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Industrial Risk
Assessment

Abdul Qadir
Lecturer
N ED University of Engineering &Technology,
Karachi

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 Risk Assessment
Systematic procedure for
–describing and
–quantifying the risk associated with
•hazardous substance,
•process,
•action or
•event

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 Risk Assessment
It involves:
– Identification of hazard
– Quantification of
• Hazard
• probability of occurrence
– Estimation of risk

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 When thinking about your risk
assessment, remember

• Hazard is anything that may cause harm,

such as chemicals, electricity, working
from ladders, an open drawer etc;

• Risk is the chance, high or low, that

somebody could be harmed by these and
other hazards, together with an indication
of how serious the harm could be.
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 Classification of Risk Assessment
According to scope of work, risk assessment
may be classified as:
• Environmental Risk Assessment

• Industrial Risk Assessment

• Reliability Risk Assessment
• Financial Risk Assessment
• Health Risk Assessment

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 Industrial Risk Assessment
Steps involved:
– Hazard Identification
– Hazard Assessment
– Consequence Analysis
– Risk Characterization

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• Hazard Assessment
– Qualitative hazard assessment
• HAZOP technique (Hazard & Operability)
– Probabilistic hazard assessment
• Fault tree analysis

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• HAZOP
Simple structured methodology for hazard
identification and assessment,
• material flow diagrams, and
• operating manuals
are examined to identify
• causes and
• consequences
for all possible deviations from normal
operation that could arise
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 Industrial Risk Assessment
HAZOP Report
Project details

Study node

Guide Parameter Causes Conseque Recommen Rank

word nces dation

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• Risk Estimation and Characterization
– Individual Risk
– Societal Risk

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• Identification of Hazards
• Checklist
• Matrix diagram of interaction
– Assessment of Hazards
• Accident sequence analysis
• Failure effect analysis
– Accident Consequence Analysis

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• Quantitative Risk Analysis
– Hazard identification
– Frequency estimation
– Consequence Analysis
– Measure of Risk

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 Five steps process for risk
assessment

1. Identify the hazards

2. Identify who can be harmed
3. Identify the current controls and
decide if more is required?
4. Record your findings
5. Review as necessary

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 5 steps to Risk Assessment
Select a site Step 1
Known or Unknown Identify hazards
associated with site

Step 3 Step 2
Evaluate hazards Identify who & what
using matrix will be damaged

Step 4 Step 5
Record assessment Review plan on arrival
by writing out plan at site & throughout day

File completed
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 Identify the hazards
• The first thing you need to do is identify the
hazards associated with the task or activity.
– One way of doing this is by using “PEME”
• People
• Equipment
• Materials
• Environment

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 “People” hazards
• People hazards cover a number of issues
• hazards are to do with the individual themselves;
• other to do with the systems that people have to use
• When thinking about people hazards, words such as
» training,
» capabilities/restrictions,
» supervision,
» communication,
» adequate numbers and
» human error should come to mind.

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 “Equipment” hazards
• relate to the equipment used and
• cover tasks associated with the
– repair,
– maintenance,
– handling,
– cleaning,
– storage and
– operation of the equipment.

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 “Material hazards”
• cover any solids, liquids or gases
associated with the task.
• Along with the substances that are
required for the specific task
– also any bi-products or
– wastes generated by the task or activity.

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 “Environment hazards”
• Its all about the surroundings
• Depending on the location and the activity,
– hazards could include
• poor lighting,
• heating and ventilation,
• poor access/egress,
• tripping/slipping hazards,
• restricted space/visibility and
• other activities taking place nearby

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 Who can be harmed?
• In case of any failure whole range of
people could be injured, e.g.
– Permanent workers in the area
– People visiting the area
– The general public walking alongside the site
– Intruders and children who break into the site

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 What are the current controls?
What control measures are currently in place
for each hazard identified
– There may be no controls,
• perhaps because the hazard hasn’t been considered
– There may be good controls in place
• because the hazard is obvious and easily controlled

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 What are the current controls?
• Controls can be broken down in 3 ways:
– Physical controls (e.g. a metal fence around a
construction site)
– Procedural controls (e.g. a safe working
procedure for the task)
– Behavioural controls (e.g. adequate
supervision and monitoring of behaviour)

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 Are further controls required?
• Ask yourself
– Can more be done?
– What other control measures are necessary?
– Look at the hierarchy of control.
– Choose the best, most effective controls
– You may have looked at a particular task,
identified the current controls and may be
thinking about adding extra controls…but how
do you know which controls measures are
best.
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 Hierarchy of Control
1 Eliminate the hazard
2 Substitute the hazard
3 Contain the hazard at source
4 Remove employee from hazard
5 Reduce exposure to hazard
6 Systematic Withdrawal Plan (SWP’s)
7 Warning signals
8 PPE
9 Discipline

The basic principle is that the more controls you use from
the top of the hierarchy the better control you will have.
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• If direct exposure leads to a certain
severity, then
– Risk = Severity X Probability.
• If probability is based on exposure, then
– Risk = Severity X Probability X Exposure

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 Evaluating the risk

RISK EVALUATION MATRIX

Moderate injury

Trivial injury
Major injury

Minor injury
Severity

Fatal
Frequency of occurrence
Very common High High High Medium Low
Frequent High High Medium Medium Low
Occasional High Medium Medium Low Low
Rare Medium Medium Low Low Low
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 Record your findings
• State clearly what task/activity the risk
assessment covers
• Ensure that the hazards and controls are clearly
listed
• Consider all those people who could potentially
be harmed
• Ensure that an appropriate member of staff
signs off the assessment
• Make sure that the completed risk assessments
are readily available to those who might need
them -Do not just file them away to gather dust!

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 Regular review of your
assessments
• Risk assessments must be reviewed on a regular
basis
– at the very least once every five years.
• The period of review should reflect the hazards,
– the greater the hazards the more frequent the review
• Should also be reviewed
– if there is a significant change to the work or
– if you believe that it is no longer valid
• Risk assessment should be a living document –it
should change as the work changes.

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