Hazard Identification &

Risk Assessment Workshop

Mr. Ahmed El Makaty

HSE Department

Rev.2
 COURSE MATERIALS

Please make sure that below described materials are provided to you
throughout the course:

1. Training presentation handout (total of 40 slides).

2. Notebook for writing notes.

3. Risk assessment form and risk assessment matrix sample; which will be
used for all group activities and audited by trainer by the end of the
course.

4. Evaluation form; which must be filled and returned to L&D Department

Training Coordinator after completion of the training course.

2
 COURSE INFORMATION MAP
Course Elements

Start Unit A Unit B Unit C End

Introduction to Risk Risk Assessment Further
Assessment Process Considerations

Administrative Course Summary

Information 10 steps to Risk
Definitions Finalizing the HIRA
(Before We Begin) Assessment
form

Feedback Form
Why do we need Steps 1 – 4 +
Course Introduction Risk Assessments? Group Activity Updating the HIRA
form

Course Main What should Risk Step 5 + Group

Objectives Assessments cover? Activity
Risk Assessment
Team

When does Risk Step 6 + Group

Assessments Activity
become ineffective? Additional Control
Requirements
Steps 6 – 9 +
What is our Group Activity
Responsibility?
Risk Ranking
Requirements

Audits
3
 BEFORE WE BEGIN

Mobile Phone Emergency No. Assembly Point

on Silent Mode 4477 8333 & Floor Marshall

Break Times Activities & Test Recognition

4
 INTRODUCTION

• Hazards and risks exist in all manufacturing industries. If left uncontrolled,

they can lead to minor or major accidents.

• The key to mitigating risks is in applying different principles of risk

management e.g. risk assessments, job safety analysis, hazard operability
studies, etc.

• Hazards identification and risk assessments are essential processes for any
organization to prevent accidents and to achieve highest standards of
safety.

Hazard Identification, Risk Assessment and Risk Management procedure covers all
risk management processes applicable in QS.

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 OBJECTIVE

The overall objective of this workshop is to ensure zero non-conformance

in risk assessment audits and inspections through providing employees
with a practical session focused on task specific Risk Assessments.

By the end of this workshop, employees should be able to:

1. Identify hazards associated with their workplace activities are

effectively.
2. Distinguish between different basic concepts of risk e.g. residual
risks, existing controls, etc.
3. Correctly complete a task specific risk assessment activity.

The purpose of this training is not to discuss the risk management procedure. Reading
and understanding the procedure is still mandatory and a pre-requisite.

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 UNIT A: INTRODUCTION TO RISK ASSESSMENT

7
 DEFINITIONS

Hazard: a hazard is any chemical or physical condition that has potential to

cause damage to people, assets and/or the environment.
Risk: the measure of human injury, environmental damage, or economic loss in
terms of both the incident likelihood & the magnitude of the loss or injury.
Consequence: the outcomes caused from being exposed to the hazards.

Risk Assessment: the process of analyzing and rating risks associated with
hazards and determining efficient controls to mitigate them.
Residual Risk: the risk remaining, associated with a job or an activity
after the precautions are taken.
Risk Ranking: numerical value given to the level of risk based on risk assessment.

The process of hazard identification must be carried out inside the plant.

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 DEFINITIONS

Spilled
oil on
the
ground

Hazard Risk Consequence

What has the potential to What could go wrong, what What is the worst case
cause harm? will happen as a result? credible outcome?

• Spilled oil • Slipping on oil, • Slight leg or back

receiving an injury injury

Other examples?
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 WHY DO WE NEED RISK ASSESSMENTS?

Risk assessments are required because:

1. They provide a systematic basis for the identification of hazards,

risks and controls associated with Qatar Steel facilities and activities;

2. They help us to ensure that all risks are maintained as low as

reasonably practicable (ALARP);

3. They provide us with a working document that Qatar Steel personnel

can use to help them understand the workplace risks and manage
them effectively.

The identification and implementation of effective controls are key to

ensuring that all workplace risks are appropriately managed.

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 WHAT SHOULD RISK ASSESSMENTS COVER?

Risk assessments should cover/address:

1. Routine, and non-routine, activities;

2. Hazards associated with plant, machinery and equipment;

3. Hazards associated with substances and materials in the workplace;

4. Hazards originating outside of the workplace that could adversely

affect the work environment;

5. Hazards associated with inclement weather or emergency

situations;

6. The complete lifecycle of facilities from specification through to

decommissioning.

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 WHEN DOES RISK ASSESSMENTS BECOME INEFFECTIVE?

Risk assessments can be influenced by:

1. Differing Risk Measurements

• Different perceptions received by different parties due to
experiences and knowledge of work.
• Not wanting to add remedial actions.

2. Risk Over/Under Controls

• Difficult controls can de-motivate employees from applying the
risk assessment requirements.
• Less controls might not be sufficient to controls the hazards.

3. Not Updated when Required

• After an accident takes place, activity changes, new tools and
equipment are introduced, etc.

Risk assessments are live documents and must be updated when required.

Other examples?

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 WHAT IS OUR RESPONSIBILITY?

Assessment Team
Engineer/Section
Department
Process Step

Manager

Head
Define scope of the assessment A R I
Legend Form the assessment team A R I

R: Responsible for Carrying out the Select area, process or job A R

Activity Identify the hazards A R
A: Accountable for the Outcome of the Identify the present controls A R
Activity
Assign probability and severity A R
C: Must be Consulted
Determine the current risk A R
I: Must be Informed
Identify remedial actions/controls A C R
Identify the responsible party A C R
Determine the residual risk A R
Review the HIRA for accuracy and
A R C
completeness
Add HIRA to database A I R
Verify controls are implemented A C R

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 UNIT B: RISK ASSESSMENT PROCESS

14
 HAZARD IDENTIFICATION & RISK ASSESSMENT STEPS

4. For each identified

3. Brainstorm all the
2. Describe the job
1. Select the job which is
which is to be carried
to be considered.
out.
hazards, elaborate the
worst-case scenario
potential hazards and
that may occur
risks associated with
without considering
the job.
any safeguards or
existing controls.

7. Identify any remedial 8. If an engineering or

6. Evaluate the
action / additional administrative
5. List down the existing probability, severity
controls required for control is introduced
controls to prevent in terms of people,
further risk reduction as remedial action,
and/or minimize asset, environment,
mentioning a the severity or
impact of the company reputation
responsible party, probability or both
consequence. and assess the level of
target date and action order of magnitude is
current risk.
status. reduced.

10. Select the next area

9. Assess the residual
of the plant or the
risk following
next job and repeat
implementation of the
the above mentioned
proposed actions or
process until the
controls.
HIRA is complete.

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 STEPS 1,2 – IDENTIFY THE JOB & DESCRIBE IT

Firstly, the specific task that will be performed must be identified.

Following points are to be considered:

1. Exact location of the activity including involved departments and

sections;

2. Nearby facilities, processes and environments that can affect the

activity being carried out;

3. How the activity will be carried out? Various tools, equipment,

machinery, chemicals, manpower, etc. required for completing all
stages of the task.

If any part of the activity is not determined, all hazards and controls
associated with the job will not reflect in the risk assessment.

Description of area/task is then mentioned in first column of the form.

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 STEPS 3,4 – IDENTIFY THE HAZARDS, RISKS & CONSEQUENCES

Hazards identification should involve:

1. Hazards associated with plant, machinery and equipment;

2. Hazards associated with substances and materials in the workplace;

3. Hazards originating outside of the workplace that could adversely

affect the work environment;

4. Hazards associated with inclement weather or emergency

situations.

Afterwards, the “risks” involved and the “consequences” of what could

happen is described on the form.

Elaborate the worst-case scenario for consequences that may occur

without considering any safeguards or existing controls.

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 EXERCISE

First Group Activity

You will be provided with a Hazard Identification

and Risk Assessment (HIRA) form and you are
required to identify a full list of hazards in a work
activity.
• Facilitator will form a group of 4/5 persons.
• Each group can decide what activity they will choose
for their exercise or advise facilitator for example.
• Maintain social distancing life-saving rule
requirements throughout all 4 group activities.

30
5 minmin

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 STEP 5 – IDENTIFY THE EXISTING CONTROLS

Existing controls determined should involve:

1. Safety rules and regulations practiced at Qatar Steel facilities;

2. Reference to documentation e.g. safety procedures, SDSs, SOPs, etc.

3. Manufacturer recommendations for certain equipment;

4. As advised by supervisors and safety team;

5. Consider the hierarchy of controls order.

The goal of the risk management process is to eliminate the hazard or

risk. Where is it not possible, hierarchy of controls must be followed.

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 STEP 5 – IDENTIFY THE EXISTING CONTROLS

Hierarchy of hazard control:

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 STEP 5 – IDENTIFY THE EXISTING CONTROLS

Hierarchy of hazard control:

1. Elimination: measures that eliminate risk, e.g. by using safer products

(water – rather than solvent-based paints).

2. Substitution: e.g. replacing a machine currently in use with one that

has a better guard or a product less hazardous.

3. Engineering controls: measures that reduce the likelihood of exposure

to the hazard, e.g. the installation of guards or local exhaust
ventilation.

4. Administrative controls: measures that minimize the risk through safe

systems of work, e.g. rotation of workers to reduce exposure or
increased safety signage.

5. Personal protective equipment: to be used where collective protective

measures (those that protect several workers) cannot be identified.

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 EXERCISE

Second Group Activity

In groups assigned, determine a range of existing

controls that can be applicable for the job chosen.

30
5 minmin

22
 STEP 6 – EVALUATE CURRENT RISK RATING

This stage of assessment is important as it can:

1. Tell us how risky the activity can be;

2. Help us in determining whether the current controls are sufficient or

not;

3. Identify potential severity on four aspects: People, Asset And

Environmental damages and effects on company Reputation.

Asset
People
Damage

Environment Reputation

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 STEP 6 – EVALUATE CURRENT RISK RATING

Potential probability:

Potential
Reputation Description
Severity
A No impact Never heard of in the Steel Industry.

Have occurred in other similar companies in the Steel Industry

B Slight impact
but not in Qatar Steel.

Has occurred in Qatar Steel. An activity or event occurs

C Limited impact
infrequently or irregularly.

Occurs several times a year in Qatar Steel. The event is

D National impact
repeatable and occurs often if events follow normal patterns.

Occurs several times a year in same location or operation

E International impact within Qatar Steel. Will be continuously experienced unless
action is taken to change events.

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 STEP 6 – EVALUATE CURRENT RISK RATING

Potential severity level on People:

Potential
People Description
Severity
0 No injury No injury or health effect.
First Aid cases or minor discomfort cases e.g. Headache, dust /
1 Slight injury or health effect fumes / gases having irritation in the nose when inhaled - a
person can return back to work after a rest.
Reversible injuries or illnesses requiring Medical Treatment
(MTC) or Restricted Workday Cases (RWC) for 5 days or but not
2 Minor injury or health effect LTI's. E.g. loss of consciousness from medical reasons only (e.g.
diabetes, epilepsy, narcolepsy etc.), needle stick injuries and cuts
from sharp objects.
Reversible injuries or illnesses resulting in RWCs for more than 5
days or LTIs e.g. punctured ear drums, fractured ribs or toes,
3 Major injury or health effect
chronic back injuries, loss of consciousness from work-related
activities e.g. blow to the head, heat induced.
Single Fatality or permanent total Single fatality, permanent disability or irreversible illness such as
4
disability corrosive burns, amputation.

Multiple fatalities or multiple irreversible illnesses. A near miss

5 Multiple fatalities
with potential for multiple fatalities.

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 STEP 6 – EVALUATE CURRENT RISK RATING

Potential severity level on Environment:

Potential
Environment Description
Severity
0 No effect No impact to the environment.
No lasting effect.
Low-level impacts on biological or physical environment, local
1 Slight effect
environmental risk within the fence and within the system.
Clean up within days.
Minor short-medium term damage to small area of limited
significance.
2 Minor effect Single exceeding of statutory or prescribed limits; single
complaint; no permanent effect on the environment.
Clean up within weeks.
Moderate short-medium term widespread impacts, repeated
3 Local effect exceeding of statutory or prescribed limits and beyond fence or
neighborhood. Clean up within months.
Severe environmental damage; Qatar Steel is required to take
extensive measures to restore the contaminated environment to
4 Major effect
its original state; extended exceeding of statutory or prescribed
limits. Clean up within months – years.

A major economic loss for Qatar Steel; constant high exceeding of

5 Massive effect
statutory or prescribed limits. Long term clean up required.

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 STEP 6 – EVALUATE CURRENT RISK RATING
Potential severity level on Assets and Production :
Potential
Assets and Production
Severity
0 No damage
Slight damage,
1 (< QAR 50,000)
Minor damage
2 (QAR 50,000 to 500,000)
Local damage
3 (QAR 0.5M to 5,000,000)
Major damage
4 (QAR 5M to 25,000,000)
Extensive damage
5 (>QAR 25,000,000)
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Description
No financial impact.
No disruption to operation, estimated cost less than QAR
50,000.
Brief disruption to operation, estimated cost of QAR 50,000 to
500,000
Partial shutdown of operation, estimated cost of QAR 500,000
to 5,000,000.
Partial loss of operation; estimated cost between QAR 5M to
25,000,000.
Substantial or total loss of operation with estimated cost in
excess of QAR 25,000,000.
 STEP 6 – EVALUATE CURRENT RISK RATING
Potential severity level on Reputation:
Potential
Reputation
Severity
0 No impact
1 Slight impact
2 Limited impact
3 National impact
4 Regional impact
5 International impact
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Description
No reputational impact.
Public awareness may exist but there is no public concern.
Some local public concern; some local media or local political
attention with potentially adverse aspects for Qatar Steel
operations.
National public concern; extensive adverse attention in the
national media. Significant difficulties in gaining approvals.
Extensive adverse attention in the regional media; regional
public and political concern. May lose consent to operate or
not gain approval.
Management credentials are significantly tarnished.
Extensive adverse attention in international media;
international public attention. Consent to operate threatened.
Reputation severely tarnished.
 STEP 6 – EVALUATE CURRENT RISK RATING

Risk Assessment Matrix (RAM):

Consequences Increasing Probability
Increasing Severity

Potential People Assets and Environment Reputation A B C D E

Severity Production Remote Unlikely Occasional Likely Frequent
Never heard of Have occured in Has occurred in Occurs several Occurs several
in the Steel other similar Qatar Steel times a year in times a year in
Industry companies but Qatar Steel same location
not in Qatar or operation
Steel within Qatar
Steel
0 No injury No damage No effect No impact
No Risk

1 Slight injury or Slight damage, Slight effect Slight impact

health effect (< QAR 50,000)
Low Risk

2 Minor injury or Minor damage Minor effect Limited impact

health effect (QAR 50,000 to
500,000)

3 Major injury or Local damage Local effect National impact

health effect (QAR 0.5M to
Medium Risk
5,000,000)

4 Single Major damage Major effect Regional

Fatality or (QAR 5M to impact
High Risk
permanent 25,000,000)
total disability
5 Multiple Extensive damage Massive effect International
fatalities (>QAR 25,000,000) impact

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 EXERCISE

Third Group Activity

In the same groups, assign risk rating for different

risks from the task chosen.

30
5 minmin

30
 STEP 7,8 – ASSIGN ADDITIONAL ACTIONS

Additional controls are required when:

1. The current controls might not be sufficient to control the risks

involved in work task;

2. The risk rating is still high and more controls in order to reduce the
risk to either medium or low;

3. More safe practices can be included and assigned to responsible

persons.

Additional controls require a responsible person for application, a

target date and current status information.

When the target date is passed, the action status has to be changed.

If no additional action then the remedial action field should

mention “Nil” and residual risk will remain same as current risk.

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 STEP 9 – EVALUATE RESIDUAL RISK RATING

This stage of assessment indicates:

1. The risk rating after both current and additional controls are
identified;

2. The residual risk indicates the acceptable risk which should be minor;

3. This process is similar to previous risk rating.

If an engineering control is introduced as remedial action, the

severity or probability or both can be reduced more than one order
of magnitude (i.e.; 4C to 2C or 3D to 3B).

If an administrative control is introduced the severity or

probability or both cannot be reduced more than one order of
magnitude (i.e.; 4C to 3C or 3D to 3C).

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 EXERCISE

Fourth Group Activity

In the same groups assigned, complete the risk

assessment by identifying one remedial action and
its residual risk rating for the task chosen.

30
5 minmin

33
 UNIT C: FURTHER CONSIDERATIONS

34
 FINALIZING THE RISK ASSESSMENT FORM

Finalizing the risk assessment form involves:

1. More information can be added in the last column of the risk

assessment;

2. Noting the revision number and date of issue;

3. Describing the persons who conducted the risk assessment

(assessment team) and obtaining their signatures;
4. Update List of Approved HIRA’s form and obtain Head of Section,
Department Manager signatures (if new HIRA is there).

Risk assessments are live documents and must be updated when required.

35
 FINALIZING THE RISK ASSESSMENT FORM

List of Approved HIRA’s for Routine and Non-Routine Activities Form

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 ADDITIONAL INFORMATION

1. Assessment team must include: plant engineer/supervisor, operations

representative, maintenance representative and HSE representative;

2. A checklist of potential hazards and controls given in Appendix 2 of

procedure and can be used by HIRA assessment teams;

3. Risk assessments must be updated when there is change in activity,

equipment, tools, any incident or HIPO nearmiss. If there is no change in
previous stated, then they must be updated at least every 1 year.

4. Job Safety Analysis must be updated after every 6 months for both
company and contractors. For employees, if activity is new and JSA is
used, it must be converted to a HIRA before execution of same activity.

5. If risk rating is H, activity must be stopped and rating must be brought to

M or L by adding remedial actions; If risk rating is M, and is acceptable
(by assessment team), then additional controls may not be required; If
risk rating is L, control measures must be adequately applied.

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 ADDITIONAL INFORMATION

7. For Step 9 of risk assessment process:

• Assessing residual risk must be done following the
implementation of the proposed actions or controls.
• The credit of risk reduction can only be taken with reduced risk
ranking on the residual risk if recommended additional action
item has been implemented and there is a “Closed” status of
remedial action.
• With “Open” status of remedial action, the residual risk will be
same as the current risk.
8. Quarterly audits are carried out to check that risk assessments are
being carried out in accordance with the procedure, and that the
associated controls are being implemented in the field;

Important procedure attachments: 1.32.1.1.08.01 (qatarsteel.com.qa)

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 SUMMARY

1. The hazard identification and risk assessment process is a legal and

compulsory requirement.

2. The first step of the hazard identification and risk assessment process is
to identify the job. If not done correctly, hazards may be missed.

3. Hazard identification process must be carried out at site where possible

to ensure that all necessary controls are covered in the risk assessment
form.

4. Residual risk rating indicates whether our current controls are effective,
or whether we require additional controls (remedial actions).

5. Risk assessments must be in a uniform format and must be

communicated to all work crew members. Understanding the hazards
and risks should be ensured in a toolbox talk or meeting.

39
 Thank you!
Questions?

40