000 HSE - CH 1 - Overview PDF

Industrial Safety &
Risk Assessment
HSEM HSE management View – Part I - Dr. Attia Gomaa - 2007 1/Ch. 1
Why HSE & RA?
Future
Current Brain-storming Targets
not
Blame-storming
• Pollution
• Accidents 1. HSE & Risk Ass. Tools
2. Awareness programs
3. HSE Systematic approach
"In the name of Allah The All Merciful The most Merciful“ - Useful Science for the Sake of God
Industrial Safety & Risk Assessment for Engineers

Dr. Attia Hussien Gomaa
attiagomaa@yahoo.com
1) American Unv. in Cairo (AUC) – Eng. Service.
2) RCM & HSE Consultant for Industrial Companies.
3) Head of Industrial Eng. Department- Fayoum University. Safety
Course Outline: First
• Introduction
• Chapter 1: Importance of Industrial Safety & Risk Assessment
• Chapter 2: HSE Management
• Chapter 3: Problem Solving Techniques
• Chapter 4: Risk Assessment
• Chapter 5: Global Performance Evaluation
• Chapter 6: Hazard Classification & Hazard Control
• Chapter 7: Job Hazard Analysis (About 70 Real Case Studies)
• Chapter 8: Risk Based Inspection (RBI) Overview (API 580)
• Chapter 9: Reliability Centered Maintenance Overview (RCM)
• Chapter 10: International Standards Overview (ISO 14001 & OHSIS 18001)
Let us be a Team Approach
Your Participation
Will Make This Presentation
More Applicable & Successful
‫”ظهر الفساد في البر والبحر بما كسبت أيدي الناس“‬
‫”المسلم من سلم الناس من لسانه ويده“‬
‫”عدوك العالم خير من صديقك الجاهل“‬
‫”إماطة األذي عن الطريق صدقة“‬
‫”معظم النار من مستصغر الشرر“‬
‫”من رأي منكم منكرا فليغيره“‬
‫”إذا عمل أحدكم عمال فليتقنه“‬
‫”وال تلقوا بأنفسكم الي التهلكة“‬
‫”إتقي شر من تجاوزت معه“‬
‫”من أعمالكم سلط عليكم“‬
‫”إعقلها وتوكل“‬
‫‪HSEM‬‬ ‫‪HSE management View – Part I - Dr. Attia Gomaa - 2007‬‬ ‫‪5/Ch. 1‬‬
“Safety first”
“Safety is a value”
“Safety is our business”
“If it is not safe, make it safe”
“Safety is everyone responsibility”
“Believe that you can make a difference”
“There is nothing permanent except change”
“Any worker is one of the following:
Trouble-maker, Reactive, Preventive, or Proactive”
“Try to be Proactive”
"Never cut what you can untie"
“Don’t Fix the problem, fix the system”
“Do not do more than one critical job at a time”
“Fire can kill you but the risk assessment can kill the Fire“
Systematic Approach for Critical Systems
Process &
Design Performance HSE
& HAZOP & Risk
Critical
PMIS Maintenance
System or Project
Critical
Inventory Cost Resources
Control Analysis
Process
Inputs & Outputs
HSE
&
RCA
Design
& Critical
HAZOP Equipment
Cost
&
Resources
Maintenance
Engine Overhaul: Replace : Repair
Item Replace Repair
(New) (010,020,030)
Cost ratio 3 1
Duration ratio 1 3
Reliability ratio 2 1
MTBF ratio 2 1
CM/PM ratio 1 2
Performance ratio 2 1
Manpower ratio 1 2
Job Safety Analysis Medium High
Equipment Criticality Critical Normal
(HSE, Process, Standby) (with standby)
In normal conditions: Repair policy if (repair cost <40%Replace cost)

Turbine Overhaul: Replace : Repair
Item Replace Repair
Cost ratio 3 1
Duration ratio 1 3
Reliability ratio 2 1
MTBF ratio 2 1
CM/PM ratio 1 2
Performance ratio 2 1
Manpower ratio 1 2
Job Safety Analysis Medium High
Equipment Criticality Critical Normal

(HSE, Process, Standby) (with standby)
Systematic Approach for Engineers
Maintenance Process
HSE
Information & Engineer Design &

Planning Materials
Process &
Managerial Down
Spare parts
View Losses
& Stock
Basic Aspect of Any Business
Quality
Process
Business
Success
Cost
Safety
Employee
Relations
Safety Team
(Accidents, Fire, .. etc.)
Approach
HSE
Analysis
Health Environment
)People) (Air, Water, Land)
Time HSE
Management
Specs
Resources
Incident:
Bad Event that degrade the efficiency of an operation.
Accident:
Bad Event that results in physical harm to people
or damage to facility.
Accident types:
• Struck Against ‫صدم في‬
• Struck By ‫صدم ب‬
• Fall To Below ‫السقوط الي أسفل‬
• Fall On Same Level ‫السقوط في نفس المستوي‬
• Caught In ‫الجذب الي جزئين متحركين‬
• Caught Between ‫االنحشار بين جزئين‬
• Contact with ‫التعرض ل‬
• Overload (Overexertion) )‫التحميل الزائد (االجهاد‬
Hazard :
Anything which has the potential to cause Harm
Hazards types:
1- Physical Hazards
2- Engineering Hazards: Hazards Substances
- Mechanical Hazards 1. Flammable
- Electrical Hazards 2. Explosive
3- Chemical Hazards 3. Toxic
4- Ergonomics Hazards 4. Irritant
5- Biological Hazards 5. Corrosive
Chapter 1
Importance of Industrial Safety & Risk Assessment
In 1995, National Safety Council (NSC) estimated that:

• Workplace accident cost > 75 billion $
• Killed workers > 11,0000 worker
• Injured workers > 7 million worker
• Lost workdays > 70 million day
• Lost workforce > 35,000 worker
Source: National Safety Council, Accident Facts, 1997 Edition.
Cairo - Egypt
> 5 million
Egyptian are
affected by
asthma.
Serious Health Impacts of Asthma
• Asthma is a potentially fatal, chronic disease
• Responsible for over 1.8 million emergency room
visits per year,
• Over 460 thousand hospitalizations per year and
• Over five thousand deaths per year
(Department of Health and Human Services, 2002).
Facts About Vehicle Accidents in Egypt
Causes of Causes of vehicle
Road/Traffic incidents
incidents in Egypt
in Egypt
• 12,000 road accidents:
• 24 % of all hospital fatalities Road condition
• 28% of children’s deaths in Vehicle condition
hospitals.
5%
10%
• Over 5000 people were killed
• Over 20,000 injured
Human error
• Very high fatalities rate per
100million kilometers driven (44 ) 85%
Most Common Human Errors:
- Over speeding
- Driving on wrong direction How to Prevent Accidents:
- Sudden stop •Observation techniques
- Sleeping while driving
- Horse playing •Space
- Speaking on the mobile phones while driving •Concentration
- Eating , drinking or smoking while driving
- Driving under the influence of drugs •Pre Departure Checks
Egyptian Oil & Gas Industries - Nature of Accidents
Causes Of Incidents %:
30% Poor Maintenance
“25% Backlog, 20% Quality, 15% Spares, 20% Planning & Feedback,
5% Poor housekeeping, 15% Others”
25% Process & Operator error

“90% Unsafe acts & 10% Unsafe conditions such as poor layout”
20% Poor Management (Process, HSE, Maintenance, .. etc.)

“70% Information, Planning & Control, 20% Awareness & Culture, 10% others”
15% Design Deficiency

“50% Design error, 35% Materials, 15% others”
10% Others
Based on data from 5 Egyptian Companies
Last 10 years Accident & Incident History & Brain Storming
Prepared by Dr. Attia Gomaa, 2007, Inprint.
Main Equipment/Item % Critical Items

(A – Rule 80/20)
1) Piping systems 30
2) Tanks 25
3) Heat Exchangers 8
4) Valves 7
5) Towers 5
6) Compressors 4
7) Pumps 3
8) Gages 2
Others 16
Total 100
90%
80% 80%
70%
60%
50%
40%
30%
20% 12%
5% 3%
10%
0%
Human factors Process Enviromental Others
factors factors
Cause of injuries
Accident Prevention
Accident
Rate
Technology
Management Systems
Human Factors
Time
Direct cost is Less than 10% of the global costs
Accident or CM or Unplanned job
Accident
Incident
Unsafe Conditions
Unsafe Acts
You only see the tip of the iceberg

Deaths
Lost Time Injuries
Medical
Treatment
First Aid Cases
Unsafe conditions
Unsafe Acts
What do accidents cost your company?
Unseen costs can Direct Costs

sink the ship! Insured
“Just the tip of the iceberg”
1. Workers’ compensation premiums
2. Miscellaneous medical expenses.
Indirect Costs
Hidden - Uninsured - Out of pocket
A few examples:
1. Cost of wages paid for for working time loss by other workers.
2. Net cost to repair, replace, or straighten up material or damaged equipment.
3. Extra cost due to overtime work.
4. Cost of wages paid supervisor activities required by injury.
5. Wage cost due to decreased output of injured worker after return to work.
6. Cost-of-learning period of new worker.
7. Uninsured medical costs.
8. Cost of time to investigate accidents, process claims.
9. Miscellaneous unusual costs. (over 100 other items may impact the employer).
Ref: Grimaldi and Simons, Safety Management, 1989.

What is HSE Systematic Approach
?
HSE Policy
Inventory
Process HSE
Review as
Necessary
Maintenance Strategic Plan
Strategic Plan
Annual
Review
Annual Plan
Annual Plan
HSE Social
Plan
Plan
Modification
Modification
Cost Documentation &&
Documentation
Records
Records
Equipment
HR Safety Process
Safety Safety
Down
Losses
HSE Material
Safety
Environmental Contractors
(Air, Water, Land) Visitors Safety
Safety Safety
WHAT DOES HSE and Risk Assessment REQUIRE?
1. Policy Team
Approach
2. Goals & Targets
3. Constraints & Problems
4. Team Approach
5. Organization Structure & Responsibility
6. Project Management Information System
7. Awareness & Training programs
8. Global Performance Evaluation
9. Management Support & Commitment & Review
10. Long Term Continues Improvement
Melt the Iceberg!
Injury
Accidents
96% of all injuries

are due to
Unsafe Acts
Safe Work Practices

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Industrial Safety &

Industrial Safety & Risk Assessment for Engineers

In normal conditions: Repair policy if (repair cost <40%Replace cost)

Equipment Criticality Critical Normal

Information & Engineer Design &

In 1995, National Safety Council (NSC) estimated that:

Source: National Safety Council, Accident Facts, 1997 Edition.

25% Process & Operator error

20% Poor Management (Process, HSE, Maintenance, .. etc.)

15% Design Deficiency

Main Equipment/Item % Critical Items

Accident or CM or Unplanned job

You only see the tip of the iceberg

Lost Time Injuries

Unseen costs can Direct Costs

Ref: Grimaldi and Simons, Safety Management, 1989.

96% of all injuries

Safe Work Practices

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