Day 2 Hazard Identification, Assesment & Control

HAZARDS IDENTIFICATION, ASSESSMENT AND
CONTROL
(BUREAU OF WORKING CONDITIONS)
HAZARDS
Any existing or potential condition in the workplace

that, by itself or interacting with other variables,
can result in death, injuries, property damage and
other losses.
Hazards are grouped into two broad categories, namely:
a) Those dealing with safety and injuries.

b) Those dealing with health and illnesses.

HAZARDS ASSESSMENT
Definition:
The systematic use of all available
information to identify hazards in order to
analyze and evaluate their overall effect
on people, property and the environment.

HAZARDS ASSESSMENT
Purpose:
Uncover overlooked hazards
Locate new hazards that developed
Determine essential factors or requirements for
specific processes or operations
Modify processes or operations if needed
Identify situational hazards
Identify human causal factors
Identify exposure causal factors
Identify physical causal factors
Determine appropriate monitoring methods

OPERATIONAL AND MANAGEMENT SYSTEMS TO
UNCOVER HAZARDS
(Hazards Analysis)
May have been overlooked in the layout of the plant or the

building and in the design of machinery, equipment and
processes;
May have been developed after production started;
May exist because original procedures and tasks were

modified.

HAZARDS ASSESSMENT
Benefits:
Identifies hazardous conditions and potential
accidents;
Provides information with which effective control

measures can be established;
Determines level of knowledge and skill as well as

physical requirements workers need to execute
specific tasks;
Discovers and eliminates unsafe procedures,

techniques, motions, positions and actions.
HAZARDS ASSESSMENT
Processes, Tasks, & Operations to be Analyzed

Frequency of Accidents
New or Altered
100 Equipment,
50 Processes and
0 Operations
1st 4th
Qtr Qtr
Severity of Injury Potential for Injury
Excessive Material Waste or

Damage to Equipment
PROCESSES FOR AN EFFECTIVE
HAZARD CONTROL PROGRAM
Hazard identification and evaluation
Ranking hazard by risk
Management decision making
Establishing preventive and corrective measures
Monitoring
Evaluating program effectiveness

SOURCES OF WORKPLACE HAZARD INFORMATION
Those who are familiar with plant operations and the

hazards associated with them;
Hazard information from manufacturers of industrial

equipment, tools and machinery acquired by the company;
From accident and old inspection reports (either internal or

external);
Hazard analysis and thorough knowledge of the demands of

a particular task;
Material safety data sheets;
Technical and Professional Associations.

HAZARDS IDENTIFICATION
Components:
Information about the industry

Information on working conditions
Information on materials and substances
Information about the machine/equipment
Other items to be evaluated

COMPONENTS OF HAZARDS IDENTIFICATION
Information about the industry:

• Workers involved
• History of accidents/illnesses and causes
• Systems of management control

Information on working conditions:
Workplace and environment
Construction of structure and facilities
Processes, operational methods and practices

Information on materials and substances:

Quantity of materials/substances involved
Substance/material data (chemical and physical)
Safety-related data (ex: explosive limit, flash point, etc.)
Toxicology related data ( toxicity, effects, etc.)
Threshold limit values

Information about the machine and/or equipment:
Design and construction
Installation and maintenance
Protective and safety devices

Other items to be evaluated:

Environmental factors Elevators and materials lift
Hazardous supplies and materials Working surfaces,
Production and related equipment platforms, etc.
Power source equipment Material handling
Electrical equipment equipment
Hand tools Transportation equipment
Personal protective equipment Warning and signaling
Personal service & first-aid facilities devices
Fire protection and control facilities Containers, storage
Walkways and roadways facilities, etc.
Structural openings and
other building structures
HAZARD IDENTIFICATION
INPUT PROCESS OUTPUT
Databases
Previous work
Experience
PROCESS OF
Site visits HAZARD Failure cases
Plant facilities IDENTIFICATION (Accidents)
Safety systems
Assumptions
PROCESS OF HAZARD IDENTIFICATION
Design, Facilities, Safety Systems,

Procedures, Assumptions
Establish Knowledge Base
Perform Hazard Review
Generate Failure Cases
Ranking/Screening of Failure Cases
Cause and Frequency Analysis

Consequence Evaluation

Identify, locate and access sources
of data, information and knowledge
(accident databases, previous reports,
Establish Knowledge Base general literature, reference
documents, other agencies, experts
Generate Failure Cases Knowledge base should:

-give a comprehensive overview
of available knowledge.
Ranking/Screening of Failure Cases -allow quick location and retrieval
of knowledge.
- allow efficient screening of the
Cause and Frequency Analysis sources of knowledge and their
Consequence Evaluation particular relevance for subjects
studied.
BUREAU OF WORKING CONDITIONS)

Use the accumulated knowledge
Procedures, Assumptions to tailor make (produce checklists,
questions, etc.) a hazard review
Establish Knowledge Base of the facilities and operations.

Hazard review output:
Generate Failure Cases
- hazards in the form of coarse
areas or groups of failures/
Ranking/Screening of Failure Cases accident types which should be
reviewed/studied further.
Cause and Frequency Analysis - factors which are important for

Consequence Evaluation mitigation or propagation of a
failure/accident.

Establish Knowledge Base

Conversion of a range of
possible accidents into a
Generate Failure Cases manageable set of discrete
accidents, using examples of
previous accidents,
Ranking/Screening of Failure Cases engineering judgement and
accumulated knowledge.
Cause and Frequency Analysis

Establish Knowledge Base Evaluation of the

frequency and
consequence of each
Perform Hazard review failure case in order to its
contribution risk
Generate Failure Cases (e.g. negligible, minor,
relevant, serious, or major)
and in order to
Ranking/Screening of Failure Cases screen out insignificant
hazards and put emphasis
on important
Cause and Frequency Analysis ones.
RANKING HAZARD BY RISK
Consequence Category
Probability Category
Exposure Category
HAZARD CONSEQUENCE CATEGORIES
Consequence Explanation
Rating (Points)
Catastrophic – may cause death or loss of a
4 facility.
Critical – may cause severe injury, severe

3 occupational illness, or major property damage.
Marginal – may cause minor injury or minor

2 occupational illness resulting in lost workday(s)
or minor property damage.
Negligible – probably would not affect

1 personnel safety or health, thus less than a lost
workday, but nevertheless is in violation of
specific criteria.
RANKING HAZARDS BY RISK
Purpose:
To address hazards according to the principle of

“worst first”. It provides a consistent guide for
corrective action, specifying which hazardous
conditions warrant immediate action, which
have secondary priority and which can be
addressed in the future.

HAZARD PROBABILITY CATEGORIES
Probability Rating Explanation

(Points) (Qualitative Estimate)
4 Likely to occur immediately or

within a short period of time when
exposed to hazard
3 Probably will occur in time
2 Possible to occur in time
1 Unlikely to occur

EXPOSURE CATEGORY
After estimating both

consequence and probability,
the next and final step is to
estimate worker exposure to
the hazard. The number of
persons regularly exposed to
the hazard must be evaluated
to determine how many
workers would ordinarily be
exposed to the hazard.

HAZARD EXPOSURE CATEGORIES
Exposure Rating Explanation

(Points)
Greater than 50 different persons
4 regularly exposed to the hazard.
From 10-49 different persons

From 5 to 9 different persons

Less than 5 different persons


RISK ASSESSMENT
*RAC No. Risk Rating Title

(Points)
1 11 – 12 Critical
2 8 – 10 Serious
3 6–7 Moderate
4 4–5 Minor
5 3 Negligible
Risk Rating = Consequence rating+Probability rating+ Exposure rating
RAC – Risk Assessment Code; Rating: min. = (3 points), max. = (12 points)
RISK PRIORITY RATING
Risk Title Correction Priority

Rating
11 – 12 Critical E = Emergency
8 – 10 Serious A = 1 week
Moderate B = 1 month
6–7
C = 3 months
4–5 Minor
D = 6 months
3 Negligible
MANAGEMENT DECISION MAKING
Providing management with full and accurate

information,including all possible alternatives, so
managers can make intelligent decisions concerning
loss control. Such alternatives will include
recommendations for:
Training and education

Environmental controls
Better methods and procedures
Equipment repairs or replacements
Re-design the workplace or its components
ESTABLISHING PREVENTIVE
AND CORRECTIVE MEASURES
General Hazard Controls:
Administrative Controls
Engineering Controls
Personal Protective Equipment

ADMINISTRATIVE CONTROLS
Personnel
Management
Monitoring
Limiting worker exposure
Measuring performance
Training and education
Housekeeping and maintenance
Purchasing

ENGINEERING CONTROLS
Isolation of source
Lockout procedures
Design
Process or procedural changes
Monitoring and warning equipment
Chemical or material substitution
PERSONAL PROTECTIVE EQUIPMENT
PURPOSE:
To reduce exposures while other controls are

being implemented.
To provide protection during activities such as

maintenance and repairs when controls are not
feasible.
To provide protection during emergencies.
To supplement other controls.

3 MAJOR AREAS WHERE HAZARDOUS CONDITIONS
CAN BE CONTROLLED OR ELIMINATED
To attack a hazard at its source.
To control the hazard along its path.
To direct control efforts at the receiver, the worker.
PATH
SOURCE RECEIVER

MONITORING
To provide assurance that hazard controls are

working properly;
To ensure that modifications have not so altered the

workplace that current hazard controls can no
longer function adequately;
To discover/locate new or previously undetected

hazards and assess effectiveness of existing
controls.
COVERAGE:
•Inspection
•Industrial hygiene testing
•Medical surveillance
EVALUATING PROGRAM EFFECTIVENESS
The final process in hazard

control is to evaluate the
effectiveness of the safety and
health program. Evaluation
involves answering the
following questions:
What is being done to locate and

control hazards?
What impact are the benefits

having on improving operational
efficiency and effectiveness?
SAMPLE
RISK ASSESSMENT MATRIX

Dept. No. of Hazards R Risk Correction Consequence Probability Exposure Recommended STATUS/
/Area Workers identified A Rating Priority Rating Rating Rating Corrective Action Remarks
Exposed C Rating
Prepared / Inspected by: ___________________________ Date: ____________________ Time:____________
Checked / Verified by: ____________________________ Date: ___________________

BUREAU OF WORKING CONDITIONS

Day 2 Hazard Identification, Assesment & Control

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HAZARDS IDENTIFICATION, ASSESSMENT AND

Any existing or potential condition in the workplace

Hazards are grouped into two broad categories, namely:

a) Those dealing with safety and injuries.

(BUREAU OF WORKING CONDITIONS)

(BUREAU OF WORKING CONDITIONS)

(BUREAU OF WORKING CONDITIONS)

May have been overlooked in the layout of the plant or the

May have been developed after production started;

May exist because original procedures and tasks were

(BUREAU OF WORKING CONDITIONS)

Provides information with which effective control

Determines level of knowledge and skill as well as

Discovers and eliminates unsafe procedures,

Processes, Tasks, & Operations to be Analyzed

Severity of Injury Potential for Injury

Excessive Material Waste or

Hazard identification and evaluation

Ranking hazard by risk

Management decision making

Establishing preventive and corrective measures

Evaluating program effectiveness

Those who are familiar with plant operations and the

Hazard information from manufacturers of industrial

From accident and old inspection reports (either internal or

Hazard analysis and thorough knowledge of the demands of

Material safety data sheets;

Technical and Professional Associations.

Information about the industry

(BUREAU OF WORKING CONDITIONS)

Information about the industry:

• History of accidents/illnesses and causes

• Systems of management control

Information on working conditions:

Workplace and environment

Construction of structure and facilities

Processes, operational methods and practices

Information on materials and substances:

Substance/material data (chemical and physical)

Safety-related data (ex: explosive limit, flash point, etc.)

Toxicology related data ( toxicity, effects, etc.)

Threshold limit values

Information about the machine and/or equipment:

Design and construction

Installation and maintenance

Protective and safety devices

Other items to be evaluated:

INPUT PROCESS OUTPUT

Design, Facilities, Safety Systems,

Establish Knowledge Base

Perform Hazard Review

Generate Failure Cases

Ranking/Screening of Failure Cases

Cause and Frequency Analysis

Design, Facilities, Safety Systems,

Generate Failure Cases Knowledge base should:

Design, Facilities, Safety Systems,

Perform Hazard Review

Cause and Frequency Analysis - factors which are important for

Design, Facilities, Safety Systems,

Establish Knowledge Base

Perform Hazard Review

Prepared / Inspected by: _______________ Date: Time:

Checked / Verified by: __________ Date: _