ACM C A04:

Management of Safety
and Health
Prof. Vishnu Namboodiri V
NICMAR, Hyderabad
 Course Outline
• Basic concepts- safety issues, industrial safety training-
NEBOSH,BOSIET etc.,

• Occupational safety, hazard-dust, impregnated timber, lead poisoning,

toxic fumes, noise, vibrations.

• Causes of accidents and measures. Accident investigation and

prevention.

• Safety for specialized structure- tunnel, dams, power plant, and oil
and gas or coal transportation.
Safety of Confined Spaces
Operations
• A “confined space” is defined to mean any place
in which, by virtue of its enclosed nature, there
arises a reasonably foreseeable specified risk,
and includes any chamber, tank,vat, pit, well,
sewer, tunnel, pipe, flue, boiler, pressure
receiver, hatch, caisson, shaft or silo in which
such risk arises.
Confined-space entry procedures
• A confined space is defined as It is a limited space or a
vessel where an employee can enter and perform
assigned work. It is not normally open to human
traffic.
• Entry to the confined space is limited or restricted.
Entry that is allowed only after the space has been
prepared for entry following certain procedures
outlined later. This is necessary to prevent
asphyxiation of the employees who need to perform
some task in this space.
Asphyxiation can be caused by:
• Lack of oxygen
• Presence of inert gas
• Presence of toxic vapour
1. What Is a Tank Entry Procedure?
2. Who Should Be Familiar with the Procedure?
3. Why Must It Be Followed?
4. Equipment Needed for Tank Entry
5. Signs to Be Displayed
6. Preparation for Tank Entry
7. The tank entry permit
8. Entering the Tank
 Causes of Accidents
• Human Error: Chernobyl Nuclear disaster-Ukraine-
1986.
• Improper Training :Chernobyl Nuclear disaster-Ukraine-
1986.
• Manufacturing Defects: British Airways Flight 38 -UK-
2008-Fuel oil heat exchanger fault
• Improper Maintenance: Electrical error causes fire in
the main trough that destroys control lines and five
main coolant pumps-East Germany-1975
Accident Theory-The domino
theory
• According to W.H. Heinrich (1931), who developed
the so-called domino theory, 88% of all accidents
are caused by unsafe acts of people, 10% by unsafe
actions and 2% by “acts of God”.

• Analyzed 75000 accidents

Frank Bird Theory-1959,1966
• Studied about 90,000 accidents
• Damage accidents are five times more than injury
accidents
• Studied about 17,53,498 accidents
• 30.2 % property damage accidents were reported
for each disabling injury .
• Ratio 1-100-500 (disabling injury-minor injury-no
visible injury/damage)
Accident sequences
• Ancestry and social environment
• Worker fault
• Unsafe act together with mechanical and physical
hazard
• Accident
• Damage or injury.
Safety work permit
• Provide a precautions for a job from starting to
completion of the work.
• Responsibility of fulfillment of the safety
requirement is with safety department, user
department and the workmen/ contractors.
• It provide strict instruction to the workers/do’s.
Work Permit Requirement
• Major & Minor Maintenance work.
• Inspection
• Construction
• Alteration
• Process Equipment cleaning
• Entry into confined space
• Excavation
• Vehicle entry into hazardous areas
Types of work permits
• Work Permit for Hot & Cold Jobs
• Confined space entry permit
• Excavation Permit
• Work at Height above 2 metres
• Electrical Work Permit on Electric Distribution
System
Hot work permits
• Issued for work using or generating heat that is
sufficient to ignite gases, vapours, dusts, etc. Some
examples are welding, flame cutting, and metal
drilling, soldering, sand blasting, grinding.
Safety tag system
• Standard-IS 8095 & 9457
• Temporary means of warnings
• To prevent wrong operations of any switch, valve,
control etc.
• They should not be used in place of or substitute
for accident prevention. Accident prevention signs
are permanent in nature.
Lockout/Tagout (LOTO)
• Intends to prevent the unexpected energization or
start-up of machinery and equipment, or the
unintentional release of
stored energy
• Lockout/tagout is the process employing specific
safety procedures and practices to control
hazardous energy during the service and
maintenance of machinery and equipment.
Caution tag:
Danger tag:
 Isolation Clasps:
Locking device:
Physical restraint devices
Safety management

• A Safety Management System

(SMS) is a systematic approach
to managing safety, including
the necessary organizational
structures, accountabilities,
policies and procedures.
Hazard and risk identification techniques

• A hazard is an agent which has the potential to

cause harm to a vulnerable target.
or its an existing unsafe condition or action which
has a potential to cause accident.

• A risk is a situation involving exposure to danger or

a combination of a probability of occurrence and its
severity of consequences
R=P(probability )x S (severity)
Type of Hazards
• Chemical-it can affect the skin by contact
• Physical- injury or risk to our body
• Biological- harmful to health of living organisms
• Noise- excessive noise
Risk management
• It is a process with the aim to increase the
probability of success and reduce the event of a
failure
• Steps of risk management:
Hazard identification
Hazard analysis
Risk analysis
Risk assessment
Risk management
Hazard identification techniques
• Analysis of available information
• Brainstorming sessions
• Visible hazards
• Invisible hazards
• Repair shop data
• Organizational charts
• Flow charts
• PHA (Preliminary Hazard Analysis)
• FMEA, FMECA
• HAZOP (hazard and operability) studies
• Fault trees — example of HAZAN (hazard analysis)
process
• Hazard indices,
Analysis of available information
• Records kept by an organization itself on incidents,
accidents, unplanned machinery breakdowns,
claims made, claims paid from insurances,
uninsured losses and so on, in terms of timing (e.g.
the periods in which they took place) and location.
Brainstorming sessions
• Brainstorming sessions are the most unstructured
form of the various hazard identification processes
but can be invaluable in many circumstances. It is a
common method used for assessing possible
construction risks.
Visible hazards
• It can be detected by various techniques like
• Plant inspection based on statutory requirements,
checklist, safety survey, safety audit, and safety
sampling
• Detection and monitoring systems
• Functional test of machinery and equipment
• Accident investigation
Invisible hazards
• Hazards like gas leaks, concentration of toxic and
hazardous vapor
• Malfunction or failure of machinery, equipment etc.
• They must be detected and controlled by itself.
Repair shop data
• It revels the clues to unsafe conditions like poor
design, defective material, poor construction, wear
and tear.
• Repetitive repairs indicate major hazards.
Organizational charts
• Organizational charts permit identification of broad
areas of risk.
• They can be produced showing various aspects of
company activity,
• e.g. the arrangement of constituent companies in a
group the management structure the departmental
structure within each company.
Flow charts
• The process is not quantitative. The most important
use is usually to identify the consequences of items
of plant malfunctioning and to assess alternative
courses of action
 PHA (Preliminary Hazard
• Analysis)
This is an initial study to determine hazard causes,
effects and controls.
• Preliminary hazard analysis (PHA) is a semi-
quantitative analysis
Electrical shock

Burns

Spark
General Steps
• Assume type of accident or hazard possible (eg.Fire,
explosion, toxic release etc.)
• Find out which plant component or system or
machine can cause this accident
(eg.storage vessel, reactor, pipeline etc.)
• Find out the event initiating the hazard or accident
(eg.release of explosive or toxic gas, leakages etc.)
• Corresponding decision shall be taken
• This study indicates which system is more or less
important from hazard point of view.
• This technique can be used in different stages,
R&D
Pre Design
Design
Commissioning
Operation
PHA procedure
1. PHA prerequisites
2. Hazard identification
3. Consequence and frequency estimation
4. Risk ranking and follow-up actions
PHA prerequisites
• 1. Establish the PHA team
• 2. Define and describe the system to be analyzed
• Collect risk information from previous and similar
systems (e.g., from accident data bases)
System functions
• As part of the system familiarization it is important
to consider:
• What is the system dependent upon (inputs)?
• What activities are performed by the system
(functions)?
• What services does the system provide (output)?
System breakdown
• To be able to identify all hazards and events, it is
often necessary to split the system into
manageable parts, for example, into three
categories:
• System parts (e.g., process units)
• Activities
• Exposed to risk (who, what are exposed?)
Selection of PHA worksheet
Hazard identification
• All hazards and possible hazardous events must be
identified. It is important to consider all parts of the
system, operational modes, maintenance
operations, safety systems, and so on.
Hazard checklist
• To get a complete survey of all possible hazards it
may be beneficial to use a hazard checklist
Common sources of hazards
• Mechanical moving parts
• Nuclear radiation
• Electromagnetic radiation (including infra-red,
ultra-violet, laser, radar, and radio frequencies)
• Collisions and subsequent problems of survival and
escape
• Fire and explosion
• Toxic and corrosive liquids
• Deterioration in long-term storage
How to identify hazards?
• Examine similar existing systems
• Review previous hazard analyses for similar systems
• Review hazard checklists and standards
• Use brainstorming in teams
• Consider human/machine interface
• Think through a worst case what-if analysis
Additional data sources
• To aid prediction of what can happen in the future
it is possible to see what actually has happened in
the past:
• Accident reports/databases.
• Accident statistics
• Near miss/ dangerous occurrence reports
• Reports from authorities or governmental bodies
• Expert judgment
Frequency and consequence
estimation
• To determine the risk, we have to estimate the
frequency and the severity of each hazardous
event.
• A hazardous event may lead to a wide range of
consequences, ranging from negligible to
catastrophic. A fire may, for example, be
extinguished very fast and give minor
consequences, or lead to a disaster.
Severity classes
Frequency classes
Risk ranking
Risk levels and actions
• Pros:
1. Helps ensure that the system is safe
2. Modifications are less expensive and easier to
implement in the earlier stages of design
3. Decreases design time by reducing the number of
surprises
• Cons:
1. Hazards must be foreseen by the analysts
2. The effects of interactions between hazards are not
easily recognized
 Why have Occupational Health?

•Moral - An employee should not have to risk injury or

death at work, nor should others associated with the
work environment.
 Why have Occupational Health?

Economic - many organisations realise that poor

occupational health and safety performance results in
cost (e.g. through social security payments to the
incapacitated, costs for medical treatment, and the loss
of the "employability" of the worker).
 Why have Occupational Health?

Economic - Employing organizations also sustain costs in

the event of an incident at work such as legal fees, fines,
compensatory damages, investigation time, lost
production, lost goodwill from the workforce, from
customers and from the wider community.
 Why have Occupational Health?

Legal - Occupational Health and Safety requirements may

be reinforced in Civil Law Employment Law and / or
Criminal Law.

It is accepted that without the extra "encouragement" of

potential regulatory action or litigation, many
organisations would not act upon their implied moral
obligations.
 Why have Occupational Health?

In this way, Occupational Health strives to maintain the

balance of health within the workplace and the provision
of advice and guidance to employers and employees.
NEBOSH (National Examination Board
in Occupational Safety and Health)
• NEBOSH’s Award NEBOSH’s Award level
qualifications provide a basic understanding of
health and safety and environmental principles
and practice and provide a perfect introduction to
other NEBOSH qualifications.

• NEBOSH Health and Safety at Work Qualification

• NEBOSH Environmental Awareness at Work
Qualification
• NEBOSH Health, Safety and Environment in the
Process Industries Qualification
NEBOSH's Certificate
• NEBOSH National General Certificate in Occupational Health
and Safety
• NEBOSH National Certificate in Construction Health and
Safety
• NEBOSH National Certificate in Fire Safety and Risk
Management
• NEBOSH National Certificate in the Management of Health
and Well-being at Work
• NEBOSH Certificate in Environmental Management
• NEBOSH International General Certificate in Occupational
Health and Safety
• NEBOSH International Certificate in Construction Health and
Safety
• NEBOSH International Certificate in Fire Safety and Risk
Management
• NEBOSH International Technical Certificate in Oil and Gas
Operational Safety
The scope and nature of
occupational health and safety

• Occupational health and safety is relevant to all

branches of industry, business and commerce
including traditional industries, information
technology companies, the National Health
Service, care homes, schools, universities, leisure
facilities and offices.
• The Health and Safety Executive’s (HSE) mission is
to ensure that the risks to health and safety of
workers are properly controlled.

• The HSE believes that effective management of

health
and safety:
1. is vital to employee well-being;
2. has a role to play in enhancing the reputation
of businesses and helping them achieve high
performance teams;
3. is financially beneficial to business.
Some basic definitions
• Health – The protection of the bodies and
minds of people from illness resulting from the
materials, processes or procedures used in the
workplace

• Safety – The protection of people from physical

injury. The borderline between health and safety
is ill-defined and the two words are normally used
together to indicate concern for the physical and
mental well-being of the individual at the place of
work.
• Welfare – The provision of facilities to maintain
the health and well-being of individuals at the
workplace. Welfare facilities include washing and
sanitation arrangements, the provision of drinking
water, heating, lighting, accommodation for
clothing, seating (when required by the work
activity or for rest), eating and rest rooms. First-aid
arrangements are also considered as welfare
facilities.

• Occupational or work-related ill-health – This

is concerned with those illnesses or physical and
mental disorders that are either caused or
triggered by workplace activities.
• Environmental protection – These are the
arrangements to cover those activities in the
workplace which affect the environment (in the
form of flora, fauna, water, air and soil) and,
possibly, the health and safety of employees and
others. Such activities include waste and effluent
disposal and atmospheric pollution.

• Accident
• Near Miss
• Dangerous occurrence – This is a ‘near miss’
which could have led to serious injury or loss of life
Four-step approach to
occupational health and safety management is
• PLAN – establish standards for health and safety
management based on risk assessment and legal
requirements.
DO – implement plans to achieve objectives and
standards.
CHECK – measure progress with plans and
compliance with standards.
ACT – review against objectives and standards and
take appropriate action
PLAN
• There are three key questions that need to be
answered during the planning process:

1. Where is the organisation at the moment in terms

of the management of health and safety?
2. Where does it want to be?
3. How does it get there?
The key requirements of this
framework are as follows:

• A clear health and safety policy

• A well-defined health and safety organisation
• A clear health and safety plan
• The measurement of health and safety
performance
• Reviewing performance
• Auditing