Chapter 1 Industrial Safety

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

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

function or the
structures of cells that
can lead to disease or
health problems“. 6
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What is a adverse health effects?

Adverse health effects include:
bodily injury,
disease,
change in the way the body functions, grows, or
develops,
effects on children, grandchildren, etc. (inheritable
genetic effects)
decrease in life span,
change in mental condition resulting from stress,
traumatic experiences, exposure to solvents, and so
on, and
effects on the ability to accommodate additional
stress.
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 RiskWhat a risk?or
is theischance
probability that a person will
be harmed or experience an
adverse health effect if
exposed to a hazard.
 It may also apply to situations
with property or equipment
loss.
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FactorsWhat is a risk
that influence the factors
degree of ?
risk
include:
how much a person is exposed to
a hazardous thing or condition,
how the person is exposed (e.g.,
breathing in a vapour, skin
contact),
how severe are the effects under
the conditions of exposure.
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Accident :
Unplanned event or sequence of

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

work
LIST INDUSTRIAL ACCIDENT
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Case 1
Flixborough (Nypro UK) Explosion 1st June 1974
• Nypro Limited
– Cyclohexane as raw material, Plant capacity
70,000 ton/year cyprolactam*, 6 reactors
• Effect to human being
– 28 death
– 36 injured
– Damage 1821 houses and 167 shop lots
– 55 public were injured.
*raw source for Nylon production

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

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

system ruptured, which may have been caused by a
fire on a nearby 8 inch pipe.
This resulted in the escape of a large quantity of
cyclohexane.
The cyclohexane formed a flammable mixture and
subsequently found a source of ignition.
At about 16:53 hours there was a massive vapour
cloud explosion which caused extensive damage and
started numerous fires on the site.
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Case 2
Union Carbide India Ltd, Bhopal, India. 3rd
December 1984
 Union Carbide Plant, Madhya Pradesh
 Pesticide plant.
 Methyl Isocyanate(MIC) immediate product
 Leakage at MIC storage tank
 Effect to human being
 10,000 death and 20,000 injured within 3 days
 Additional 25,000 death by 1994
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Bhopal Leakage – Accident Summary
 At 23.00 hrs on 2 December 1984, an

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

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

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Case 3
Skikda, Algeria Explosion
19th January 2004
 explosion at LNG plant (6 trains)
 Damage almost the whole plant facilities
Effect to human being

 27 death
 72 injured
 7 missing
Effect to surrounding area
 Damaged of Power station
 Refinery – on fire and need to be close.
Before
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Case 4
Port Kembla, NSW, Australia
• 28th January 2004

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

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

– The explosion was fuelled by massive
accumulations of combustible sugar dust
throughout the packaging building
– 14 death
– 38 injured
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Case 7
Explosion at West Fertilizer Company in
West Texas
• 17th April 2013
– An ammonium nitrate explosion
– 14 death
– 160 injured
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Case 8
Chemical Tanker Ablaze & Explodes Off in
Labuan, Malaysia
• 26th July 2012

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

work
WORK ACCIDENT PHOTOS
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1.2 Working Identification
SAFETY & HEALTH

TERMS AND DEFINITION
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DEFINITION
Hazard :
“source, situation or act with a potential for
harm in terms of human injury or ill health,
damage to property, damage to the
workplace environment, or combination of
these”
May also
A chemical or physical condition
known as
that has the potential to cause
damage to people, property or
the environment
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The harm that results

from an uncontrolled
hazard FIRS
T
is called…
AID
●
Fatality
ACCIDEN
TS
●
Major accident
(MAJOR
Minor
CONSEQUENCES
●
/MINOR)
Accident
/OUTCOME/ NEA
RMI
INCIDENT/ SSES
CASES
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Example of Hazards and Their Effects

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

on
 Biological Hazard.
Ergonomic
Mechanical
Electrical
Psychosocial
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Failure to Identify Hazards
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Working at Heights
Worker could fall and sustain injury.

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Hoisting Equipment
Load could shift or fall.

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

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

 repetitive and forceful movements,
 vibration,
 temperature extremes, glare (light
illumination) and
 awkward postures that arise from
improper work methods and improperly
designed workstations, tools, and
equipment.
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Ergonomic Hazards
Awkward Posture
Glare
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Awkward posture (uncomfortable position)
 Bad sitting posture  Good sitting posture
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TUTORIAL
a. Define the term ‘hazard’

b. Provide TWO (2) examples of hazard
from each category; physical hazard,
chemical hazard and biological hazard
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Terms and definition
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Terms and definition

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

fatality) results from a work
accident/single exposure
involving a single accident in
the working environment
 Recordable case.
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Occupational Injury
Examples are:
• Thermal and chemical burns
• Cuts, abrasions and punctures
• Fractures or crushing injuries
• Respiratory irritations
• Instantaneous hearing loss
• Amputations
• Sprains or strains
• Broken bones
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OCCUPATION ILLNESS
 Any abnormal condition or disorder
(other than an injury) that resulted from
a work-related exposure to a biological,
chemical or physical agent.
 These include both acute and chronic
illnesses or diseases that may be caused
by inhalation, absorption, ingestion or
direct contact.
 Recordable case
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Occupational Illness
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CATEGORIES EXAMPLES
Lung diseases Silicosis, asbestosis, pneumoconiosis, or
other similar disorder
Physical Heatstroke, sunstroke, heat exhaustion,
disorders freezing, frostbite and other environmental
effects; radiation exposure; and effects
form non-ionizing radiation sources such as
welding flashes, UV rays, microwaves and
sunburn
Other Anthrax, infectious hepatitis, tumors, food
poisoning, and gradual hearing loss
Skin diseases Dermatitis, eczema or rash that is caused86
Occupational Illness
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CATEGORIES EXAMPLES
Poisoning Exposure to lead, mercury,
cadmium, arsenic or other heavy
metals; inhalation of carbon
monoxide, hydrogen sulfide or
other gases; exposure to benzene
compounds, carbon tetrachloride,
or other organic solvents; exposure
to toxic levels of insecticide
sprays; and exposure to other 87
chemicals such as formaldehyde,

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FATALITY CASES
 Injuries or illnesses that
results in death, regardless
of the time between the
injury and death or the
length of the illness.

Recordable case
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Nonfatal Cases Without Lost

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

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

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

IN Table 1-2
PAGE 6
CROWL AND LOUVAR
CHEMICAL PROCESS SAFETY
(FUNDAMENTALS WITH APPLICATION)
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TUTORIAL
Study the case below:
a. Determine the name of the incident (fatality/occupational
injury/first aids/occupational health/non-fatal
recordable case)
b. Decide the case type whether it is recordable case or
non-recordable case
Case 1: Fatal electrocution to worker using ungrounded hand

held electric drill. Possible cause of the incident is the drill
was not double insulated. Incident occurred on 26th January
2015
a) Incident: Fatality case
b) Case type: Recordable case
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TUTORIAL
Case 2: Grinding machine operator, not wearing eye
protection, incurs eye injury from flying chip; medical
treatment required; injury occurs on Monday; employee
returns to regular job at regular time on Wednesday
a) Incident: Occupational injury
Case 3: Worker lacerates hand on the sharp edges of

the conveyor line; medicated plaster was given to the
worker to apply on. No medical treatment required;
worker remains on the job
a) Incident: First Aids
b) Case type: Non-Recordable case
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TUTORIAL
Case 4: Rokiah becomes “ill” due to noxious odors from
remodeling operation in the assembly area. Receives
permission from supervisor to take rest of the day off. She
doesn’t go to a doctor or clinic. She report to regular work
on time the next day
a) Incident: Occupational health
Case 5: Mutusamy, the storekeeper fell and sprains his

ankle while tried to pallet in the warehouse; he was
moved to administration department to carry out office
job for two work-weeks
a) Incident: Non-fatal recordable case
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Accident Statistics for

some industries
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Accident Statistics for some

industries
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Fatality Statistics
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Accident and Loss

Statistics
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Accident and Loss Statistics

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 Measures of effectiveness of safety

programs
 Statistical methods : characterize
accident and loss performance.
 Systems:
 OSHA Incidence Rate (OSHA IR)
 Fatal Accident Rate (FAR)
 Fatality Rate
 report the number of accidents and/or fatalities
for a fixed number of workers during a specified
period. 104
OSHA Incidence Rate

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 Based on cases per 100 worker years

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

200,000
(injuries & illness)
OSHA IR
(based on lost =
workdays) total hours worked by
all employees during period covered
* OSHA INCIDENCE RATE [BASED INJURIES &

ILLNESS]
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TUTORIAL
A company has 17 full-time employees and 3 part-
time employees that each work 20 hours per week.
This equates to 28,400 labor hours each year. If the
company experienced 2 recordable injuries, then the
OSHA Incidence Rate is:
OSHA IR = (2 x 200,000) /28,400

= 14.08
 What is now known is that for every 100
employees, 14.08 employees have been involved in
a recordable injury or illness.
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TUTORIAL
How many injuries occurred in
a chemical industry if the
OSHA incidence rate is 0.49?
 For every 100 employees, 0.49 employees

have been involved in a recordable injury.
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NOTE
 Please note that smaller companies that
experience recordable incidents will most likely
have high incident rates, or the incident rates
will fluctuate significantly from year to year.
 This is because of the small number of
employees (and hence the lower number of
labor hours worked) at the company.
 Calculations are more meaningful at larger
companies that have a higher labor hour count.
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Lost Time Case Rate

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

X 200,000
Cases
LTC =
Rate total hours worked by
all employees during period covered
* LTC Rate is BASED on number of

cases that contained lost work days.
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TUTORIAL
Using the previous company example, assume that
one (1) of the two recordable cases had lost work
days associated with the incident.
The calculations would look like this:

LTC Rate = (1 x 200,000) / 28,400
= 7.04
 What is now known is that for every 100

employees, 7.04 employees have suffered lost
time because of a work related injury or illness.
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Fatal Accident Rate (FAR)

 British chemical industry
 Number of fatalities based on 1000
employees working their entire
lifetime.
[An employee works a total of 50 years]
 FAR is based on 108 (100,000,000)
working hours.
[1000 employees x 50 years x 50
work weeks/year x 40 hours/week ]
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Fatal Accident Rate (FAR)
FAR = (Number of fatalities x 108)

Total hours worked by all
employees during period covered
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TUTORIAL
Calculate FAR if the number of
death per person per year is 4.8 x
10-5 and the employee works 8-hours
shift 300 days per year?
FAR = (4.8 x 10-5 x 108)

8 hr/day x 300 days/year
Number of fatalities based on
1000 employees working their
FAR = 2 entire lifetime.[An employee works a
total of 50 years]
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TUTORIAL
A plant employs 1500 full time
workers in a process with a FAR of 5.
How many industrial related deaths
are expected each year?
FAR (5) = Number of fatalities x 108

1500 x 8 hr/day x 300 days/year
Number of fatalities = 0.18

expected each year
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Fatality Rate (FR)

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

(per year) in applicable
population
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 The same formula can also be used to

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

TRANSFER RATE (DART)
 Those rates are normally used in big
company.
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1.3 Hazard Identification Methods
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Unsafe Places and / or equipment

Identify the hazards!
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Identify
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the hazards!
Unsafe Places and / or equipment

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

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

HAZARDS CONSEQUENCES
Falling objects ……………
Toxic chemical ……………

Exposure to radioactive ……………
Infected by HIV ……………
Awkward posture ……………
(uncomfortable position)
Fire & explosion ……………

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 Hazard Identification
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HAZARDS IDENTIFICATION
(HAZID)
“the process of recognizing that
hazard exists and defining its
characteristics.”
It is essential to identify the hazards
and reduce the risk in advance of an
accident
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There are various approaches to hazard
identification:
1. Experience based reviews/Expert
judgments
2. Review of documentation from vendor
3. Review of legal and other requirements
4. Walkthrough/survey/inspection using
prepared checklist based reviews
5. Job Safety/Hazard Analysis (JS/HA)
No single tool fits all applications 130
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identification:
 Experience based reviews / Expert
judgments.
Learning experience from consultants, OJT etc
 Review of documentation from vendor
such as machine manual, maintenance list etc
 Review of legal and other requirements
Legal document such as:
 Occupational Safety and Health Act 1994 (Act 514)
 Factories & Machinery Act. 1967 (Act 139)
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identification:
 Walkthrough / survey / inspection

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

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

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

e.g. flammability
whatis the auto-ignition temperature,
what is the flash point, how can a fire be
extinguish etc
e.g. toxicity
what are the Threshold limit value (TLV)*,
what PPE is needed etc.

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*A level to which it is believed a worker can be exposed a chemical substance day after
day for a working lifetime without adverse health effects.
HAZARD IDENTIFICATION, RISK ASSESSMENT & RISK CONTROLS (HIRARC) Form No: ATTACHMENT 2
CLD 20002 Occupational

Safety & Health
SCET
Signature
Process/Activity Prepared By MICET
Name
Date
Signature

Department/Section Reviewed By Name
Date
Signature

HIRARC NO & REV No Approved By Name
Date
Hazard Identification Risk Assessment
Cond. Current Control Measures Likeli Futher Control Measures
No Job Steps/Sub-Activities No Of Hazards Consequences Table hood Severity Risk Level
Asses.

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1.4 Hazards & Operability Studies

(HAZOP)
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Hazards & Operability Studies

Widely
known &
To investigate how a plant might
used
deviate from its design purpose
Consequences of these deviations on
the process are then assessed, and

control measure needed to detect
deviations are established
Brainstorming approach of a
multidisciplinary team consists of 5-

7 people
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 Perform by a multi-discipline teams.
 Operation personnel; production and
maintenance.
 Procurement personnel; production control
(purchasing)
 Safety, Health and Environment personnel.
 Supplier ( sometimes)
 Requires a thorough examination of
process-flow diagrams & piping and
instrumentation diagrams,
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 Use of guidewords like no, more, less,
as well as, etc to screen all possible
causes.
 Guidewords are applied to various
process parameter like flow,
temperature, pressure, liquid, level,
composition and any other variable
affecting the process
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No
Cooling coils
Flow
High
Low
Temp.
Low
High
Agitation
Stirrer
No 147
More
MICET
ADVANTAGES OF HAZOP
1. PFD are examined line by line by

multidiscipline team.
2. Potential problem areas of the
design can be identified to allow
early design modification.
3. Promotes extensive dialogue
between designers and operators;
hence better understanding
148
MICET
DISADVANTAGES OF HAZOP
1. Excessive time required in review; hence

target time date cannot be achieved.
2. Unmanageable of board documentation,
especially for a complex system
3. Increase in the total capital cost; due to
additional / modification design or
equipment requested by the HAZOP team
149
MICET
EVENT TREE ANALYSIS

(ETA)
150
MICET
EVENT TREE ANALYSIS (ETA)

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

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

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

sequences
MICET
EVENT TREE ANALYSIS

MICET
EVENT TREE ANALYSIS

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

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

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

MICET
Results
Success
Failure
MICET
FAULT TREE ANALYSIS

(FTA)
MICET
FTA - How Does It Work?

 Deductive method for identifying
ways in which hazards can lead
accidents
 Approach starts with a well-
defined accident or top event
 Logic symbols are used to provide
graphical representation
MICET
160
MICET
FAULT TREE ANALYSIS

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

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

MICET
FAULT TREE ANALYSIS

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

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

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

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

injuries or illness
 Simple human error could lead to a
severe accident
 New to your operation
 Complex process
MICET
1.5 BIOLOGICAL HAZARD
171
MICET
BIOLOGICAL HAZARDS
 also known as biohazards
 refer to biological substances that pose a
threat to the health of living organisms,
primarily that of humans & animals such as:
 medical waste, fungi, moulds
 microorganism, bacteria, parasites
 virus, organic dusts
 workers maybe at risk of
 viral or bacterial infection.
 allergies
 respiratory diseases 172
MICET
COMMON OCCUPATIONAL DISEASES

Result from such exposure:
1. HIV/AIDS
2. Hepatitis B & C viruses and other
blood borne pathogens
3. Tuberculosis infections among health
care workers
4. Asthma (expose to organic dusts)
5. Chronic parasitic infections among
agricultural/forestry workers
173
MICET
BIOHAZARDS TRANSMITION
Biohazards can be transmitted to

a person through:
a. Inhalation
b. Injection
c. Ingestion
d. Contact with the skin
174
MICET
BIOHAZARDS CLASSIFICATION
..to decide on what to do to safeguard the
workers from the hazards:
a. Any accident involving biohazards
materials can result in infection
b. When working with biological agents
or materials for which epidemiology*
and etiology** is not known or not
completely understood, it must be
assume that materials present a
biohazards
175
*distribution; ** causes
MICET
Occupational Exposure to BIOHAZARDS

Workers who handling & manipulation of
biological agents:
a. Research Laboratory
 technician/scientist
b. Health Care Facilities
 laundry/house keeping/health care
staff
c. Agriculture
animals transmissible to human
176

MICET
BIOHAZARDS Control Program
1. Employee Health
 pre-placement examination for
new employee.
 periodic physical examination as
part of surveillance program
 Vaccination
177
MICET
2. Laboratory Safety & Health

 employee training.
 avoid if possible entering into a
biohazards area
 avoid eating, drinking, smoking &
gum chewing in biohazards area
 wearing PPE always
178
MICET
3. Biological Safety Cabinet

 to protect workers from
exposure to aerosols especially
when there is contact with
biohazards in laundry activities.
179
MICET
4. Animal Care & Handling

 periodic examination, disposal
of manure, cleanliness,
collection of medical history
and treatment.
180
MICET
181
MICET
BIOHAZARDS ~ Preventive Methods

 Wear appropriate PPE
 Never discard syringes, needles or any
apparatus used in testing involve
microorganism
 Employ good, sterile techniques when open
any tubes, bottles and culture plates-
minimize contamination
 Storage vessels containing biohazard
agents must be labeled to provide
identification of their content
182
MICET
183
MICET
184
MICET
1.6 RISK ASSESSMENT
185
 Risk is the chance or
MICET
What is a risk? that a

probability/likelihood
person will be harmed or
experience an adverse health
effect if exposed to a
hazard.
 It may also apply to situations
with property or equipment
loss.
186
MICET
RISK ASSESSMENT
“the overall process of
estimating the
magnitude of risk and
deciding whether or
not the risk is
tolerable/acceptable”
187
MICET
RISK ASSESSMENT..con’t
Risk assessment is the process where you:
identify hazards,
analyze or evaluate the risk associated
with that hazard, and
determine appropriate ways to eliminate or
control the hazard.
The OSH Answers Risk Assessment has
details on how to conduct an assessment and
establish priorities.
188
MICET
What is Risk Assessment?
Risk consists of 2 dimensions

Probability Consequence
(Likelihood) (Severity)
189
MICET
What is Risk Assessment?

Determination of likelihood x consequence
by:
 Describing scenarios involving the
hazard
 Analysis of probability of each event
 Analysis of consequence of each
event
190
Process of Risk Assessment

MICET
No Activities
1 Identification of the potential harmful hazards
2 Measurement to estimate the consequences of
the hazards.
3 Estimation of the probability of the occurrence of
each hazards consequence.
4 Quantitative calculation of risks & comparison
with potentially acceptance hazard levels.
5 Characterization of the hazard risks to be
managed, along with the assumptions &
uncertainties.
6 Ranking of the risk hazards for management
Basic Risk Assessment Tools &

MICET
Techniques
There are various risk assessment tools
and techniques:
 Informal, intuitive techniques based upon:
experienced judgment, checklists, codes and
standards.
 Qualitative - scenario-based assessment
using a Risk Matrix.
 Quantitative techniques using fault trees,
event trees, failure modes and effects
analysis, consequence analysis.
192
MICET
Probability/Likelihood
We can determine the safety probability based
on the following:
 Historical data / Trends
 The number of employees exposed and their
competency level
 The frequency and duration of exposure
 The proximity of employees to the danger
zone
193
MICET
Probability/Likelihood Rating
Rating Likelihood (L) Description/Example
MOST LIKELY The most likely result of the hazard / event
5 being realized (once per week)
POSSIBLE Has a good chance of occurring and is not

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

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

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

(once per 100 years)
194
MICET
Severity / Consequences
 The degree of harm

to people, damage to
property, environment
and reputation.
195
MICET
Severity / Consequences
Rating Severity (S) Description/Example
CATASTROPHIC Numerous fatalities, irrecoverable property
5 damage and productivity
FATAL Approximately one single fatality major

4 property damage if hazard is realized
SERIOUS Non-fatal injury, permanent disability

3
2 MINOR Disabling but not permanent injury
NEGLIGIBLE Minor abrasion, bruises, cuts, first aid type

1 injury
196
Risk Levels
MICET
 Risk Matrix combines the probability and

consequence of a defined scenario to define a risk
level
 Risk matrix is typically divided into FOUR levels of
risk, each with defined approval levels, based on
the risk level before any additional or alternative
risk reduction measures are considered e.g.:
 Extreme risk – immediate action required
 High risk – urgent management attention needed
 Medium risk – management attention as soon as
possible
 Low risk – longer term action may be required
through process of continuous improvement
197
MICET
What is a Risk Matrix

A risk matrix represents a simple,
straightforward, qualitative or semi-
quantitative template to…
 determine the magnitude of
potential risks, and
 establish a decision-making basis
198
MICET
Risk Assessment
Consequence/
Likelihood (L)/ severity (S) of the
Relative
Risk = probability of X harmful effects of a
occurrences specified hazardous
event occurring
Relative
Risk = L X S
199
MICET
Risk Matrix
Severity (S)
Likelihood (L) 1 2 3 4 5
5 5 10 15 20 25
4 4 8 12 16 20
3 3 6 9 12 15
2 2 4 6 8 10
1 1 2 3 4 5
High
Medium
200
MICET
Risk Matrix
RISK DESCRIPTION ACTION
A High risk required immediate action to
control the hazard as detailed in the hierarchy
15 - 25 HIGH of control. Actions taken must be documented
on the risk assessment form including date for
completion.
A Medium risk requires a planned approach to
controlling the hazard and applies temporary
5 - 12 MEDIUM measure if required. Actions taken must be
documented on the risk assessment form
including date for completion
A risk identified as Low may be considered as
acceptable & further reduction may not be
1 - 4 LOW necessary. However, if the risk can be resolved
quickly & efficiently, control measures
201
should
MICET
Then ….
after you identify uncontrolled hazards,
you will take steps to eliminate or reduce
them to an acceptable risk level
Acceptable Risk :
“a risk that has been reduced to a level that
can be tolerated by the organization having
regard to its company’s policy and legal
obligation”
202
MICET
Risk Assessment
All risks must be
reduced…… RISK
High
As UNACCEPTABLE
Low
Medium REDUCE
FURTHER IF
As POSSIBLE
Reasonably
Low
DESIRABLE
Practicable.
203
MICET
Why it is important ….
To prevent workplace injuries and
illness by ….
looking at your workplace operations
safely,
establishing proper job procedures
ensuring that all employees are
trained properly
204
MICET
RISK PRIORITIZATION (or Significant Risk)

based on…..
 highest injury or illness
 Potential cause severe or disabling
injuries or illness
 Simple human error could lead to a
severe accident
 New to your operation
 Complex process
205
MICET
What is a Significant Risk?
Answer:
A significant risk is a
condition of work that will
likely adversely affect
safety and health of workers
Significant = priority
206
MICET
Significance Criteria according to business

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

 Concerns of
issues (the Market).
interested parties.  Concern of parent
company.
Potential liabilities
resulting from the
Concern of investors,
impact/risk
insurers and financial
 Effect on public institutions
image of organisation
207
CLD 20002 Occupational Safety & Health
What do you think?
SCET
MICET
Risk To Coyote?
Risk To Road-Runner?
“Cai-yo-tea”
208
Risk = Likelihood x Severity

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

release 210
MICET
FIRE
 Chemical reaction in which
substance combines with oxidant
and releases energy
 Need 3 elements;
 fuel,
 oxidizers,
 ignition source
211
MICET
3 elements for FIRE

 Fuel
gasoline, acetone (liquid)
plastic, wood (solids)
propane (gases)
 Oxidizers
hydrogen peroxide (liquid)
metal peroxides (solids)
oxygen, fluorine (gases)
 Ignition source
spark, flames, static electricity, heat
212
MICET
EXPLOSION
 Rapid expansion (mechanical /chemical
reaction) of gases resulting in a rapidly
moving pressure or shock wave
 Types of explosions
 mechanical explosion
 confined explosion
 unconfined explosion
 boiling liquid expanding vapor explosion
(BLEVE)
 dust explosion
213
MICET
Estimation of explosion strength
Blast damage from explosion:
r
Ze 
m1/ 3TNT
Ze = scaled distance (ft/lb1/3 or m/kg1/3)

r = distance from the explosion
m = mass of TNT [Tri Nitro Toluene]
214
MICET
215
MICET
216
MICET
TUTORIAL
A vessel contains 50 lbs of TNT. The vessel
accidentally falls over and ruptured. The
cloud is ignited and an explosion occurs.
Determine the overpressure from this
explosion 100 feet away. What type of
damage is expected?
Given info:
m = 50 lbs (22.73 kg) r = 100 ft (30.48 m)
Using Ze formula, r
Ze 
m1/ 3TNT
217
MICET
TUTORIAL
a. One kilogram of TNT exploded. Compute the
overpressure at a distance of 30 m from the
explosion. Estimate the injury to people and the
damage to structures 100 m away
b. A reactor contains the equivalent of 10,000 lb of
TNT. If it explodes, estimate the injury to
people and the damage to structures 500 ft
away
Given info:
1kg = 2.20 lbs 1ft = 0.3048 m
Using Ze formula, Ze  r
m1/ 3TNT
218
MICET
TUTORIAL
Micet Safety Consultant Sdn Bhd rule is to design occupied
control rooms to withstand a 2 metric tons blast of TNT at
125 ft.
a) Determine the overpressure does this correspond to?
State the types of damage.
b) Recommend the distance (in ft) of a residential area, if
the 2 metric ton of TNT blast the house should receive
no more than minor damage to house structures?
Given info:
1kg = 2.20 lbs 1ft = 0.3048 m
Using Ze formula, Ze  r
m1/ 3TNT
219
MICET
THANK
YOU

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CLD 20002 Occupational Safety & Health

Universiti Kuala Lumpur 1

Malaysian Institute of Chemical and Bioengineering Technology

1.0 Industrial Safety

What is a adverse health effects?

"any change in body

What is a adverse health effects?

Unplanned event or sequence of

1.1 Introduction to safety at

LIST INDUSTRIAL ACCIDENT

*raw source for Nylon production

Flixborough Explosion – Accident Summary

 On 27 March 1974, it was discovered that a

Flixborough Explosion – Accident Summary

 Late afternoon, 1 June 1974, a 20 inch bypass

Bhopal Leakage – Accident Summary

 At 23.00 hrs on 2 December 1984, an

Bhopal Leakage – Accident Summary

The pressure inside the storage tank was

Bhopal Leakage – Accident Summary

Bhopal Leakage – Failings in technical measures

Effect to human being

• 28th January 2004

Taiwan Kaohsiung Gas Pipeline Explosions

• 07th February 2008

• 26th July 2012

1.1 Introduction to safety at

WORK ACCIDENT PHOTOS

1.2 Working Identification

SAFETY & HEALTH

The harm that results

Example of Hazards and Their Effects

Radiati  Chemical Hazard.

Failure to Identify Hazards

Worker could fall and sustain injury.

Load could shift or fall.

Environmental & Radioactive Hazards

 Ergonomic hazards refer to workplace

Ergonomic hazards include…

Awkward posture (uncomfortable position)

 Bad sitting posture  Good sitting posture

a. Define the term ‘hazard’

Terms and definition

Terms and definition

Any injury (including

chemicals such as formaldehyde,

Nonfatal Cases Without Lost

Work Related Accident- Definition

Work Related Accident- Definition

 Driving to or from work is not

MORE TERMS AND DEFINITION

Case 1: Fatal electrocution to worker using ungrounded hand

b) Case type: Recordable case

Case 3: Worker lacerates hand on the sharp edges of

Case 5: Mutusamy, the storekeeper fell and sprains his

Accident Statistics for

Accident Statistics for some