Safety Engineering Modules

MODULE TITLE : SAFETY ENGINEERING
TOPIC TITLE : AN INTRODUCTION TO SAFETY ENGINEERING

LESSON 3 : INDUSTRIAL SAFETY TERMINOLOGY
SE - 1 - 3
Teesside University 2011
Published by Teesside University Open Learning (Engineering)

School of Science & Engineering
Teesside University
Tees Valley, UK
TS1 3BA
+44 (0)1642 342740
All rights reserved. No part of this publication may be reproduced, stored in a

retrieval system, or transmitted, in any form or by any means, electronic, mechanical,
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published and without a similar condition including this
condition being imposed on the subsequent purchaser.
1
________________________________________________________________________________________
INTRODUCTION
________________________________________________________________________________________
There are a number of terms which are in common use in safety engineering and
which you will meet in this lesson. In everyday language many of these terms
are virtually synonymous (have the same meaning), but in the world of safety
engineering they have quite specific meanings. It is important that you are
familiar with these terms and understand their meanings when you meet them.
Try to memorize as many of these words as possible at this stage. To help you
to do this, there are some Self-Assessment Questions included in the body of
the lesson.
In the second part of this lesson we shall be examining one of these terms
"risk" in more detail.
________________________________________________________________________________________
YOUR AIMS
________________________________________________________________________________________
At the end of this lesson you should be able to:
explain the meaning of some of the common terms used in industrial

safety engineering
understand how the term 'risk' is applied within an engineering

system.
Teesside University Open Learning

(Engineering)
2
________________________________________________________________________________________
STUDY ADVICE
________________________________________________________________________________________
We strongly recommend that you memorise as many as possible of the terms in

the first part of the lesson. To help you to do this, spend as much time as
possible on the first set of Self-Assessment Questions.

(Engineering)
3
________________________________________________________________________________________
A GLOSSARY OF INDUSTRIAL SAFETY TERMINOLOGY IN COMMON AND

RECOMMENDED USAGE
________________________________________________________________________________________
NOTE: Terms in italics are defined more fully elsewhere in this glossary.
HAZARD AND RISK
Hazard
A state or condition having the potential

to cause a deviation from uniform or
intended behaviour which, in turn, may
result in damage to property, people or
the environment. For example, a
chemical process can realize its potential
through, for instance, fire or explosion
(catastrophically) or by corrosion
(insidiously).
It is neither desirable nor usually
practicable to confidently rank or
measure a hazard in terms of size or
severity.
Risk
The time-related, or location-related

likelihood of a hazard actually resulting
in an undesired event. Risks can be
quantitatively expressed in terms of
probability or frequency. (We will be
examining these terms more fully later in
this lesson.)
Risk Assessment
This includes value judgements

concerning the significance of the risk
measurement results.

(Engineering)
4
Social Risk
The risk to a group of people exposed to

a major hazard. This is usually
quantified on a F - N curve (see earlier
lesson). Societal risk can be more
accurately defined geographically if such
factors as distance, blast effects, gas
concentration and wind characteristics
are known or predictable.
Residual Risk
The element of risk remaining after all

economically acceptable improvements
have been made.
CONSEQUENCES
Explosion
A mechanically, or chemically, generated

rapid release of energy, which in turn
generates a blast (or shockwave)
capable of causing considerable damage
due to the velocity of pressure pulses
transmitted from the explosion.
(Particular types of explosion will be
identified later in the course.)
Explosion Pressure
A term used to quantify the effects of an

explosion the pressure developed
above atmospheric pressure at a specific
receptor, e.g. a brick wall or a storage
tank.

(Engineering)
5
Overpressure
This term is applied to the additional

internal pressure inadvertently arising
within equipment in excess of its design
pressure.
Fire
A combustion process which generates

heat, smoke or flame, or any
combination of these.
Upper and Lower
The concentrations of a flammable

substance in air or oxygen above or
below which, respectively, combustion
will not be sustained.
Flammability Limits
Fire Prevention
Measures adopted to prevent an outbreak

or escalation of fire in a particular
location.
Fire Protection
Design features, systems or equipment

(e.g. a sprinkler installation) which
minimise damage from fire in a
particular location.
Toxicity
The ability of a toxic (poisonous)

substance, when absorbed by living
tissue (either ingested or via the skin), to
cause injury or destroy life.
Carcinogen
A substance capable of causing cancer.
Asphyxiation
Danger to, or termination of, life due to a

deficiency of oxygen.

(Engineering)
6
Threshold and
Exposure Limits
There are numerous categories of these,

each specific to a time-related human
exposure to toxic substances. They are
used to regulate the proximity of workers
to materials of known toxic effects.
RELEASE AND DISPERSION
Release
The unintentional escape of a hazardous

substance or of energy (e.g. heat and/or
pressure) from a containment system,
usually due to equipment breakdown or a
control logic failure. There are various
types of release, including:
instantaneous release (i.e. of a

finite quantity of material)
continuous release (i.e. over a

prolonged period)
jet release
pinhole release.
Pool Evaporation
Pool evaporation of a spilled volatile

liquid is a calculable phenomenon.
Burning Rate
The burning rate of a flammable vapour

is also calculable.

(Engineering)
7
Flashing Flow
The behaviour, upon release, of a

superheated liquid, part of which
"flashes off" thereby creating a twophase flow of liquid and vapour/gas.
Flash Fraction
The portion of a superheated liquid that

will vaporize upon release to the
atmosphere.
Dispersion
The mode of integration and dilution,

usually in the environment, when a
hazardous fluid is discharged.
Gas Cloud
A generic term which is self-explanatory,

but which usually needs more precise
definition according to whether the
released material is of higher or lower
density than the surrounding air (i.e.
"dense" or "buoyant").
Plume
A gas cloud resulting from a continuous

release.
Weather Category
An index system denoting the extent of

air turbulence and thermal stability. It is
an influencing factor in the safe dispersal
of flammable or toxic discharges.

(Engineering)
8
ASSESSMENT TECHNIQUES AND CRITERIA
Loss Prevention
A systematic, often rigorous, procedure

aimed at the prevention of incidents, or
the estimation and minimising of their
consequences. All objectives and some
of the most useful techniques are
covered in this course.
Hazard Analysis
A term which should be confined to the

further and quantitative assessment of
hazards which have already been
identified and warrant examination of
size, frequency and consequences. This
approach is consistent with the accepted
philosophy that if a specific potential
hazard cannot be eradicated (e.g. by
designing-out), then it is necessary to
assess the level of risk likely to result.
Site Safety Assessment
The incisive appraisal of all facets of

equipment integrity and safe working
behaviour within a total work area (e.g.
a complete factory). This includes
management response to the maintenance
of acceptable safety standards. It is
invariably conducted at long intervals by
a competent, independent outside body or
consultant.

(Engineering)
9
Safety Audit
A critical review, at (typically) annual

intervals, of a selected part of a total
operating facility (e.g. a plant unit,
internal emergency team, fail-safe
control functions). It is usually
conducted internally.
Checklist
A relatively frequent, simple and rapid

endorsement of the satisfactory (but
usually visual) condition of plant items
and safety equipment.
Safety or Hazard
These are terms of wide interpretation,

sometimes implying site assessment
standards but more often confined to a
search for potential hazards.
Review/Survey
Safety Case

(Engineering)
A term, introduced more recently, which

describes a fully documented justification
for a proposed or existing hazardous
installation. It is sufficiently comprehensive to include selective quantitative
hazard analyses and emergency plans,
and is used in conjunction with the
Control of Major Accident Hazards
(COMAH) Regulations 1999.
10
Probability
A dimensionless number within the

range 0 1 representing:
(a) the probability of a particular
outcome from a specified event
(e.g. success or failure of an action)
(b) the probability of a particular state
or condition existing at a specified
time (e.g. equipment availability or
non-availability).
Reliability
Since "probability", in a safety context,

usually implies "probability of failure or
of a failed state", this term can be
regarded as the opposite; that is, the
probability that a required system or
individual will respond predictably
upon demand at the required point in
time under defined conditions.
Frequency
The number of occurrences of a

specified event over a time period of
interest (usually a year).
Failure
A term that is incorporated into several

specific applications, the meanings of
which are self-explanatory, e.g.

(Engineering)
failure mode
fail to danger fault
failsafe
11
Criterion
(plural: criteria)
Target Fatal Accident Rate

(Engineering)
common cause failure: failure of

more than one protective device or
system attributable to the same
cause. (This expression is of
particular interest to the processing
industries. For example, a failure of
the public electricity or cooling
tower supplies can cause a
shutdown of several facilities
simultaneously.)
common mode failure: resultant

identical failure patterns in
components or systems occurring
simultaneously due to a common
cause. For example, overheating of
a series of pumps.
A standard of safety performance to

which a measured performance may be
compared.
The number of deaths recorded or
predicted within a prescribed group in a
stated environment during 108 hours of
exposure. An example of this can be
obtained from calculations based on
1000 chemical plant operators working
for 40 hours per week for 50 weeks a
year, for a working lifetime of 50 years.
12
Fatal Accident Rate (F.A.R.)
The number of deaths recorded or

predicted per year.
Now do the first set of Self-Assessment Questions on pages 13 to 15.

Complete these questions before moving on to the next part of the lesson.

(Engineering)
13
________________________________________________________________________________________
SELF-ASSESSMENT QUESTIONS
________________________________________________________________________________________
1.
Match each term with one of the brief definitions given below.
1 Hazard
4 Fire prevention
7 Toxicity
2 Societal risk
5 Fire protection
8 Release
3 Explosion pressure
6 Residual risk
the ability of a poisonous substance to cause injury or death
the unintentional escape of a hazardous substance or of energy from a

containment system
a state or condition having the potential to cause a deviation from

uniform or intended behaviour which may result in damage to
property, people or the environment
the element of risk remaining after improvements have been made
design features, systems or equipment intended to minimise damage

from fire
measures intended to avert the outbreak of fire in a particular location
the pressure developed above atmospheric pressure resulting from an

explosion
risk to a group of people exposed to a major hazard
Your answer
A_____ B_____ C_____ D_____ E_____

F_____ G_____ H_____

(Engineering)
14
2.
Which of the following do you think best defines the term "risk" in an
industrial safety context:
(a) the element of risk remaining after all economically acceptable
improvements have been made
(b) a condition which is likely to cause damage to property
(c) the likelihood of an undesired event occurring which can be
expressed in terms of its size and severity
(d) the likelihood of an undesired event occurring which can be
expressed in terms of probability or frequency?
3.
Which of the following do you think best defines the term "loss
prevention":
(a) the total elimination of all potential hazards
(b) the assessing of how an individual or system will respond in the
event of a major incident
(c) a systematic procedure aimed at either the prevention of incidents or
the estimation and minimising of their consequences
(d) the quantitative assessment of hazards based on the notion that it is
not possible to eliminate all potential risks?

(Engineering)
15
4.
Give brief definitions for the following terms:

(a)
(b)
(c)
(d)
(e)
(f)
dispersion
plume
explosion
safety audit
criterion
upper and lower flammability limits.

(Engineering)
16
________________________________________________________________________________________
ANSWERS TO SELF-ASSESSMENT QUESTIONS
________________________________________________________________________________________
1.
A7
E5
B8
F4
2.
(d)
3.
(c)
4.
Check your answers against the definitions given in the lesson.

(Engineering)
C1
G3
D6
H2
17
________________________________________________________________________________________
CATEGORIES OF RISK
________________________________________________________________________________________
On page 3 we gave a brief definition of the term "risk". We will now look
more closely at the various categories of risk which could arise within an
engineering context.
There are two main categories of risk:
risks to life (site personnel and/or the general public)
risks to plant and profits.
RISKS TO LIFE
Risks to life can be sub-divided into two main groups.

1.
'Ordinary' Risks
These are common to all plants and arise principally from human activity
on or around the plant. Examples include:
falling off the structure

tripping over obstacles
impact by falling objects
contact with moving parts of equipment
physical operations such as lifting, scaffolding, flexing or carrying
out maintenance.
These risks are, of course, applicable only to plant personnel and not to
the general public.

(Engineering)
18
2.
'Process' Risks
These vary from plant to plant, the main classes of risk being:
fire or explosion due to emission of flammable material

emission of toxic or corrosive materials
discharge of hot scalding fluids
discharge of cold sub-zero fluids
blast effects or projectiles arising from equipment
rupture/fragmentation
asphyxiation risks.
Thus, process risks can arise only in the event of loss of containment of
the plant inventory and the general public as well as plant personnel can
be at risk.
RISKS TO PLANT AND PROFITS
These risks, which are concerned with damage to the plant, or with plant
unavailability for other reasons, can also be conveniently classified into two
main groups.
1.
Risks due to incidents where there is also a risk to life
The main risks falling into this category are some of the "process risks"
previously mentioned, which lead either to plant unavailability in their own
right (e.g. equipment rupture, fire, explosion) or to a plant shutdown pending
an enquiry (e.g. toxic release or other dangerous incidents).
Some of the "ordinary risks" to life previously mentioned may sometimes also
call for a plant shutdown pending investigations.

(Engineering)
19
2.
Risks due to incidents where there is no risk to life
The risks falling into this category are purely operational risks such as
equipment breakdown or unavailability

blockages of equipment or pipework
fouling of equipment.
Now attempt the second set of Self-Assessment Questions on page 20.

(Engineering)
20
________________________________________________________________________________________
SELF-ASSESSMENT QUESTIONS
________________________________________________________________________________________
These Self-Assessment Questions cover the material on pages 17 to 19.

5.
(i) If, as a result of identifying the likelihood of a particular hazard

occurring, a change to a system is decided upon, should you
immediately:
(a) record the hazard, and action taken, in the plant records for
future reference
(b) move on to search for other possible hazards
(c) re-examine the system in its changed condition for any
new problems which could thereby arise
or
(d) sign-off the study as completed?
(ii) Now list the four actions above in what you consider to be a logical
order.
6.
Categorize, as you see fit, the following events into the "risk table" or
matrix on page 21.
(a) falling into an excavation
(b) extinction by high winds of a flare-stack pilot flame
(c) a runaway fork-lift truck
(d) lighting a welding torch in a 'no-smoking' area

(Engineering)
21
(e) escape of refrigerant from an insulated storage vessel
(f) using scaffolding with toe-boards missing
(g) blockage of feed to an oil-fired heater due to cold climate
(h) ignition of flammable solvent by static discharge due to breakage of
earthing conductor
(i) leakage of ammonia from a high-pressure pipe joint
(j) bearing failure in an air compressor
Your Answer
'ORDINARY' RISK
'PROCESS' RISK
RISK
TO
LIFE
NO
RISK
TO LIFE

(Engineering)
22
________________________________________________________________________________________
ANSWERS TO SELF-ASSESSMENT QUESTIONS
________________________________________________________________________________________
5.
(i) (c)
(ii) (c), (b), (a), (d).
6.
'ORDINARY' RISK
RISK
TO
LIFE
(a) (c) (f)
NO
RISK
TO LIFE
(j)

(Engineering)
'PROCESS' RISK
(d) (e)
(h) (i)
(b) (g)
23
________________________________________________________________________________________
SUMMARY
________________________________________________________________________________________
This lesson has covered the more important aspects of safety language, a vital
step towards avoiding misinterpretations and misunderstandings which are
themselves potential sources of hazards.
You have also now been introduced to the disciplined manner in which causes
and effects of deviant occurrences need to be handled, and the scope of these
risks which prevail within industrial activities.
We are now able to consider how human awareness and response to hazard
identification may best be improved.

(Engineering)

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MODULE TITLE : SAFETY ENGINEERING

TOPIC TITLE : AN INTRODUCTION TO SAFETY ENGINEERING

Teesside University 2011

Published by Teesside University Open Learning (Engineering)

All rights reserved. No part of this publication may be reproduced, stored in a

At the end of this lesson you should be able to:

explain the meaning of some of the common terms used in industrial

understand how the term 'risk' is applied within an engineering

Teesside University Open Learning

Teesside University 2011

We strongly recommend that you memorise as many as possible of the terms in

Teesside University Open Learning

Teesside University 2011

A GLOSSARY OF INDUSTRIAL SAFETY TERMINOLOGY IN COMMON AND

A state or condition having the potential

The time-related, or location-related

This includes value judgements

Teesside University Open Learning

Teesside University 2011

The risk to a group of people exposed to

The element of risk remaining after all

A mechanically, or chemically, generated

A term used to quantify the effects of an

Teesside University Open Learning

Teesside University 2011

This term is applied to the additional

A combustion process which generates

Upper and Lower

The concentrations of a flammable

Measures adopted to prevent an outbreak

Design features, systems or equipment

The ability of a toxic (poisonous)

A substance capable of causing cancer.

Danger to, or termination of, life due to a

Teesside University Open Learning

Teesside University 2011

There are numerous categories of these,

RELEASE AND DISPERSION

The unintentional escape of a hazardous

instantaneous release (i.e. of a

continuous release (i.e. over a

Pool evaporation of a spilled volatile

The burning rate of a flammable vapour

Teesside University Open Learning

Teesside University 2011

The behaviour, upon release, of a

The portion of a superheated liquid that

The mode of integration and dilution,

A generic term which is self-explanatory,

A gas cloud resulting from a continuous

An index system denoting the extent of

Teesside University Open Learning

Teesside University 2011

A systematic, often rigorous, procedure

A term which should be confined to the

Site Safety Assessment

The incisive appraisal of all facets of

Teesside University Open Learning

Teesside University 2011

A critical review, at (typically) annual

A relatively frequent, simple and rapid

These are terms of wide interpretation,

Teesside University Open Learning

A___ B_ C_ D_ E___