CHE435 PROCESS SAFETY

WELCOME !!!
Technical Safety Awareness
The Law
The DOLE is the lead agency of the
government in charge in the
administration and enforcement of
laws, policies, and programs on
occupational safety and health.

(Legal basis: Presidential Decree No.

442)
LABOR CODE OF THE PHILIPPINES
 OSH LAWS & ISSUANCES

Book IV, Title I – Occupational Safety

Medical, Dental and and Health Standards,
Occupational Safety (OSHS)1978
 A set of mandatory
rules on OSH which
codifies all safety
orders.

Patterned after the

Standards of other
developed countries

Objective: protection of workers

from occupational risks and hazards
Coverage: all workplaces, except safety in
mines
OCCUPATIONAL SAFETY AND HEALTH
STANDARDS (OSHS)

• Mandatory rules on Occupational Safety and

Health promulgated pursuant to Article 162,
book IV of the Labor Code.
• Provide legal framework for all safety and health
programs of DOLE.
• Impose responsibility on the employer and duty
on all workers to observe S & H measures.
• OSHS are administered and enforced by the
Department of Labor.
 Rights & Responsibilities

• Worker Rights
– You have the right to
• Know about hazards in your workplace
• Participate in keeping the workplace healthy
and safe
• Refuse unsafe work
 Rights & Responsibilities

• Worker Responsibilities
– Always practice safe work procedures
– Report unsafe conditions as quickly as
possible to your supervisor or employer
– Properly wear any protective equipment
the job requires
– Do not do anything on the job that will
endanger yourself or others
 Rights & Responsibilities

• Employers must
– Take every reasonable precaution to protect a
worker’s health and safety
– Make sure necessary safety equipment is provided,
used properly and maintained
– Inform workers and supervisors of any hazards
and how to handle them
– Ensure that safe procedures are followed in the
workplace
– Provide information, instruction and competent
supervision to protect the health and safety of
workers
8
RULE 1040 – Health and Safety Committees

A group of employees and management

staff that plans and develops policies in
all matters pertaining to safety and
health in the workplace.

1041 : A committee shall be organized

within one (1) month from the date the
business starts operating. The committee
shall be re-organized every January of the
following year.
 Workers Have Rights!!
• Right to a safe and healthy workplace
• Right to training about safety and health hazards,
including information on chemicals and materials
that could be harmful to your health
• Right to protective clothing and equipment
• Right to work without racial or sexual harassment
• Right to refuse to work if the job is immediately
dangerous to your life or health
• Right to report safety and health problems to
employer/DOLE-BWC
 Why Do You Work?

• MONEY!!!!

- Work experience
- Independence
- Parental influence
- Personal and
professional
fulfillment
Things we value most?

Accident
Accidents are Caused
They can be prevented
What types of injuries do we experience?

Most common types of

injuries sustained :

Cuts 34%
Contusions 18%
Sprains 16%
Burns 12%
Fractures 4%
Industrial Accidents
Industrial Revolution
18th Century
Child Labor
 Global OSH Situationer

• 270 Million Accident Report

• 350,000 of which are fatal

• 160 Million work-related

illnesses/diseases
 Workplace Fatalities

2 Million every year

More than 100,000 every month

5,000 everyday

4 every minute
 Philippine OSH Situationer
Common types of accidents were:

1. Falls
2. Machine Accident
3. Electrocution

4. Collapse of structure/
excavation
5. Suffocation

Devpro
Devpro
 Profile of Victim

The most commonly-

injured workers
were:
male, married, 26-30
years old with 1-5 years
of service and assigned in
the first shift.”
Do you know that due to work
related ailments or injuries there
is an average of 6,000 people die
everyday equivalent to one every
15 seconds.

Source: ILO Data

In the Philippines

• The incidence of work-related

sickness, injury or death has
remained high through the
years, however, compliance with
reporting of work related
accidents is very low.
SAFETY TERMINOLOGY

• Safety
• Hazards
• Accident
• Incident
• Risk
• Loss Control
• Safety Programs
• Safety Management
• Safety Inspection
• Accident Investigation
• Pro-active Safety
• Reactive Safety

25
 What Is An Accident?
An unplanned, unwanted, but controllable
event which disrupts the work process
and causes injury to people.

Most everyone would agree that an accident is unplanned and unwanted. The idea
that an accident is controllable might be a new concept. An accident stops the
normal course of events and causes property damage or personal injury, minor or
serious, and occasionally results in a fatality.
 What is an “Accident”?
By dictionary definition: “an unforeseen event”, “chance”,
“unexpected happening”, formerly “Act of God”

• From experience and

analysis: they are
“caused occurrences” Fatalities

– Predictable - the logical Severe Injuries

outcome of hazards
Minor injuries
– Preventable and
avoidable - hazards do not Close calls
have to exist. They are
caused by things people do
Hazardous conditions
-- or fail to do.
 What Is An Incident?

An unplanned and unwanted event which disrupts

the work process and has the potential of resulting
in injury, harm, or damage to persons or property.

An incident may disrupt the work

process, but does not result in
injury or damage. It should be
looked as a “wake up call”.

Example of an incident: A 50 lb carton falls

off the top shelf of a 12’ high rack and lands
near a worker. This event is unplanned,
unwanted, and has the potential for injury.
 Accidents Don’t Just Happen

• An accident is not “just one of those

things”.
• Accidents are predictable and
preventable events.
• They don’t have to happen.
Most workplace injuries and illness are not due to “accidents”. More often than not it
is a predictable or foreseeable eventuality.
By “accidents” we mean events where employees are killed, maimed, injured, or
become ill from exposure to toxic chemicals or microorganisms (TB, hepatitis, HIV)
A systematic plan and follow through of investigating incidents or mishaps and
altering behaviors can help stop a future accident.

Let’s take the 50 lb carton falling 12 feet for the second time, only this time it hits a
worker, causing injury. Predictable? Yes. Preventable? Yes. Investigating why the
carton fell will usually lead to solution to prevent it from falling in the future.
 “The Tip of the Iceberg”
Accidents
Accidents or injuries are the tip of
the iceberg of hazards.
Investigate incidents since they are
potential “accidents in progress”.

Incidents

Don’t investigate only accidents. Incidents should also be reported and

investigated. They were in a sense, “aborted accidents”.
Criteria for investigating an incident: What is reasonably the worst outcome,
equipment damage, or injury to the worker? What might the severity of the worst
outcome have been? If it would have resulted in significant property loss or a
serious injury, then the incident should be investigated with the same thoroughness
as an accident investigation.
Accidents – are the result of a combination
of causes, as :
 the work methods;
 the worker;
the work environment;
 the equipment used;
the organizational structure and
 the climate at the time of accident.

Accidents occur as a result of a fault in the

total system, not a fault in a individual worker.
What Causes Injuries?
Acts of
Nature Unsafe
2% Conditions
10%

20%

78 %
Unsafe
Acts
88%

UNSAFE CONDITIONS UNSAFE ACTS

ACTS OF GOD

© Texas Workers’ Compensation Insurance Fund 2001

 What is Safety ?

• Freedom of oneself from HAZARDS.

• Control of hazards to attain an

acceptable level of RISKS.

• Control of hazards through injury

prevention and damage control.
CONTROL
To regulate or restrain.

RISK
Is a chance of a physical and
personal loss. The degree of
exposure or chances of exposure to
hazards
35
 HAZARDS

Are Unsafe Practices or Conditions,

that if not controlled, may result into
the occurrence of an accident or an
incident.

H.W. HEINRICH STUDY

 Unsafe Practices - 88%
 Unsafe Conditions - 10%

36
 UNSAFE ACTS

Are behaviors which could

permit the occurrence of an
accident or incident.

Deviation from standard

procedures or practices.

37
 Unsafe Acts
•Unauthorized operation of
equipment
•Making safety device
inoperable
•Using defective equipment
•Non wearing of PPE
•Improper position
 Unsafe Acts

•Operating at improper
speed
•Improper lifting
•Servicing equipment in
operation
•Horseplay
•Working under the influence
of Drugs and Alcohol
 FACTORS THAT LEAD TO UNSAFE ACTS

• Personal Factors
Inadequate Physical Capability
Inadequate Mental Capability
Physical Stress
Mental & Psychological Stress
Lack of Knowledge
Lack of Skill

42
 UNSAFE CONDITIONS

Are circumstances which

could permit the occurrence
of an accident or incident.

Deviation from standard

conditions (equipment,
materials, or environment).

43
Unsafe / Substandard Conditions

• Inadequate guards / barriers

• Defective tools/equipment/materials
• Congestion or restricted body
movement
• Inadequate warning systems
• Fire / explosion hazards
• Poor housekeeping / disorder
• Noise / radiation exposure
• Extremes of temperature / ventilation
 Causes of Unsafe Conditions

• Job / management system factors

– Poor/inadequate
leadership/supervision
– Inadequate purchasing /
tools/equipment
– Inadequate maintenance /
engineering
– Inadequate work standards
 Hazards also occur due to

• Lack of control or
absence/inadequacy of:
–Systems
–System Standards
–Compliance to set standards
Accident Formula

Unsafe Acts
+
Unsafe Conditions
=
Accidents

S
 Hazard Awareness
• WHAT IS A HAZARD ?
Anything that has the potential to cause harm, to People,
and/or damage to Property or the Environment

• Four Basic Groups /

Families :-
PHYSICAL
CHEMICAL
BIOLOGICAL
ERGONOMIC
 Acids and Caustics
Workplace
Vehicles Hazards
A wkw ard
Body
Lo i ti o ns,
w P os
Pip HanSteam Energy
NOISE
DUST
es gin
g rp
Op Sh a
en High Voltage s
Dit E d g e
az ards
Sli ch ri pp i n gH
pp es T
er y Electricity
Su o rk in g
rf a l eva t ed W
ces E
No Areas
i se Confined Spaces
Hot Surfaces
 Physical Hazards
• Mechanical : Machinery, Gears, Sharp edges, Moving things,
Springs, Falls, Trips, Knocks etc
• Noise : Pressure above 85dB (A) Lepd
• Fire : Heat, Smoke, Fumes, Deteriorating environment, poor
vision
• Vibration : Whole body (drivers) or hand / arm
• Radiation's : Ionising or Non-ionising
• Electricity : Direct energy from a conductor or
Electromagnetic radiation
• Lighting : Too much or too little
• Heat (thermal) : Heat stroke / Stress
 Chemical Hazards

• Dust
• Fumes
• Gases
• Vapours
• Mist
• Fibres
• Solids
• Liquid
 Biological

The main Causative organisms are

• Bacteria
– Salmonella, Listeria, E-Coli, Campylobactor,
Leptospirosis Legionella
• Viruses :
– Hepatitis, Flu, Colds, Aids etc
• Moulds and Fungi
– Cheese moulds
– Mushroom spores
– Mouldy hay, etc
 Ergonomic Hazards
Safety Engineering
‘The Fit of the Workplace to the Person’
• Anatomical :
– The Physical fit of the workplace to the
person, e.g. poor design of equipment
(Machinery, Workstations and Tools..)
which do not ‘fit’ causing workplace
aches and pains, and back injuries
• Physiological :
– The Task, Layout or Sequences causing
Tiredness, Mistakes, Stress and Fatigue
• Psychological :
– The Learning process, Emergency
Reactions

Philosophy of Ergonomics…
“ Fit The Task To The Person”
Which are the routes of entry?

Skin
Substances that penetrate the skin

 chemicals
 biological
 botanical (plants)
Nose
Substances that enter through the nose

 dusts
 fumes
 gases

Mouth
Substances that enter through the mouth

 chemicals
 fumes
 gases
Eyes
Substances that affect the eye

 chemicals
 ultraviolet light (from welding)
 biological
 HAZARD CONTROL

Involves developing a
program to recognize,
evaluate, and eliminate (or at
least reduce) the destructive
effects of hazards arising
from human errors and from
conditions in the workplace.

57
 LOSS CONTROL
Is accident prevention, achieved
through a complete safety and health
hazard control program. Loss control
involves preventing employee
injuries, occupational illnesses, and
accidental damage to the company’s
property. It also includes preventing
injuries, illnesses, and property
damage that may visitors and the
public.

58
 HAZARD ANALYSIS
A process of
identifying risks and
job hazards basically
begins with a thorough
analysis of causes of
accidents with the aim
of arriving-up with an
improved/new
standards.

Hazard Analysis
SAFETY INSPECTION

A process of
revealing hazards
and following
through the
necessary corrective
actions which results
to a safer workplace.
 SAFETY AUDIT
Is a critical
examination of the
safety and health
management
programs to
determine their
effectiveness and
compliance to
regulatory standards.
 SAFETY PROGRAM
A plan or outline of activities
conducted to promote safety
consciousness among Safety Program

management and workers in

work places in order that
accidents and/or illness can
be eliminated or minimized
to the lowest reducible level.
Components of Safety Management
System

• PEOPLE
• EQUIPMENT
• MACHINE
• ENVIRONMENT
VS.
Reactive safety

When a group of people do some corrective

action only after an occurrence of accident.
..they assume that everything’s alright as long as
there are no accident in spite of the presence of
hazardous action and conditions at the workplace.
 Pro-active safety

When a group of people becomes pro-active, it starts with

a basic assumption that they can work in the workplace
without accidents…

…they believe they have the ability and capacity to work

without suffering accidental damage to themselves or to
the materials with which they work.
Safety Management Measures

1. It should be Proactive rather than

Reactive.

2. It should be Preventive and

Predictive rather than Corrective.
SAFETY AT WORK
 1

Working at height

Gravity never takes a

break
 3
Fatalities from falls are a senseless
waste of human life. The majority of
deaths are readily preventable with
a minimum of planning and the
implementation of simple and
inexpensive safety procedures.

It is totally unacceptable to have people working

at heights without proper consideration of the
work to be performed, the hazards associated
with that work and the means to remove or
reduce those hazards.
 Fall Protection Options

Personal Fall Guardrails Safety Net

Arrest System
(PFAS)

71
 10

Check
Checkfor forburns,
burns,
tears, splits
tears, splits
ororany
anydamage
damage

Check
Checkthat
thatall
all
hardware,
hardware,buckles
buckles
and
andstraps
strapsare
areinin
good
goodorder
order

When
When worn,
worn, aaharness
harness
must fit snuggly
must fit snuggly but
but
not
nottoo tight
too tight

Harness
Harnessmustmustbebeadjusted
adjusted
totosuit
suitthe
thewearer
wearerand
and
let all adjustments out
let all adjustments out
when
whentaking
takingthe
theharness
harness
off
off
Safety Line Anchorages

Must be independent of
any platform anchorage
and capable of
supporting at least 5,000
lbs. per worker

OSHA Office of Training & Education 73

 Unprotected Sides & Edges

Unprotected edge

Unprotected sides and edges must have

guardrails or equivalent
OSHA Office of Training & Education 74
 Fall Hazards

Falls may occur:

• While climbing on
or off the scaffold
• Working on
unguarded scaffold
platforms
• When scaffold
platforms or planks
fail
76
 Fall

• Floor Openings
• Scaffolds
• Ladders
 Ladder
4:1 Rule
50 ft max.
.75 m
FIXED handhold
Rule of 3
3-pt Contact

2 Hands 1 Foot

1 Hand 2 Feet

Hands are Free

• If you can fall more than 6 feet, you
must be protected
• Use fall protection on:
walkways & ramps, open sides &
edges, holes, concrete forms & rebar,
excavations, roofs, wall openings,
bricklaying, residential construction
• Protective measures include guardrails,
covers, safety nets, and Personal Fall
Arrest Systems
Prevention Before Protection 14

Do It Right The First

Time, You May Not Get
A Second Chance
Electricity

30 V
 Electricity - The Dangers
• About 5 workers are
electrocuted every week
• Causes 12% of young
worker workplace deaths
• Takes very little
electricity to cause harm
• Significant risk of causing
fires

84
 Electrical Accidents
• Leading Causes of Electrical Accidents:
– Drilling and cutting through cables
– Using defective tools, cables and equipment
– Failure to maintain clearance distance of 10 feet
– Failure to de-energize circuits and follow
Lockout/Tagout procedures
– Failure to guard live parts from accidental worker
contact
– Unqualified employees working with electricity
– Improper installation/use of temporary electrical
systems and equipment
– By-passing electrical protective devices
– Not using GFCI (ground fault circuit interrupters)
devices
– Missing ground prongs on extension cords
 Hazards of Electricity
• Shock – Most common and can cause electrocution
or muscle contraction leading to secondary injury
which includes falls
• Fires – Enough heat or sparks can ignite combustible
materials
• Explosions – Electrical spark can ignite vapors in the
air
• Arc Flash - can cause burns ranging from 14,000
degrees f. to 35,000 degrees f
• Arc Blast – In a short circuit event copper can
expand 67,000 times. The expansion causes a
pressure wave. Air also expands adding to the
pressure wave
 Ohm’s Law

I=V/R

I = Current (Amperes) (amps)

V = Voltage (Volts)

R = Resistance (ohms)

Georg Simon Ohm (1787-1854)

How you should be
thinking about
electric circuits:

Voltage: a force
that pushes the
current through
the circuit (in
this picture it
would be
equivalent to
gravity)
How you should be
thinking about
electric circuits:

Resistance:
friction that
impedes flow of
current through
the circuit (rocks
in the river)
How you should be
thinking about
electric circuits:
Current: the
actual
“substance” that
is flowing
through the
wires of the
circuit
(electrons!)
 Electricity – How it Works

• Electricity is the flow of

energy from one place to
another
• Requires a source of
power: usually a
generating station
• A flow of electrons
(current) travels through
a conductor
• Travels in a closed circuit

91
Electrical Accident
 Electrical Shock
An electrical shock is received when
electrical current passes through the body.

You will get an electrical shock if a part of

your body completes an electrical circuit
by…

• Touching a live wire and an electrical

ground, or
• Touching a live wire and another wire at a
different voltage.

93
EFFECT TO THE HUMAN BODY

Involuntary Action
Disturbance to
normal body
function
Burn
Ventricular
fibrillation
Death
Secondary accident
 Shock Severity

• Severity of the shock

depends on:
– Path of current through the
body
– Amount of current flowing
through the body (amps)
– Duration of the shocking
current through the body,
• LOW VOLTAGE DOES NOT
MEAN LOW HAZARD
95
 Common Electrical hazards
• If you touch a live wire or other
electrical component while standing
in even a small puddle of water
you’ll get a shock.
• Damaged insulation, equipment, or
tools can expose you to live
electrical parts.
• Improperly grounded metal switch
plates & ceiling lights are especially
hazardous in wet conditions.
• Wet clothing, high humidity, and
perspiration increase your chances
of being electrocuted.
Preventing Electrical Hazards - PPE

•Proper foot
protection (not
tennis shoes)
•Rubber insulating
gloves, hoods,
sleeves, matting,
and blankets
•Hard hat (insulated -
nonconductive)
Preventing Electrical Hazards –
Proper Wiring and Connectors
• Use and test GFCI’s
• Check switches and
insulation
• Use three prong plugs
• Use extension cords only
when necessary & assure
in proper condition and
right type for job
• Use correct connectors
 Burns
• Most common shock-
related injury
• Occurs when you touch
electrical wiring or
equipment that is
improperly used or
maintained
• Typically occurs on hands
• Very serious injury that
needs immediate attention

99
 Control

Insulation
Isolation
10 ft. or 3 m
Grounding
PPE
Electricity Travel Through Air

LINC International Management & Consulting Group

 Electrical Safety
Only licensed
electricians are
permitted to carry out
electrical repairs and
access installations.

Before any work is

performed on any
electrically powered
Equipment or Systems,
the electricity must be
isolated and tagged at
the primary source.

102
 Electrical Safety

Electrical Safety
• Inspect all electrical equipment prior to
use.
• Check tag is current.
• Do not pull, drag or stretch cables over
edges.
• Do not hang or support equipment by its
lead.

103
 Electrical Safety

Person in Contact with Electricity

• Switch off the electricity and then pull or

push the victim to safety.
• If the electricity cannot be switched off, do
not directly touch the person with any
part of your body.
• Push or pull the victim clear using dry,
non- conductive material - never use any
metallic or wet objects.
• Call for emergency assistance.

104
 Things to Remember

Electricity is invisible
Even Low Voltage is
Dangerous 30 V
Water and Electricity don’t
mix
High Voltage Electricity can
travel through air
Electricity can Instantly kill
you!
Unsafe Practices/ Conditions

Report Defective
Electrical Appliances
or Tools!
Machine
Safety
Machine Guarding

Fatalities
 Many fatalities have resulted
from employees getting
caught in rotating shafts such
as well boring drills & lathes.
 Safety Guards

• Are required to prevent

accidents.
• Protect people, not the machine.
• Hazardous parts include point of
operation components, control
mechanisms, parts that transmit
power, and parts that retain
stored energy
 Regulatory Requirements

• Regulatory requirements found in

29 CFR 1910, Subpart O
• OSHS Under Rule 1200
• Delineates general requirements
 12.02. Provisions of Guards:

• All moving parts of prime movers,

transmission equipment and all
dangerous parts of driven machinery
• shall be effectively guarded, unless so
constructed or located to prevent any
person or object from
• coming or brought into contact with
them.