1

INDUSTRIAL SAFETY, HEALTH

AND ENVIRONMENT

Course Learning
Outcomes(CLO)
After completing this subject, the students
should be able to :

Explain clearly the industrial safety, occupational

health hazards in workplaces environment.
Apply potential occupational health hazards in
workplace.
Conduct basic safety assessments using methods
and tools that they have learned.
Measure and demonstrate a safe, feasible
occupational health and conducive working
environment.

Assessments
3

Case Study 15% (CS1, CS2 & CS3)

Lab 10% (Lab 1 & Lab 2)
Project 15%
Test 1 10%
Test 2 10%
Final Exam 40%

INDUSRTIAL SAFETY, HEALTH

AND ENVIRONMENT

CHAPTER 1 : INTRODUCTION TO
INDUSTRIAL SAFETY, HEALTH & HAZARD
ANALYSIS

WHY NEEDS TO STUDY

ISHE?
Any ideas?

Occupational injuries are most

common disaster in an industrial
setting

Learning Outcomes
7

Define clearly the terms

occupational safety and health,
workplace accidents and hazards
Name two approaches of hazards
analysis
Describe the importance of Risk
Assessment

1.1 What is OSH

8

Occupational Safety and Health (OSH)

A cross-disciplinary area
concerned with protecting the
safety, health and welfare of
people engaged in their work
environment.

1.1 What is OSH

9

As a secondary effect, OSH may also

To protect co-workers, family

members, employers,
customers, suppliers, nearby
communities, and other
members of the public who are
impacted by the workplace
environment.

1.1 What is OSH

10

many

governments realize that

poor occupational safety and
health performance results in cost
to the State.

e.g.

through social security

payments to the incapacitated,
costs for medical treatment, and
the loss of the employability of
the workers.

1.1 What is OSH

11

OSH standards are, generally

speaking, further reinforced in both
civil law and criminal law;

it is accepted that without the

extra encouragement" of
potential regulatory action or
litigation, many organizations
would not act upon their
implied moral obligations.

12

In Malaysia, OSHA 94 is an Act

which provides the framework to
secure the safety, health and
welfare among all Malaysian
workforce and to protect others
against risks to safety or health in
connection with the activities of
persons at work.

The aims of OSHA are:

13

1. To secure the safety, health and welfare of persons at

work against risks to safety or health arising out of the
activities of persons at work.
2. To protect person at a workplace.
3. To promote an occupational environment.
4. To provide the means whereby the associated
occupational safety and health legislation may be
progressively replaced by a system of regulations.

Workplace accident
1.2 Definition Of Workplace Accidents

Awork accident,workplace
accident,occupational accident,
oraccident at workis a "discrete
occurrence in the course of work"
leading to physical or mental
occupational injury.[1]

European Commission, European Statistics on Accidents at Work (ESAW)

, Methodology, 2001

1.2 Definition Of Workplace

Accidents
15

Work injuries can be classified by the

type of accident from which they
resulted.
The most common causes of work
injuries are:

Exposure to extreme temperatures.

Electric shock. ( Chpter 3 : Abu)
Exposure to hazards of noise and
vibration. (Chapter 4 : Faizol & Safiuddin)
Suffered of toxic substances and airborne

1.2 Definition Of Workplace

Accidents
16

Ergonomical disorders such as

overexertion and compression (Chapter 6 :
Imran & Fikri)
Impact accidents (Chapter 7 : Syazwana &
shahida)
Mechanical injuries ( Chapter 8 : Ikmal,
Nazmi & Faiz)
Fires (Chapter 9 : Atifin)

1.3 Hazard Analysis Method

17

Hazard is an inherent physical or

chemical characteristic that has
the potential for causing harm to
people, the environment, or
property
Hazards are intrinsic to a material, or
its conditions of use.

1.3 Hazard Analysis Method

18

Examples
Hydrogen sulfide toxic by
inhalation
Gasoline flammable
Moving machinery kinetic energy,
pinch points

Some examples of HAZARD

19/49

1984

Bhopal, India Toxic Material

Released

2,500
immediate
fatalities;
20,000+
total
Many other
offsite
injuries

HAZARD:
Highly Toxic
Methyl Isocyanate

Some examples of HAZARD

20/9

1984 Mexico City, Mexico Explosion

300 fatalities
(mostly offsite)
$20M damages

HAZARD:
Flammable LPG
in tank

Some examples of HAZARD

21/49

1988 Norco, LA Explosion

7 onsite fatalities, 42 injured

$400M+ damages

HAZARD:
Flammable
hydrocarbon vapors

Some examples of HAZARD

22/49

1989 Pasadena, TX Explosion and Fire

23 fatalities, 130 injured; damage $800M+

HAZARD:
Flammable
ethylene/isobutane
vapors in a 10 line

1.3 Hazard Analysis Method

23

There are two approaches to hazard

analysis:
1. Preliminary hazard analysis
2. Detailed hazard analysis

I.3.1 Preliminary Hazard Analysis

(PHA)
24

A preliminary hazard analysis is

conducted to identify potential hazards
and prioritize them according to the:
(1) likelihood of an accident or injury
being
caused by the hazard;
(2) severity of injury, illness or property
damage
that could result if the hazard caused

I.3.1 Preliminary Hazard Analysis

(PHA)
25

Analysis based on applying prior

experience or knowledge of a hazard
or failure to identify future hazards,
hazardous situations and events that
can cause harm
In estimating their probability of
occurrence for a given activity, facility,
product or system.

I.3.1 Preliminary Hazard Analysis

(PHA)
26

How to perform?
Identification of the possibilities that
the risk event happens
Qualitative evaluation of the extent of
possible
injury or damage to health that could
result
Identification of possible remedial
measures

PHA Steps
27

1.
2.

3.

4.

5.

Identify known hazards

Determine the cause(s) of the
hazards
Determine the effects of the
hazards
Determine the probability that an
accident will be caused by a hazard
Establish initial design and
procedural requirements to
eliminate or control hazards

Sample of PHA form

28

1.3.2 Detailed Hazard Analysis

29

Typically, a preliminary hazard

analysis is sufficient. However, in
cases where the potential exists for
serious injury, multiple injuries, or
catastrophic illness, a detailed
hazard analysis is conducted.
A number of different methods can
be used for conducting detailed
analyses.

1.3.2 Detailed Hazard Analysis

30

The most widely used of these are as

follow:

Failure mode and effects analysis (FMEA)

Hazard and operability review (HAZOP)
Human error analysis (HEA)
Fault tree analysis (FTA)
Risk analysis (RA)
Technic of operation review (TOR)

31/49

FMEA Failure Modes, Effects

Analysis

FMEA is a very structured and reliable

method for evaluating hardware and
systems.
Easy to learn and apply and approach
makes evaluating even complex systems
easy to do.
Can be very time-consuming (and
expensive) and does not readily identify
areas of multiple fault that could occur.
Not easily lent to procedural review as it
may not identify areas of human error in

FMEA Failure Mode

32

Keywords

Rupture
Crack
Leak
Plugged
Failure to open
Failure to close
Failure to stop
Failure to start
Failure to continue
Spurious stop

Spurious start
Loss of function
High pressure
Low pressure
High temperature
Low temperature
Overfilling
Hose bypass
Instrument bypassed

FMEA on a Heat Exchanger

Failure
Mode

Causes of Symptoms Predicted

Failure
Frequency

Tube
rupture

Corrosion
from fluids
(shell side)

H/C at
higher
pressure
than
cooling
water

Impact

Frequent Critical
has
could
happened cause a
2x in 10 yrs major
fire

Rank

items by risk (frequency x impact)

Identify safeguards for high risk items
33/49

34/49

FMEA Failure Modes, Effects

Analysis
Manual analysis to determine
the consequences of component,
module or subsystem failures
Bottom-up analysis
Consists of a spreadsheet where
each failure mode, possible
causes, probability of occurrence,
consequences, and proposed
safeguards are noted.

35

Failure Modes & Effects

Analysis (FMEA)

Many organizations use FMEA as a

reliability analysis tool separate from
safety
A safety version of FMEA is:

FMECA Failure Modes & Effects Criticality

Analysis

FMEA is used in DoD, NASA, DoE, Private

Industry
See Form on next slide

36

HAZOP
37/49

Hazard and Operability

Analysis

Identify hazards (safety, health,

environmental), and

Problems which prevent efficient

operation

EXAMPLES OF HAZOP
38/49

1.

Choose a vessel and describe intention

2.

Choose and describe a flow path

3.

Apply guideword to deviation

Guidewords Include None, More

Of, Less Of, Part Of, More Than,
Other Than, Reverse

EXAMPLES OF HAZOP
39/49

Deviations Are Expansions, Such As

No Flow, More Pressure, Less
Temperature, More Phases Than
(There Should Be),

40

HAZOP
41/49

4.

5.

6.

7.
8.
9.

Can deviation initiate a hazard of

consequence?
Can failures causing deviation be
identified?
Investigate detection and
mitigation systems
Identify recommendations
Document
Repeat 3-to-8, 2-to-8, and 1-to-8

HAZOP
42

43/49

Loss of Containment
Deviations
Pressure too high
Pressure too low (vacuum)
Temperature too high
Temperature too low
Deterioration of equipment

Fault-Tree Analysis (FTA)

44

Developed in 1962 at Bell Telephone

Labs
Uses Boolean Logic to evaluate events
Build a tree structure

Fault Tree Analysis

45

At the top is a principal or undesired

event
Broken down into contributing factors
Further subdivided into event causes
Preliminary hazard analyses or other
analyses may identify major undesirable
events
After the tree is constructed, qualitative
or quantitative analysis is performed

Symbols commonly used in

FTA.

46

Human Error Analysis (HEA)

47

Human Error Analysis (HEA) is used to

predict human error, not to review what
has occurred.
Two approaches to HEA can be effective:
(1) Observing employees at work and
noting
hazards (the task analysis approach.
(2) Actually performing job tasks to get a
firsthand
feel for hazards.

Technic of Operation Review (TOR)

48

Technic of operation review (TOR) is an

analysis method that allows supervisors
and employees to work together to
analyze workplace accidents, failures,
and incidents.
It answers the question "Why did the
system allow this incident to occur?" Like
FMEA and HAZOP, this approach seeks to
identify systemic causes, not to assign
blame

Risk Analysis (RA)

49

Risk analysis is an analytical

methodology normally associated
with insurance and investments.
However, risk analysis can be used
to analyze the workplace, identify
hazards, and develop strategies for
overcoming these hazards. The risk
analysis process focuses on two key
questions:
How frequently does a given event

1.4 Risk Assessment

50

Risk assessment in this context is the process of

quantifying the level of risk associated with the
operation of a given machine.' It should be a
structured and systematic process that answers
the following four specific questions:
How severe are potential injuries?
How frequently are employees exposed to the
potential hazards?
What is the possibility of avoiding the hazard if it
does occur?
What is the likelihood of an injury should a safety
control system fail?

SUMMARY
51

1.

2.

A hazard is a condition or combination

of conditions that, if left uncorrected,
may lead to an accident, illness or
property damage
Hazard analysis is a systematic process
for identifying hazards and
recommending corrective action. There
are two approaches to hazard analysis;
preliminary and detailed.

SUMMARY
52

3.

4.

A preliminary hazard analysis involves

forming an ad hoc team of experienced
personnel who are familiar with the
equipment, material substance, and
process being analyzed.
Experience and related expertise are
critical in conducting a preliminary
hazard analysis.

53

ANY QUESTIONS?

Exercise
54

1.

2.

3.

Give definition of occupational safety

and health.
What are the common causes of work
injuries. State five (5) of them.
Detailed hazard analysis involves the
application of analytical, inductive, and
deductive methods. Give five (5)
methods of detailed hazard analysis.

55

Give definition of occupational safety

and health.

A cross-disciplinary area concerned

with protecting the safety, health
and welfare of people engaged in
their work environment.

56

What are the common causes of work

injuries. State five (5) of them.

Exposure to extreme temperatures

Electric shock
Exposure to hazards of noise and
vibration
Suffered of toxic substances and
airborne contaminants
Ergonomical disorders such as

57

Give five (5) methods of detailed hazard

analysis.
Failure Mode and Effects Analysis (FMEA)
Hazard and Operability Review (HAZOP)
Human Error Analysis (HEA)
Fault Tree Analysis (FTA)
Risk Analysis (RA)
Technique of Operation Review (TOR)