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PEC Islamabad UET Lahore Dr. Shahid Naveed 23. April 2008 / Dr. Ing Naveed Ramzan 2

Crossing a road Driving a car Riding a motor bike Air travel

Climbing a Ladder Using an electrical appliance Using a knife Using a garden tool

Activities in Daily Li fe

Activities in Daily Life have some kind of safety risksCan you list the risks involved in each case.
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Climbing a scafoulding Using a hammer or a wrench Working in a loud sounds of machines Changing a pipe connection Working on a lathe machine Switching on/off an electric motor Firing a furnance Releasing gas from a cylinder Unloading a truck

Routine Activities i n Industry

Routine Activities in industry have safety risksCan you list the risks involved in each case.

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Chemical Industry ....High pressure High temperature,

high through put with productslike chemicals, paints, fuels, etc.

Mechanical industry . Assembly lines, machine parts, etc.Electrical Industry ..Power generation, transmission,

developments, electronics , etc.Civil Works ...Buildings, mega structures,

roads, bridges , etc.Petroleum Industry ..Drilling, processing, transmission of

hydrocarbon fluids , etc.Mining Industry ..Mining of materials like coal and

minerals, ore beneficiation , etc.Metallurgical Industry.. Processing of metals, alloys and

production of steel , etc.

Imagine the safety risks involved in all these industries!

Broad Classification of Industry

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Some Statistics

Activity FAR per 10 8 Individual risk ofdeath per personper year x 10 8

Travel

Air 0.02

Train 3-5 0.03

Bus 4 2

Car 50-60 2

Occupation

Chemical industry 4 0.5

Manufacturing 8 -------

Shipping 8 9Coal mining 10 2

Agriculture 10 -------

Staying at Home 1-4 -------

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} An Incident is an unpleasant event thatmay lead to an accident.

} A " near miss " is a form of an accident thatdoes not result in injury or property damage.

} Accident is an unplanned, undesiredevent which may or may not result in injury

or property damage, that interferes with thecompletion of an assigned task.

Basic Definitions

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Link amongst incide nt, near-miss, accident

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} Unsafe Conditions - hazardous conditions orcircumstances that could lead directly to anaccident

} Unsafe Acts - occurs when a worker ignores oris not aware of a standard operating procedure orsafe work practice designed to protect the workerand prevent accident

} Inherent nature of manufacturing facility/machine

Why accidents take place?

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} Lack of guarding on machinery} Defective tools or equipment} Crowding workers into one area} Inadequate alarm systems

} Fires & explosions} Poor housekeeping} Hazardous atmospheres} Excessive noise} Inadequate lighting

Typical Unsafe Con ditions

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}Operating equipment/machinery without permission} Defeating safety devices

} Using defective equipment} Using the wrong tool for the job} Not using personal protective equipment

} Incorrect lifting techniques} Working while intoxicated} Horseplay

Typical Unsafe Acts

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Safety and Risk

Concept of Safety.

Concept of Risks

Any industrial activity without a threat to life, assets,environment etc is the responsibility of the engineers. Allsuch work assignments have to ensure safe conditions.

Safety is a relative term. It has been categorized throughmany terms e.g. process safety, occupational, inherentsafety.

No known activity in the world can be rated as absolutely safe .There is always some kind of risk involved.The risks are often categorized as high , low ,

acceptable .In industry managing the risks with appropriateprocedures and defense measures is very important.

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Industrial Safety

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Safety Concept, Safe ty shells
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Safety Concept, Safe ty Shells

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A casual definition of Risk isRisk = P * S

Where P is the probability of occurrence & S is the severity of an event

Another casual definition is

Risk = [ (I) * (P)] - (D)Where f(I) is intrinsic risk; f(P) is presence factor defined in terms of thequantity of substance; and f(D) is the defense factor to safeguard thehappening of the event.

Risk = { hazard, exposure, safeguard}

Definition of Risk

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Risk = frequency * consequence

Definition of Risk

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ExtremeFrequency

HighFrequency

ModerateFrequency

Low

Frequency

Negligible Average Critical Severe

Hazard Effects Category

D

egreeofCau

sativeHazard

Conceptual Categori es of Risk Measures

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Safety vs Risk

Risk is measure of Safety

Risk and safety are inverse of each other

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To ensure safety for ..

} Safety for Personal} Safety for Equipment

} Safety for Community} Inherent Safety

Take measures at design level, duringoperation, training and adopting defensemechanisms

Why Invest in Safet y?

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UK, USA Acceptabl e Risk Criteria

UK Health and Safety Executive Criteria:

FAR (Fatality Accident Rate)

Number of fatality in life time working in an industry

FAR = (Number of fatalities)*10 8 /(Total hours worked by

all employees during period covered)

Acceptable FAR value 1.0

US EPA

For carcinogens/or other events

a lifetime risk of 1 in million (1.0E-06) is defined as acceptable

For non-carcinogens

A hazard index less than 1.0 is defined acceptable

Hazard indexHazard index Dow index, Mond indexDow index, Mond index

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Frequencyofevent 1.0E-05

1.0E-081.0 100

Number of fatalities10

1.0E-06

Unacceptable region

Conditional

Acceptable

Dutch Acceptable R isk Criteria

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ALARP} As Low As Reasonable Practicable (ALARP)

1.0E-09

1.0E-07

1.0E-05

1.0E-03

1.0E-01

Individualrisk(IR)

Unacceptable region

The ALARP

Negligible risk

Broadly acceptable region

The lower the risk less proportionately, it isnecessary to spend to reduce it. This concept ofdiminishing proportion is shown by the triangle

Tolerable only if risk reductionIs impracticable or cost isgrossly disproportionate tothe improvement gained

Acceptable Risk Cri teria - ALARP

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How much to Inves t in Safety?

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Safety-Cost Pyrami d

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Safety and Cost O ptimization
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Example I : Identify th e Risks

Assess the risk for a simple

job to gain assess to a faulty

pressure transmitter using a

portable ladder

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Example II : Indentify t he Risk

HAZARDS1.

2.

3.

4.

5.

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Possible Identifications !!

Your list probably includes the

following:

-- The Ladder may slip

-- Ladder may break

-- I might fall off

You may have included less obvious

hazards such as

-- the pressure transmitter might

leak-- drop of tools on someone heads

-- burning myself on steam tracing

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Simple Example: Ident fy the Hazards

In drawing up the list of hazards one may list both hazards and theeffects of the hazards

NO ACTIVITY IS ABSOLUTE SAFE

-- The ladder slipping is hazard

-- twisting your ankle might be an effect of this hazard

Similarly

-- exposed steam tracing would be hazard

-- burning yourself on it is an effect of the hazard

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KEY QUESTI ONS TO ASK

v What could go wrong

v What will happen if it does

v How serious is the effect

v How likely is it to happen

It will also help us decide whether

-- it is safe to carry on

-- the risk is acceptable

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Lectures to follow today} Hazard Identification in Process industry} Frequency and Consequence Estimation
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