Industrial Safety

2nd Year
Dept. of Metallurgy and Materials Engineering

Dr. Marwa A. Abbas

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 Course Outline

Introduction and Fundamental Concepts

Accident Theories and Accident Analysis

Risk Assessment and Safety Analysis

Fire and Explosion and Their Control

Hazards and Safety in:

Welding and Cutting Processes
Iron and Steel Making
Powder Metallurgy processes
Petroleum Industry

Waste Management
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 References
Roger L. Brauer, “Safety and Health for Engineers”.

International Labour Office “Safety and Health in the Iron and Steel
Industry”.

Lars Harms-Ringdahl, “Safety Analysis: Principles and Practice in

Occupational Safety”.

George Swartz, “Job Hazard analysis – A guide to Identifying Risks in

the Workplace”.

Tatyana A. Davletshina “Industrial Fire Safety Guidebook”.

John Ridley and John Channing, “Safety at Work”.

Srinivasan Chandrasekaran, “Health, Safety, and Environmental

Management in Offshore and Petroleum Engineering”
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 1st Lecture
Introduction & Fundamental Concepts

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 Outline

Importance of Safety

Terminology: Safety, Security, Hazard, Risk and

Accident

Occupational Safety & Health (OSH), and OSHA

Health, Safety and Environment (HSE)

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 Outline

Importance of Safety

Terminology: Safety, Security, Hazard, Risk and

Accident

Occupational Safety & Health (OSH), and OSHA

Health, Safety and Environment (HSE)

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Importance of Safety

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Unsafe Act or Conditions

Accident

Losses & Injury

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SAFETY…..is part of everyday living. It is an important
consideration for everyone in everything he/she does, at home, at
work or play, on streets and highways – wherever he/she goes.

Safe operating practices and procedures ….are vital in

all industries especially in metallurgy business because the work is
hazardous, involving massive machinery, heavy tools and great
physical strength.

Following the safety measures ….reduces, controls and

eliminates the hazards and accordingly, prevents injury, death,
physical and financial damage of plant and damage of environment.

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 Why is Safety Important?
The First Reason: Human, Moral Basis
Our society places high value on human life and welfare. This fact
provides the first and overriding reason for safety “humanitarianism”.

The Second Reason: Law

Each person has a different degree of regard for others and uses
different standards for right and wrong.
To minimize these differences, society formalizes standards of conduct
among people. This body of formalized standards is the “law”.

The Third Reason: Cost

Property damage, hospitalization, health and life insurance, productivity.

The Fourth Reason: Environment

Pollution, emissions, chlorofluorohydrocarbons,…

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 Outline

Importance of Safety

Terminology: Safety, Security, Hazard, Risk and

Accident

Occupational Safety & Health (OSH), and OSHA

Health, Safety and Environment (HSE)

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 What is Safety?

Safety…. is the state of being

relatively free from harm, danger,
injury or damage.
Safety…. is a healthy activity of
prevention from being exposed
to hazardous situation. By
remaining safe, the disastrous
consequences are avoided,
thereby saving the life of human
and plant in the industry.
Safety…. is No Accident.

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 Safety and Security

In both cases, we are talking about something that could cause

harm to another person, many persons, or property.

The difference between safety and security is the intent to do

harm.

If there is water on the floor, this would normally be considered

a safety issue because someone could slip and become
injured.

Safety…. is the protection from injury or loss by circumstance,

accident, or carelessness.

If someone intentionally puts something in place to cause

injury or damage, this would be a security issue.

Security…. is the protection from injury or loss caused by

intended action.
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 Hazard
A hazard is the potential for an activity, condition, circumstance,
or changing conditions, or circumstances to produce harmful
effects.
A hazard: is the potential to cause harm. Harm including ill health
and injury, damage to property, plant, products or the
environment, production losses or increased liabilities.
A hazard: is unsafe conditions.

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 Risk Definition
Risk… is a measure of both the probability and severity of a
hazard to harm human health, property or environment
Risk = Probability (Likelihood) x Severity (Consequences)

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 Accident and Incident
An Accident: is an unintended, unplanned single or multiple
event sequence that is caused by unsafe acts, unsafe conditions,
or both and result in immediate or delayed undesirable effects:
Personal injury, equipment failure/collapse, damage of the
environment.
An Incident (near miss): is an undesired circumstances and
‘near misses’ which could cause accidents (has the potential to
result in loss).

A near miss is an unplanned

event that did not result in
injury, illness, or damage – but
has the potential to do so.

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 Accident and Incident – Cont’d

Unsafe Acts & Conditions

Unsafe Acts Unsafe Conditions
Operating equipment at Defective tools or equipment
improper speeds Blocking of working area
Using equipment improperly Poor housekeeping
Using defective equipment Excessive noise
Failure to wear PPE Poor illumination
Improper working position Poor ventilation
Servicing equipment in
motion
Defeating safety devices

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 Accident and Incident – Cont’d
Accidents Sequences

Unsafe conditions observable or predicted

Hazards
from knowledge

Not directly observable - probability of harm

Risk to system elements being realised from
exposure to hazards and danger.

Harm Damage to system elements

long or short term
Accidents

Injuries
Damage
Death

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 Accident and Incident – Cont’d

Accidents Costs (Iceberg)

Direct Costs

Hidden Costs

Direct : Indirect Costs = 1:4 (some industry 36) 22

 Accident and Incident – Cont’d
Direct Costs
Medical expenses.
Compensation paid to an injured employee for time away from work.
Costs for repair or replacement of damaged items.

Indirect/Hidden Costs
Lost time of injured employee.
Time lost by other employees to assist injured coworker, to see what is going on, and
to discuss events.
Time lost by a supervisor to assist injured worker, investigate incident, prepare
reports, and make adjustments in work and staffing.
Time spent by company first aid, medical, and safety staff on case.
Damage to tools, equipment, materials, or property.
Losses due to late or unfilled orders, loss of bonuses, or payment of penalties.
Payments made to injured employee under benefit programs.
Losses resulting from less than full productivity of injured workers on return to work.
Loss of profit because of lost work time and idle machines.
Losses due to reductions in productivity of coworkers because of concern or reduced
morale.
Overhead costs that continue during lost work.

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 Outline

Importance of Safety

Terminology: Safety, Security, Hazard, Risk and

Accident

Occupational Safety & Health (OSH), and OSHA

Health, Safety and Environment (HSE)

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 Occupational Safety and Health (OSH) - OSHA
Occupational Safety and Health (OSH) is generally defined as the science
of the anticipation, recognition, evaluation and control of hazards
arising in or from the workplace that could impair the health and well-being of
workers, taking into account the possible impact on the surrounding
communities and the general environment.

OSH concerned with the safety, health and welfare of people engaged
in work or employment.

The goal of occupational safety and health programs is to provide a safe

and healthy work environment.

OSH deals with workplace hazards which have risks to the health and
safety of people at work.
The Occupational Safety and Health Administration (OSHA) is an
agency of the United States Department of Labor.
OSHA's mission is to assure safe and healthful working conditions for
working men and women by setting and enforcing standards and by
providing training, outreach, education and assistance 25
 Outline

Importance of Safety

Terminology: Safety, Security, Hazard, Risk and

Accident

Occupational Safety & Health (OSH), and OSHA

Health, Safety and Environment (HSE)

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 Health, Safety and Environment

Health, Safety and Environment (HSE) shall always be

the focus in. At all levels in the Company, from
managers to each employee, all activities shall be
performed in such a way that HSE is given the same
priority as other business activities.
HSE is a Management responsibility which follows
the Company’s line organization in Divisions and
Projects. It shall be run in such a way that:
 health and safety are promoted for all employees,
 a safe and beneficial working environment is provided, and
 the environment and property are protected.

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 Health, Safety and Environment – cont’d

THE OBJECTIVES OF HSE

Safety of human life and health

Safety of the environment
Safety of premises and materials
Safety of documents and data
Safety of the users of products and services

No Activities Shall Compromise The Safety of People & The Environment.

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 Health, Safety and Environment – cont’d

HEALTH
Companies seek to conduct their activities in such a way as to
avoid harm to the health of their employees and others; and to
promote, as appropriate, the health of their employees.

SAFETY
Companies work on the principle that all injuries should be
prevented and actively promote, amongst all those associated
with their activities, the high standards of safety and discipline.

ENVIRONMENT
Companies practice in their operations progressive reductions
of emissions, Effluents and discharges of waste materials that
are known to have a negative impact on the environment with
the ultimate aim of eliminating them. 29
 Health, Safety and Environment – cont’d

KEY ELEMENTS TO ACHIEVE A SIGNIFICANT

IMPROVEMENT IN SAFETY PERFORMANCE.

Visible management commitment to safety

Sound safety policy
Safety to be a line management responsibility
accountable for safety policy or performance
Competent safety advisors
High and well understood safety standards

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 Health, Safety and Environment – cont’d

KEY ELEMENTS TO ACHIEVE A SIGNIFICANT

IMPROVEMENT IN SAFETY PERFORMANCE.

Techniques to measure safety performance

Realistic safety targets and objectives
Audits of safety standards and practices
Effective safety training
Comprehensive investigation and follow-up of
injuries and incidents
Effective motivation and communication
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Course Work

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