures and delay to fulfill orders
❖ Unfavourable public relations
❖ Product spoiled by accident
❖ Lost time by fellow workers
❖ Loss of skilled labourers
❖ Recovery and salvage of damaged
equipment
❖ Economic loss to injured‟s family
❖ Degradation of efficiency due to loss of
experienced and trained personnel
❖ Cost of employer for continuing the full
wages to the injured employee even his
service in not worth
❖ Cost of training to the new employee
❖ Rehabilation of the injured employee

HOW TO REDUCE THIS
COSTS?
There are several steps you can take to
reduce the chance of accidents and ill
health happening;
1. Find out what could harm
2. Identify who might be harmed-
including your visitors
3. Decide what you should do to prevent
anything happening to them
4. Take action in a planned way,
recording what you have done
5. Check these actions are still working
from time to time
58

HOW TO REDUCE THIS
COSTS?
• You can cut down on your cost by
preventing accidents in the workplace.
Saving on the costs of these events is an
investment in the future of the business
• The cost of accident only have real
meaning when related to your business.
You should compare them to your
overall operating costs or annual
turnover, or the added work or sales
neede to cover them. You can then judge
how significant they are
59

Accident Investigation and
Prevention in the Work
place

Why do Accident Occur in a Workplace
When there are inadequate Health, Safety,
Environmental and Fire precautions in the
workplace/ site (Lack of safe system of work).
61

Some of the Accident Scenes in our Workplace
62

Why Accidents are Investigated in Workplace?
• To prevent reoccurrence of the accident.
• To show managerial commitment to safety of the
workforce.
• To determine the cost associated with an accident based
on insurance company.
• To ensure that workers’ compensation claims are
established according to the level of the accident.
• To improve positive safety culture of the organization.
63

Who should form part of Accident Investigation
Committee?
• Safety Manager or his representative
• Safety committee members
• Immediate supervisor
• Department manager or his representative
• Safety officer
• Accident witness
64

Steps Involved in Accident Investigation
• Visit the scene, make exclusive the area of the accident
to avoid removing the evident, draw the sketches and
taking photo for evidence.
• Interview the witness for the witness statement from the
worker if any is available.
• Set up accident investigation team, then they will
evaluate and analysis the accident to Identify the events
(root & immediate causes of the accident) that leads to the
accident.
65

66
• Report the findings after the investigation in a plan
documented manner and communicate the preventive and
corrective measures to respective workers to prevent the
reoccurrence through Tool box Talk for workers and email,
presentation for staff.
• Develop a plan and Implement the corrective action plan put
in place.
• Evaluate the effectiveness of the actions taken for continuous
improvement in the system in the form of accident review
board.

67
The Causes of Accident in the Workplace
There are two categorized major causes of accident in a workplace:
Unsafe Acts
Workers smoking in undesignated area
Improper lifting
Influence of drugs or alcohol
Workers operating machines without experience
Unsafe Conditions
Machine without guard
Congested area
Wet floor
Inadequate warning system
Defective/damaged tools

In Every Accident, there is the Root Cause
• The root cause of an accident are those safe working
practices or managerial procedures that were not yet
implemented results to accident.
• Some of the examples are inadequate training for
workers in high risk activities, none implementation
of planned safe system of work in the workplace .
68

Accident Reporting
• Accident reporting is the formal way of documenting a
particular accident in the system. It needs to be
reported immediately after accident occurrence.
• All information concerning the victim is recorded
accordingly.
• Detailed description of what happened that lead to the
accident will be stated in the report
69

How do you Prevent Accident from Occurring?
• Accidents in the workplace can be prevented by ensuring
that all safe system of work is in place.
• Risk Assessment of work activities are conducted and its
control measures makes functional in the site.
• Early detection of mechanical faults can also safe guard the
breakdown of the equipment that will result to accident in the
workplace.
• Employee awareness, Training, Immediate correction of
identified hazards and investigation of reported accidents to
prevent future accidents.
70

72
HierarchyofControls
• Elimination
• Substitution
• Engineering controls
• Administrative controls
• Personal protective equipment (PPE)

73
Elimination
• Elimination removes the hazard at the
source.
• This could include changing the work
process to stop using a toxic chemical,
heavy object, or sharp tool.
• It is the preferred solution to protect workers
because no exposure can occur.

74
Substitution
• Substitution is using a safer alternative to
the source of the hazard.
• When considering a substitute, it’s
important to compare the potential new risks
of the substitute to the original risks.
• This review should consider how the
substitute will combine with other agents in
the workplace.
• Effective substitutes reduce the potential for
harmful effects and do not create new risks.

75
Engineeringcontrols
• Engineering Controls reduce or prevent
hazards from coming into contact with
workers.
• Engineering controls can include modifying
equipment or the workspace, using
protective barriers, ventilation, and more.

76
The most effective engineering
controls:
• Remove or block the hazard at the source before it comes
into contact with the worker.
• Prevent users from modifying or interfering with the
control.
• Need minimal user input for the controls to work.
• Operate correctly without interfering with the work
process or making the work process more difficult

77
AdministrativeControls
• Administrative controls establish work
practices that reduce the duration,
frequency, or intensity of exposure to
hazards.
This may include:
• Work process training
• Job rotation
• Ensuring adequate rest breaks
• Limiting access to hazardous areas or
machinery

78
Personalprotectiveequipment(PPE)
• PPE is equipment worn to minimize exposure
to hazards.
• Examples of PPE include gloves, safety
glasses, hearing protection, hard hats, and
respirators.
• When employees use PPE, employers
should implement a PPE program.
• While elements of the PPE program depend
on the work process and the identified PPE.

79
• The program should address:
• Workplace hazards assessment
• PPE selection and use
• Inspection and replacement of damaged or worn-out
PPE
• Employee training
• Program monitoring for continued effectiveness

81
Other Practices
• Safety Education And Training Education and
training provides employers, managers,
supervisors, and workers with knowledge
and skills needed to do their work safely and
avoid creating hazards that could place
themselves or others at risk.
• Awareness and understanding of workplace
hazards and how to identify, report, and
control them.

82
• Safety Education And Training
• Action item 1: Provide program awareness training
• Action item 2: Train employers, managers, and
supervisors on their roles in the program
• Action item 3: Train workers on their specific roles in
the safety and health program
• Action item 4: Train workers on hazard identification
and controls

83
Why Hazard Control measures?
• To minimize injury in workspace.
• Reduce adverse health effects .
• Control damage to plant or equipment.

84
Approaching steps to control
hazards in industries
• Identification of Hazards
•Training
•Maintenance Culture
•Chemical and Environment Hazards precautions
•Heat management
•Fire Safety
•Ergonomics
•Shrub Control
•Disaster Management Planning
•Planning, Project and Construction

RISK ANALYSIS AND
QUANTITATIVE RISK
ASSESMENT
85

86
RISK
• HAZARD
• Source of a risk.
• RISK
• Risk is the probability of exposure of individuals,
population, or ecosystems to hazardous conditions.
•

87
RISK (Contd…)
• A heap of toxic chemical may be a hazard to human health but
is not a risk till some one is exposed to it.
• Risk can be lowered by reducing the components of risk the
probability that hazardous conditions will exist, probability of
exposure of people to hazardous conditions, the severity of
consequences.

88
RISK ANALYSIS
• It is a systematic process to estimate the level of risk for
identified & approved risks.
• This involves estimating the probability of occurrence &
consequence of occurrence & converting the results to a
corresponding risk
• It helps investigators in taking right decisions that have the
potential to make greatest improvements in safety, health and
environment.

89
RISK ANALYSIS (Contd…)
• It provides a scientific framework to help decision makers to have
choice between solving or mitigating safety, health and environment
problems.
• Risk analysis may be used right from construction, operation,
generation, dis- posal to scarping obsolete plant and vacating a site.
• Risk analysis presents rigorous and quantitative results in a simple
format to help investigators make the appropriate, economic, ethical,
and political decisions.

90
• Risk analysis includes hazard identification, risk assessment,
risk management, and risk communication.
• Risk analysis are based on scientific and empirical information
that reflects a thorough understanding of the hazards of the
operation and the measures required to control the hazards.
• Risk analysis is carried out by trained personnel only. Help of
safety consultant can be taken.

91
• The reasons for the methods used and assumptions made are
well documented for future references.
• The risk analysis and assessment are updated as and when
changes are made in the system.
• Overall risk analysis is updated at a fixed periodicity
depending upon the size and complexity.

92
HAZARD IDENTIFICATION
of occurrence of
• Hazards should be identified for all;
• New activities
• Existing activities where the rate
undesired events is abnormally high
• Management of change
• Existing activities with new exposures

93
RISK ASSESMENT
• An important step in risk analysis is the risk assessment
• It provides an estimate of the severity and likelihood of
harm to populations/ecosystems from exposure to a
hazard. It includes
(i) Source identification (i.e., identification of
actual/potential hazards, their location and probable
frequencies of exposure)

94
RISK ASSESMENT (Contd…)
(ii)Exposure assessment (identification of actual/probable recipients on an
exposure including concentration and times of exposure)
• (iii) Estimating the quantity of a hazard that may reach organs/tissues and
the percentage of exposed population that will be harmed/injured by
exposure, and
• (iv) Risk characterizations (calculation of a numerical estimate of risk).

95
• Risk assessment enables to identify hazards at industrial site
and take engineering and managerial steps to mitigate the same.
• Risk assessments supply information to decision makers and
require practical data to provide a foundation for their validity
and to establish confidence in their output.

96
• Various statutory rules and regulations on Safety, Health and
Environment are:
• (i) Environment Protection Act 1986 and Rules made there under
including the Manufacture, Storage and Import of Hazardous
Chemicals Rules, 1989 (MSIHC) amended in 1994 and 2000
• (ii)Chemical Accidents (Emergency Planning, Preparedness and
Response) Rules, 1996.

97
• (iii) Public Liability Insurance Act 1991, amended 1992 and
the Public Liability Insurance Rules 1991, amended 1993.
• (iv) Factory Act 1948 and Factory Rules.
• (v) Petroleum Act 1934 and Petroleum Rules 1981 amended
2002.

98
• (vi) Gas Cylinder rules 2004 and Static and Mobile Pressure
Vessels (SMPV) (unfired) Rules 1981 amended in 1993.
• (vii) Explosives Act 1984 and Explosive Rules 1983.
• (viii) The Electricity Act 2003 and India Electricity Rules 1956

99
IDENTIFYING RISK
• Identifying technical risks to project costs.
• The risks associated with construction will typically vary by
technology, fuel, and site location, and so it is likely that each project
will have a peculiar set of risks which need to be identified.
• (a) Project management structure. A strong project management
structure is essential for delivering a plant on time and within budget.
Regardless of the contracting philosophy, it helps address complex
issues and minimize project problems' consequences.

100
IDENTIFYING RISK (Contd…)
(b) Scope and basis of turnkey contract. Turnkey contracts ideally
cover the entire project scope but may exclude infrastructure beyond
the site boundary. Additional contractual interfaces increase risks, and
reducing the scope raises project risk. Special attention is needed for
turnkey contractor work handover acceptance conditions.
(c) Ground conditions and geological risk Turnkey contractors
typically accept ground conditions and geological risks after
conducting surveys.

101
• In the absence of such a survey, or if the site chosen has
obvious geological draw- backs, the turnkey contract price is
unlikely to be firm.
• (d) Infrastructure risks outside site limits. These may
include
• Fuel handling, storage, at port or mine
• Railway, conveyor, or pipeline connection for fuel delivery
• fuel storage, blending, conveyor, or pumping systems.
• Construction transport difficulties

102
(e) Risks arising from design. If the turnkey contract is based on
a functional specification, the contractor is responsible for plant
design. However, if the project company establishes the design,
any issues arising from design defects are not the turnkey
contractor's responsibility.
(f) construction risks The turnkey contractor should bear the
principal risks related to plant construction.

103
(g) Climate and weather risk. Clearly, the monsoon creates
great difficulties or outdoor construction, which has to be
programmed within period outside the monsoon season .Equally
severe weather surprises can cause significant delays.

104
IDENTIFICATION AND ASSESSMENT OF MAJOR
RISKS IN AN INDUSTRIES
• It is necessary to present risks in an index format aids
decision-makers, statutory authorities, and industrialists in
effectively controlling and mitigating industrial activities..
• The important approaches to rank the hazards of chemical
process industries are;
(i) Fire and Explosion Index (Dow Index) and Toxicity Index,
(ii) calculation of damages likely from the fires, explosions
and toxic releases
(iii) combing the damages with probabilities of occurrence in
terms of Individual Risk and Societal Risk.

105
RISKS IN AN INDUSTRIES (Contd…)
• The Control of Industrial Major Hazard (CIMAH) Rules
• Notified by the states under the Factories Act and the Manufacture,
Storage and Import of Hazardous Chemicals Rules 1989 require the
upper level hazardous installations to prepare the safety report to
include
(a) Assessment of possible release of hazardous chemicals or of energy
(b) Possible dispersion of released chemicals
(c) Assessment of effects of releases.
•

106
IDENTIFICATION AND ASSESSMENT OF
MAJOR RISKS IN AN INDUSTRIES (Contd…)
• These evaluations are termed as consequence analysis. Combining
these computations with the probabilities of accidents will complete
the process of risk analysis.
• To visualize the accident scenario, it is first necessary to identify
various hazard. in the plant and study about the consequences.
• Technique for identifying the hazards is HAZOP- long time and
human resources to carry out this analysis for its use to scan the
complete plant.
• This method is commonly used for especially vulnerable parts of the
plants.
•

107
RISKS IN AN INDUSTRIES (Contd…)
• A comparatively simpler technique called Preliminary Hazard
Analysis (PHA) is usually followed for scanning of hazards in
the whole plant.
• PHA consist of
• (a) Collection of information
• (b) Conducting the analysis
• (c ) Recording the results

108
QUANTITATIVE
(QRA)
RISK ASSESSMENT
• Use of QRA has been provided by the need to identify
risk at a number of chemical and petroleum plants. The
requirements of QRA are:
• To identify hazards, analyze risk from the hazards and
evaluate ways either to eliminate hazards or to manage
risk.
• Appropriate review of risks to be conducted at least once
in three years for existing units, pipelines and marketing
installations for ongoing operations based on:
• 1. Multidisciplinary Internal Safety Audits.
• 2. OISD External Safety Audits.
• 3. Walk through Safety Audits

109
QUANTITATIVE RISK ASSESSMENT (QRA)
(Contd…)
• 4. HAZOP.
• 5. Previous Risk Assessment.
• 6. Previous Quantitative Risk Analysis
• Appropriate Risk Analyses and assessments are conducted for
new projects that include:
• 1. Philosophy Review.
• 2. Plant Review-Plant layout, Process Technology
• 3. Process design safety.

110
QUANTITATIVE RISK ASSESSMENT (QRA)
(Contd…)
• 4.HAZOP.
• 5. Construction safety.
• 6. Safety check lists.

111
QUANTITATIVE RISK ANALYSIS
PROCEDURE -QRA
• 1. System Description.
– First identifies and establishes the scope of safety and hazard
analysis.
– Compilation of the process/plant information
– Example : Site location, meteorological data, process flow
diagrams (PFDs), piping and instrumentation diagrams (P &
IDs), layout drawings, operating and maintenance procedures,
technology details, process chemistry,thermodynamic data and
demographic data is required to carry out the study.

112
QUANTITATIVE RISK ANALYSIS PROCEDURE –
QRA
(Contd…)
2. Hazard Identification.
• Critical step in QRA.
• Many aids are available including internal and external
safety audits, walk through safety audits, What-if
analysis, Hazard and Analysis (PHA), check
detailed process knowledge, engineering
lists,
codes,
Equipment Failure Analysis, Hazard Index Technique
and collective experience

113
QRA
(Contd…)
• 3. Modeling of Release Scenarios And Scenario Selection.
• A robust and tried out technology is called for to carry
out the modeling exercise for the listed likely accident
scenarios that have potential to create damage especially
to property and personnel outside the boundary limit.
Based on the extent of damage, a brainstorming session
is required to list out.

114
QUANTITATIVE RISK ANALYSIS PROCEDURE
–QRA
(Contd…)
• 4. Consequence Analysis.
– It is the methodology used to determine the potential for
Operability (HAZOP) studies, Failure Mode and Effect Analysis
(FMEA), Preliminary Hazard damage or injury from specific
incidents.
– A single incident (eg, rupture of a pressurized flammable liquid
tank) can have many distinct consequences eg. Vapour Cloud
Explosion, Boiling Liquid vapour Cloud Explosion, flash fire or
jet fire.

115
QRA
(Contd…)
– These outcomes are analyzed using source and explosion
and fire models.
– Effect models are then used to determine the sequence to
people or structures.
– Actions such as sheltering or evacuation can reduce the
magnitude of the consequence and these may be included
in the analysis.

116
QRA
(Contd…)
• 5. Likelihood Analysis.
– It is the methodology used to estimate the frequency or
probability of occurrence of an incident.
– Estimates may be obtained from historical incident data.
• 6. Risk Estimation.
– This combines the consequences and likelihood of all
incident outcomes from all selected scenarios to provide a
measure of risk.
– The risk of all selected incidents are individually estimated
and summed to give an overall measure of risk.

117
QUANTITATIVE RISK ANALYSIS PROCEDURE
–QRA
(Contd…)
• 7. Utilisation of Risk Estimates.
– It is the process by which the results from a risk
locations analysis are used to make decisions
depending upon the goals set for study.
– The goals could be
• (i) To compare the estimated individual and societal risks
criteria and comment on the tolerability of the risk

118
QRA
(Contd…)
• (ii) To identify major risk contributors and to recommend
remedial measures for risk reduction
• (iii) To carry out cost-benefit analysis for the
implementation of the remedial measures
• (iv) To address land use planning including suitability of
siting, layout and design

119
ROLES AND FUNCTIONS OF
SAFETY PROFESSIONAL-JOB
SAFETY ANALYSIS

Who is a Safety Officer?
• The safety officer is an internal
employee who is assigned to prevent
accidents, respond to emergencies and
evaluate the effectiveness of the
company‟s safety programs.
• A safety officer identifies safety hazards,
investigates them thoroughly, and
controls them before someone gets hurt.
121

122
• The safety officer is the „head‟ of the safety department and,
in most organizations, reports to the Chief Operations Officer.
• The safety officer also checks if the safety program is
working effectively and efficiently to meet all requirements
of the OSHA standards.(OCCUPATIONAL SAFETY AND
ADMINISTRATION)
HEALTH
Who is a Safety Officer?
(contd)

122
Roles of a Safety Officer in an
Organization?
• In general, safety officers have three main roles:
• Planning
• Organizing
• Supervising

123
Organization? (contd)
• Planning
Safety officers must create a safe environment by making sure
they have all the necessary equipment for their team.
• They also have to ensure that they have all the required things for
their team. (Making sure that the employees have all the necessary
tools to finish their work safely is also a part of the responsibility.)

124
Organization? (contd)
Organizing
Safety officers are also responsible for organizing their
workload so that no harm will come to them or anyone else
during their work activities.
They have to make sure that employees can complete the
tasks without causing any damage to the workplace or
anyone else.

126
Roles of a Safety Officer in an Organization?
(contd)
• Supervising
Safety officers are responsible for supervising everyone who
works under them to ensure that they are doing their work
safely.
• When supervising, they need to make sure that each person
knows their role in the process and where they fit in.
• Safety officers handle a broad range of tasks, including various
first-aid procedures and safety checks on equipment.
• They also help set up and operate emergency equipment
correctly.

126
What Are the Responsibilities of a
Safety Officer?
1. A leading safety officer must start to identifying Hazards in
the Workplace as like few are below.
a. Physical hazards.
b. Chemical Hazards.
c. Mechanical Hazards.
d. Ergonomically Hazards.
e. Environmental Hazards.
f. Radiation Hazards.
g. Physocholocial Hazards.
h. Electrical Hazards.

127
What Are the Responsibilities of a Safety
Officer? (contd)
2. Communicating Hazards prevailing in their
respective Workplace .
3. Initiating the counter Measures to control the
Hazards to an Acceptable Level by initiating the
following 3 Measures.
a .Engineering.
b .Administrative Control.
c .PPE .

128
4. Initiating various Kind of Trainings to the employees .
a. Induction Training.
b. Job Specific Training.
c. Specalists Training.
d. Refresher Training.
e. Manager & Supervisor Training.
5. Performing Safety Inspection at the Work place to
identify the unsafe Act and Unsafe Conditions.
Officer? (contd)

Officer? (contd)
6. Recognizing & Awarding the Positive Attitude employees
on Safety.
7. Conducting investigations on Near Misses, Incidents and
Accidents and identifying Root causes to prevent the
Recurrences.
8. Carrying out the Audit to make the Procedures ,Permits in
line with the Legal Standards.
9. Liasoning with the Government Agencies like Director of
Industrial Safety , Fire Departments and Pollution Control
Boards. 130

131
Officer? (contd)
10.Conducting Risk Assessments for various Activities before
launching of any Work.
11.Conducting Tool Box Talk for the employees in a Phased
Manner for all sections of the organization.
12.Conducting HAZOP Study for New Launching Projects
before implementing into the Plant Scale.
13.Preparing Onsite Emergency Plan to Prepare to combat any
kind of untoward eventuality within the organization
premises.

131
Officer? (contd)
14. Preparing Off site Emergency Plan to Prepare to combat any
kind of untoward eventuality beyond the organization
Premises.
15. Involving in the process of preparing Safety Policy and
communicating to all employees by various means of
communication.
16. Involving in the Process of Selecting the contractors and
coordinating with them before start up the work and during the
execution work.

132
JOB SAFETY ANALYSIS
• A job safety analysis (JSA) is a procedure which helps
integrate accepted safety and health principles and
practices into a particular task or job operation.
• In a JSA, each basic step of the job is to identify potential
hazards and to recommend the safest way to do the job.
Other terms used to describe this procedure are job hazard
analysis (JHA) and job hazard breakdown.

133
JOB SAFETY ANALYSIS (contd)
Some individuals prefer to expand the analysis into all aspects
of the job, not just safety. This approach is known as total job
analysis.
Methodology is based on the idea that safety is an integral part
of every job and not a separate entity. Here only health and
safety aspects will be considered.

134
What are the four basic
steps?
• Four basic stages in conducting a JSA are:
1. selecting the job to be analyzed
2. breaking the job down into a sequence of steps
3. identifying potential hazards
4. determining preventive measures to overcome these hazards

135
Benefits of doing a Job Safety
Analysis?
• The major advantages of this method include that it does
not rely on individual memory and that observing or
performing the process prompts the recognition of hazards.
• An advantage of this method is that more people are
involved in a wider base of experience and promoting a
more ready acceptance of the resulting work procedure.

136
Benefits of doing a Job Safety Analysis?
• The analysis process may identify previously undetected
hazards and increase the job knowledge of those
participating. Safety and awareness is raised,
health
workers
between
acceptance of safe
and supervisors is
work procedures is
communication
improved, and
promoted.

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