RSR ENGINEERING COLLEGE

HEALTH, SAFETY AND ENVIRONMENTAL MANAGEMENT PRACTICES

(20A01705)

(Open elective course – IV)

UNIT - I

Accident Investigation & Reporting:

Accident Investigation:
The National Safety Council (NSC) defines an accident as an “unplanned,
undesired event, not necessarily resulting in injury, but damaging to property
and/or interrupting the activity in process.” The NSC defines an incident as “an
undesired event that may cause personal harm or other damage.” Although the
Occupational Safety and Health Administration (OSHA) does not have specific
standards for accident investigation, as a best practice, all accidents and
incidents should be investigated regardless of severity. Near-miss incidents in
which no damage or harm resulted should also be included. Some employers
create an accident investigation checklist to ensure that all areas are covered,
as an accident scene can often be chaotic and filled with heightened emotions.
Completing an accident investigation will be beneficial in determining safety
hazards or safety training that will need to be addressed to reduce the risk of
more injuries.
STEP 1: ASSESS THE INJURY
When a workplace accident occurs, the first thing to do is to identify any
injured employees and assess the severity of the injury. Once the severity of
the injury has been ascertained, the employer must determine if immediate
medical attention is necessary.
STEP 2: OBTAIN MEDICAL TREATMENT IF NECESSARY
If no medical attention or only first-aid is required, the employer may proceed
to Step 3.
If immediate medical attention is necessary, the employer should have a
manager take the employee to the nearest emergency room or urgent care
facility or call 911 to request medical assistance to the worksite depending on
the severity of the injuries. State workers’ compensation laws have different
requirements regarding the use of panel physicians for nonemergency
treatment. Employers will need to check if their state requires employees to
select from a list of approved physicians or allows the employee the right to
choose a medical care facility/physician to receive treatment.
The employer should then provide the employee with all appropriate forms
relating to medical treatment for work-related injuries. This could include
some or all of the following forms:
 Medical treatment consent form.
 Workers’ compensation panel of physicians.
 Return-to-work release for completion by the physician.
 Copy of the employee’s job description (to provide to the physician).
 Copy of the company’s light duty policy.
Completion of these forms will provide valuable information to help the
employer determine the best way to accommodate the employee’s return to
work and to promote a healthy recovery from the sustained injuries.
STEP 3: INTERVIEW INJURED EMPLOYEE AND WITNESS(ES)
Once the injured employee’s medical needs have been seen to, the next step is
to interview the employee and gather information on what, when, how and
why the injury occurred. The injured employee should complete an incident
report to provide an overview of what happened to cause the accident. The
employer should interview all witnesses who have first-hand knowledge of the
accident, and each witness should complete a witness statement.
Organizations may also want the supervisor to complete an incident report
that details what he or she witnessed or any history of the work environment
that may have led to the accident. Questions to ask during the investigation
might include:
 What was the employee doing at the time of the accident?
 Was the employee qualified to perform this operation?
 Were company procedures being followed?
 Is the job or process new?
 Were proper tools or equipment being used?
 Was the proper supervision being provided?
 Had the employee received training on this operation prior to the
accident?
 Where did the accident take place?
  What was the physical condition of the area when the accident occurred
(for example, was the temperature of the area hot or cold; if outside,
was it wet or muddy, was debris in the way or was the area clear)?
 What were witnesses doing at the time of the accident?
 What immediate or temporary action could have prevented the accident
or minimized its effect?
 What long-term or permanent action could have prevented the accident
or minimized its effect?
Had corrective action been recommended in the past but not adopted?
STEP 4: OBSERVE ACCIDENT SCENE AND ANALYZE THE FACTS
Next, employers should observe the accident scene and take photographs of
the area, including objects, wet floors and equipment that may have
contributed to the accident (e.g., filing cabinet drawer was left open, and
employee tripped over the drawer; electrical cord was exposed, and employee
tripped over cord; crack in concrete floor caused an uneven surface).
Action plans should be immediately implemented to correct any issues that
can be addressed to ensure that the work area is safe for employees and
customers, such as tagging out faulty equipment. Some questions that the HR
professional may look to answer while observing the scene include:
 What prompted this investigation?
 Why did the incident occur?
 What are the facts surrounding the occurrence? (This is the heart of the
investigation—the investigator must determine who, what, when, where
and why.)
 Has a previous action been taken to correct the problem? If so, what
was it? Why did it fail this time?
 What should be done going forward to correct the problem?
 Is there a new method that should be used to correct the problem? Is
there a way to eliminate the cause(s) of the incident?
Employers should document any actions they have taken to secure an unsafe
worksite.
STEP 5: FILE A WORKERS’ COMPENSATION CLAIM
Next, organizations should contact their insurance carriers and file a work-
related injury report. All information required by the insurance carrier should
be provided; employers should also provide statements and any other relevant
supporting documentation, including available doctor’s notes, therapy and
medical treatment statements, and a return-to-work statement. For more
details on workers’ compensation claim administration, see How to Administer
a Workers’ Compensation Claim. All work-related claims must be recorded on
the OSHA 300 log. For details on how to complete an OSHA 300 log, see How
to Complete the OSHA Form 300.
STEP 6: FOLLOW UP
The employer should follow up with the employee after the accident
investigation has concluded to see how the employee is doing. If the employee
is hospitalized, someone from the organization should visit the employee in
the hospital. A get-well card signed by co-workers, a fruit basket or flowers will
send the message that the company really cares about its employees and will
encourage the employee to return to work. If the employee initially declined
medical treatment, the employer should confirm with the employee that no
medical treatment related to the accident has been necessary.
STEP 7: CORRECTIVE ACTION
Corrective action should be identified in terms of how to prevent a recurrence
and improve the overall operations of the company. If an employee violated a
major or minor safety rule, the employer will need to follow its company work
rule violation policy and take the corrective action necessary. Taking
immediate corrective action will ensure workplace safety and help reduce or
eliminate work-related injuries. If a company has a safety committee, members
should review investigations of all accidents to help form recommendations for
appropriate corrective action to prevent future reoccurrence. Thorough
investigations will help employers identify causes of accidents and will reveal
any accident trends.
Accident Reporting:
An Accident Reporting and Investigation Plan prescribes methods and practices
for reporting and investigating accidents that can be read and understood by
all managers, supervisors, and employees. No matter how conscientious the
safety efforts are, accidents are going to happen, sometimes due to human or
system error.
This written Accident Reporting and Investigation Plan is intended to
demonstrate The University of Mary Washington’s compliance with the
requirements in OSHA 29 CFR 1904 by:
 Prescribing methods and practices for reporting and investigating
accidents
  Providing a means to deal with workplace accidents in a
standardized way.
In addition, it is the policy of the University to comply with all Workers’
Compensation laws and regulations.
The requirements of this plan apply to all operations and departments at the
University.
ADMINISTRATIVE DUTIES:

The University of Mary Washington’s Worker’s Compensation Coordinator is

responsible for developing, maintaining, and reporting First Records of Injury
to Virginia State Department of Risk Management. This function is shared by
the Department of Human Resources and the Department of Public Safety.
The departments responsible for the program:
 Are responsible for the OSHA 300A Log as well as compensatory
reports for the employee.
 Have full authority to make necessary decisions to ensure the
success of this plan.
 Are qualified by appropriate training and experience to
commensurate with the complexity of the plan.
 Administer or oversee the accident reporting and investigation
program.
 Conduct the required investigations and incident evaluations.
All employee accidents are reviewed by a committee of UMW representatives
from all trades, skills and professions for adequate recommendations and
remediations.
ACCIDENT REPORTING PROCEDURES
Employees injured on the job are to report the injury to their supervisor as
soon as possible after the incident/accident, and when it is safe to do so. Near
miss accidents or incidents (when an employee nearly has an accident but is
able to avoid it) should be reported as well. All accidents and incidents should
be reported for prevention purposes.
The supervisor must immediately notify the Department of Human Resources
and the Department of Public Safety when an incident/accident occurs.
If they are not available, a report should be forwarded for their review and the
supervisor shall conduct an investigation and interview. The Employer’s
Accident Report, VWC Form No.3 is required to be completed by the
employee’s supervisor. Injuries involving a student, UMW visitor or contractor
needs to be reported to University Police for an Incident Report to be filed and
forwarded to the UMW Risk Management Office. All accident reports and
police reports involving accidents with or without injuries are reviewed by
OEMS.
Any employee witnessing an accident is to call for emergency assistance when
needed. In addition, the employee is to immediately report the accident to his
or her supervisor and take part in answering questions related to the Accident
Report and Accident Investigation.

ACCIDENT INVESTIGATION PROCEDURES:

Thorough investigation of all accidents will lead to identification of accident
causes and help:
 Reduce economic losses from injuries and lost productive time.
 Determine why accidents occur, where they happen, and any trends
that might be developing.
 Employees develop an awareness of workplace problems and
hazards.
 Identify areas for process improvement to increase safety and
productivity.
 Note areas where training information or methods need to be
improved.
 Suggest a focus for safety program development.
For all accident investigations, OEMS or its designee will perform the following
duties:
 Conduct the accident investigation at the scene of the injury as soon
as safely possible to do so.
 Ask the employee involved in the accident and any witnesses, in
separate interviews, to tell in their own words exactly what
happened.
 Repeat the employee’s version of the event back to him/her and
allow the employee to make any corrections or additions.
 After the employee has given his/her description of the event, ask
appropriate questions that focus on causes.
  When finished, remind the employee the investigation was to
determine the cause and possible corrective action that can
eliminate the cause(s) of the accident.
 Complete an accident investigation report with the employee and
review data with employee for accuracy. This will provide
information to put into database format.
The accident investigation report is used to:
 Track and report injuries on a monthly basis.
 Group injuries by type, cause, body part affected, time of day, and
process involved.
 Determine if any trends in injury occurrence exist and graph those
trends if possible.
 Identify any equipment, materials, or environmental factors that
seem to be commonly involved in injury incidents.
 Discuss the possible solutions to the problems identified with the
safety team and superiors.
 Proceed with improvements to reduce the likelihood of future
injuries.

INJURY/MEDICAL ISSUES:
If a workplace accident results in injury or illness requiring hospitalization of
three or more employees, or a fatality of one or more employee, the
University’s Worker’s Compensation Coordinator will report the incident
within eight hours by phone or in person to the nearest VOSH office.
If an injured person is taken to a doctor, a statement from the doctor will be
attached to the Accident Report form.

RECORD-KEEPING:
UMW’s Worker’s Compensation Coordinator is responsible for maintaining the
following records and documentation:
 OSHA 300A log of injuries and illnesses
 Accident investigation reports
 Employer’s Accident Report
UMW OEMS is responsible for maintaining the following records and
documentation:
 Training records
 Investigation and Interviews
TRAINING:
This plan is a document guiding the action and behaviours of employees, so
they need to know about it. To communicate the new Accident Reporting and
Investigation Plan, all employees are given a thorough explanation as to why
the new plan was prepared and how individuals may be affected by it.
The information and requirements of this written plan are presented to
employees during new hire orientation or as the plan is reviewed and
modified, but at least annually.

PROGRAM EVALUATION:
The accident reporting and investigation program is evaluated and updated by
UMW Worker’s Compensation Coordinators and OEMS annually to determine
whether the plan is being followed and if further training may be necessary.

Concepts of HAZOP:
Major Accident Hazards and critical safety issues are inherent in the processes
involved in refining, mining, chemical and other primary —particularly if those
processes don’t work as planned. Process safety risk can multiply across each
process within a facility and across every facility within a large national or
multinational corporation, and even one small incident can lead to a more
serious risk pathway developing as well. That’s why insurance companies,
licensing authorities and government agencies, like the U.S. Occupational
Safety and Health Administration and the European Agency for Safety and
Health at Work, require Process Hazard Analysis (PHA) to identify, reduce and
manage workplace hazards. One common method for PHAs is a Hazard and
Operability study, better known as a HAZOP.
What Is a HAZOP?
A HAZOP is a systematic assessment tool used to identify and address potential
hazards in industrial processes before an incident occurs that could affect the
Safety of people or assets while hindering Productivity. HAZOP studies are
typically performed while new facilities are being designed and constructed,
when new processes are added or when processes change. Most regulatory
agencies also require periodic HAZOP studies on existing processes.
The HAZOP assessment is typically performed by a small team that breaks each
step of a process down for individual review to identify potential deviations
from the original process design. Like all PHAs, HAZOPs go beyond the review
of how a process is supposed to operate in order to identify unintended
outcomes and explore their potential ripple effects on health and safety.
How to Perform a HAZOP Study
HAZOP studies are performed when new facilities are built, when new
processes are introduced or changes are made. They are also used to look at
existing operation and maintenance processes. Typically businesses will
assemble a small team of internal experts to conduct the HAZOP and then
bring in an outside consultant to help facilitate the study. Teams are selected
based on their knowledge of the HAZOP method and/or knowledge of the
design, operation, engineering, maintenance or Safety of the process being
studied. Often, companies may also choose to add an engineer who is
unfamiliar with the process to provide an external point of view.
Once assembled, the team will complete the study in four phases:
1. Define the scope of the study.
2. Prepare and collect necessary data (process safety information).
3. Examine the process and, using potential deviations, brainstorm causes
of hazardous scenarios and their possible consequences to determine if
they are significant.
4. Document findings, make safety improvement recommendations and
record any changes necessary to reduce risk.
The HAZOP method involves breaking down the process into small,
manageable sections called “nodes.” The HAZOP study team will examine the
process one node at a time, brainstorming potential scenarios that deviate
from the original process design. The team will then define what might cause
such a scenario as well as the consequences of the scenario and associated
risk. The team will also identify what, if any, mitigating controls may already be
in place to help manage and reduce the potential risk. After that, the team will
outline specific recommendations to reduce the likelihood of the deviation or
reduce associated risks and assign responsibility for carrying out those
recommendations. The team will repeat this process until all possible
deviations have been exhausted before moving onto the next node.
HAZOP Software
Each scenario identified during the HAZOP study should be documented on
worksheets so they can be reviewed, checked and referenced throughout the
study and afterward for quality control. Documentation is also essential to stay
compliant with regulators and insurance companies. Because of the complexity
of the HAZOP method, the complexity of most processes reviewed, and the
sheer volume of information that must be consulted, most organizations turn
to software to ease the documentation process, such as Sphera’s Process
Hazard Analysis (PHA Pro) & HAZOP Software.
Software offers businesses a framework to standardize risk assessment data,
record scenarios and ensure recommendations are followed through.
Centralized data storage also helps streamline assessments by allowing teams
to easily access and build on previous work. The result is a more efficient
process with less operational disruption and reduced likelihood of safety
incidents.
PHA:

What is PHA?

Process Hazard Analysis (PHA) is an in-depth and systematic effort to identify

and analyse potential hazards’ impact on industrial processes. The findings
from a PHA assist corporate executives and the Board to make informed
decisions to improve plant safety and to prevent or mitigate catastrophic
accidents.

A PHA study evaluates potential sources and consequences of catastrophic

events such as chemical spills, flammable or toxic releases, fires, and
explosions. PHA focuses on every element of the process equipment,
instrumentation and controls, and human actions. It is applied to determine
and communicate that the elements either pose no hazard, pose uncontrolled
hazards, or pose hazards controlled with the proper mitigations.

Methods of PHA

The US Department of Labor’s Occupational Safety and Health Administration

(OSHA) has identified several ways to conduct process hazard analysis:

 What-if
 Hazard and Operability Study (HAZOP)
 Failure Mode and Effect Analysis (FMEA)
 Fault Tree Analysis

The particular PHA method applied is influenced by the complexity of the

analysed process and the organization’s experience with the process. HAZOP is
the most widely utilized PHA method for performing a detailed analysis of a
wide range of hazards from the design phase to routine operations.

Safety Measures in design and process Operations:

HAZOP:
As HAZOP undertakes the careful review of complex processes involved in the
handling and processing of chemicals and materials that can potentially harm
workers and stakeholders if not properly contained and handled, it is
important to follow the following steps:
1. Build a HAZOP team
Create a multidisciplinary HAZOP team composed of a team leader and
members who can collaborate and provide different perspectives based on
their fields of expertise at realizing sources of risks and possible deviations
from design. An example of HAZOP team members would be design engineers,
those who are very familiar with operations, and safety professionals.

2. Identify processes, P&ID, and HAZOP nodes

When beginning a HAZOP study, it is important to identify the processes in
operations, be familiar with the process/piping and instrumentation diagram
(P&ID), and be aware of all the nodes.

P&ID are drawings or diagrams that provide the visual representation of

interconnected processes, equipment, and controls in the physical plant.
HAZOP nodes are sections in the entire process where changes happen and
they need to be reviewed along with Material Safety Data Sheets (MSDS) so
that parameters can be defined and deviations are identified.
3. Define the parameters, determine deviations, and select guide words
Define parameters or safe operating limits during the review of nodes so that
deviations can be determined and guide words are selected.

Examples of common HAZOP guide words:

 No or not
 More
 Less
 High
 Low
With the use of guide words, workplace hazards can be clearly identified as
they are the deviations that go beyond acceptable parameters or safe
operating limits.

4. Identify controls and establish safety monitoring

With hazards identified, the corresponding hazard mitigation or elimination
strategies should be applied to maintain the safety of the workplace. With
ongoing processes and production, monitoring should also be established to
ensure that safeguards are still effective and safety procedures are being
followed.

Monitoring is only effective when it is actually conducted regularly. With Safety

Culture as mobile safety monitoring software, you can ensure that safety
checks and audits are conducted regularly through scheduled inspections and
automated notifications. Administrators can schedule and assign inspections
and be made aware if inspections are indeed being done on time and on a
regular basis. Register here for free.
Another safeguard is to automate safety monitoring through
sensors. Sensors can trigger automated notifications for intended personnel
whenever safety parameters are exceeded in real-time.

5. Communicate HAZOP results and improve processes

The result of the HAZOP analysis can be used to help elevate safety within the
plant and improvements in safety practices and processes should be
communicated to as appropriate to employees e.g. occupational safety,
chemical safety and hygiene safety processes.
An effective approach to safety training or program will also help hasten the
implementation of changes and reinforce safety across the board.
HAZOP is rigorous and can take a lot of time and resources to complete, but by
following HAZOP steps and using tools that can help hasten the process
without compromising the quality of the process and its result, HAZOP can be
effectively conducted and completed sooner and the workplace can be made
safer and more efficient.

PHA:
Common methods for PHA include “bowtie” analysis, Fault Tree Analysis (FTA),
Failure Mode and Effect Analysis (FMEA), Hazard and Operability studies (HAZOPs)
and “What If” analyses. Here is a brief overview of these common methods:

 A Bowtie Analysis helps organizations get a visual presentation of their

potential risk exposure and possible scenarios for that risk along with
barriers to protect against the risk.
 A Fault-Tree Analysis starts with listing potential failed outcomes and
working backward to identify possible causes.
 An FMEA helps evaluate design failures by first identifying “failure
modes” or how an operation would play out given potential failures.
Then an effects analysis is conducted to outline outcomes for each failure
mode.
 A HAZOP is the systematic assessment tool used to evaluate an industrial
process for potential deviations by breaking it in small, manageable steps.
 A “What If” Analysis is a structured brainstorming session about what
could go wrong within an operational process from human error to
equipment failures. The goal is to identify hazard scenarios and ensure
safeguards are in place to prevent these scenarios from occurring.
Depending on local, regional and national guidelines, a PHA is required when
industrial processes that involve hazardous chemicals are established as well as at
regular intervals thereafter or after major facility and/or equipment changes.
Safety measures in design and process operations:
Implementing safety measures in design and process operations is crucial to
prevent accidents such as insertion incidents, explosions, and fires. Here are
some specific safety measures related to insertion, explosion prevention, fire
prevention, and sprinkler systems:

1. Insertion Safety Measures:

- Adequate training: Ensure that employees are well-trained in operating
machinery or equipment to prevent accidents related to incorrect insertion of
tools or materials.
- Clear guidelines: Provide detailed instructions and clear markings for proper
insertion procedures to avoid mishandling or incorrect placement.
- Regular inspections: Conduct routine checks on equipment and machinery
to ensure they are in proper working order and to prevent any malfunction that
could lead to accidents.

2. Explosion Prevention Measures:

- Hazard assessment: Identify potential explosive materials or processes
within the operation.
- Ventilation systems: Ensure proper ventilation to prevent the buildup of
flammable gases or vapours.
- Regular maintenance: Conduct routine maintenance of equipment and
machinery to prevent malfunctions that could lead to explosions.
- Use of non-explosive materials: Whenever possible, substitute or limit the
use of highly explosive materials in the operation.

3. Fire Prevention Measures:

- Fire-resistant materials: Use fire-resistant materials in construction and
equipment to reduce the risk of fire.
- Fire safety training: Provide employees with fire safety training and conduct
regular drills to ensure they know how to respond in case of a fire emergency.
 - Fire detection systems: Install and maintain fire detection systems like
smoke detectors, heat sensors, and fire alarms.
- Fire extinguishers and emergency exits: Have easily accessible fire
extinguishers and clearly marked emergency exits throughout the premises.

4. Sprinkler Systems:
- Installation and maintenance: Ensure proper installation and routine
maintenance of sprinkler systems to ensure they are functional at all times.
- Regular testing: Periodically test the sprinkler systems to guarantee they
activate correctly when needed.
- Integration with fire alarms: Integrate the sprinkler system with the fire
alarm for an automatic response to detected fires.

5. Regulatory Compliance:
- Adhere to local and industry-specific safety regulations and standards.
- Regular audits and compliance checks to ensure the operation meets safety
standards and guidelines set by regulatory bodies.

Remember, a comprehensive safety plan should involve a combination of

engineering controls, administrative controls, training, and personal protective
equipment to ensure the safety of individuals and the operation as a whole.
Regular risk assessments and continuous improvement in safety protocols are
crucial for maintaining a safe work environment.