Module V

(Hazard identification and analysis)

•Hazard and risk, Types of hazards –Classification of Fire, Types

of Fire extinguishers, fire explosion and toxic gas release,
•Structure of hazard identification and risk assessment.

•Identification of hazards: Inventory analysis, Fire and explosion

hazard rating of process plants
-The Dow Fire and Explosion Hazard Index (F&EI),
-Preliminary hazard analysis,

-Hazard and Operability study (HAZOP)) – methodology, criticality

analysis, corrective action and follow-up.

-Control of Chemical Hazards, Hazardous properties of chemicals,

Material Safety Data Sheets (MSDS).
 HAZARD AND RISK

•Hazard is a source or a situation with potential to cause harm in

terms of human injury or ill-health, damage to property or
environment or both.
• A hazard is something that can cause harm, example: electricity, chemicals,
working up a ladder, noise, a keyboard, a bully at work, stress, etc.

•A risk is the chance of injury, damage or loss that any hazard will actually
cause to somebody.
•"Risk" is the product of hazard and exposure. Thus, risk can be reduced by controlling
or eliminating the hazard or by reducing workers' exposure to hazards.
•The degree of probability of loss is also known as risk
 TYPES OF HAZARDS
• Mechanical Hazards.
• Electrical Hazards.
• Chemical Hazards.

Mechanical Hazards:
Common sources of mechanical hazards are:

❑Unguarded or inadequately guarded moving machine parts.

❑Machine tools, hand tools, handling materials, lifting and other appliances.

Control Measures

❑Installing Machine Guards to prevent direct contact with moving parts and
Emergency Stop Systems to swiftly halt the machinery in case of hazards.

❑Regular Maintenance and Inspections to identify and address potential

mechanical issues.
 Electrical Hazards:

Causes of the electric hazards :

❑ Electric shocks may be caused by an Exposed live conductor or a

Faulty piece of equipment.

❑ Ageing and attack by foreign materials causes Insulation failures

which causes electrical fires or cases of electrocution

Control Measures
❑ Conduct Regular Inspections of electrical systems and equipments.

❑ Install Proper Grounding to prevent excess voltage and Overcurrent

Protectors which prevent electrical fires caused by overloaded circuits.
 Chemical Hazards

Causes of Chemical Hazards:

❑Improper Storage and Handling of chemicals can lead to spills, leaks

which pose risk to individuals.

❑Mixing Incompatible Chemicals results in violent reactions, release of

toxic fumes and other hazardous outcomes.

Control Measures

❑Implementing Proper Ventilation systems and Isolation of

Processes to minimize chemical exposure.

❑Enforce the use of Personal Protective Equipment (PPE), including

gloves, goggles and respiratory protection, to protect individuals from
chemical contact.
 CLASSES OF FIRE
Class A: solid materials such as wood or paper, fabric, and some plastics
Class B: liquids or gas such as alcohol, ether, gasoline, or grease
Class C: electrical failure from appliances, electronic equipment, and wiring
Class D: metallic substances such as sodium, titanium, zirconium, or magnesium
Class K: grease or oil fires specifically from cooking
 CLASSES OF FIRE

1.Class A Fire

❑Class A fires are produced from common combustible materials including

wood, paper, fabric, rubber, and plastic.

❑They have relatively low ignition temperatures, and once the fuel or oxygen
has been depleted, the fire will burn out (eg Garbage fire).

❑ Water and foam agents are most often used when fighting Class A fires.
2.Class B Fire

❑Class B fires occur when flammable liquids or gases such as alcohol,

kerosene, methane, or oil-based coolant ignite.

❑They are most common in industrial settings, but they may also occur
in residential or commercial settings.

❑ They have a low flashpoint, which means they burn easily at any
temperature if exposed to a fire source.

❑ Class B fires also spread rapidly and produce a thick black smoke
as they burn.

❑ Water is not effective when dealing with Class B fires. Instead,

Carbon Dioxide (CO2) or dry chemical agents are often used to fight
these fires
3.Class C Fire

❑ Class C fires are those fires that have live electrical currents or
electrical equipment as a source of fuel.

❑ They are most common in industrial settings that deal with

energy or electrically-powered equipment, like wind turbines.

❑ Electrical fires cannot be fought with water. In fact, it can make

it worse.

❑ Instead, a non-conductive chemical agent, including clean

agents, should be used to put out the flames.
4.Class D Fire

❑ Class D fires describe those fires that occur with a combustible metal
fuel source.

❑ Common combustible metals include aluminum, lithium, magnesium,

potassium, titanium, and zirconium.

❑These types of combustible metals are most often used in laboratories

and in manufacturing, so the biggest danger for Class D fires occurs in
these industries.

❑ Water can cause some combustible metals to explode, so it should

not be used to fight Class D fires

❑ Instead, dry powder agents can be used to absorb heat and smother
the flames by blocking off the fire's oxygen supply
5.Class K Fire

❑Class K fires occur as a result of the combustion of a cooking

liquid like oil, vegetable fat, or animal fat.

❑Class K fires are most common in the food service and

restaurant industry, but can occur in any kitchen.

❑ Water should not be sprayed onto Class K fires.

❑ Instead, wet chemical agents are the best method to use.

 TYPES OF FIRE EXTINGUISHERS

❑ A fire extinguisher is a handheld active fire protection device usually filled with a
dry or wet chemical used to extinguish or control small fires, often in emergencies.
It is not intended for use on an out-of-control fire.

❑ Different types of fire extinguishers exist in order to address the 5 different classes
of fires.

❑ Each fire class describes the fuel or material a fire is burning or what caused it to
start - therefore, using the right extinguisher is essential to put out the fire safely
 Water
❑ Water is the primary liquid used in these extinguishers, although sometimes other
additives are also included.

❑ A drawback for pure water fire extinguishers is that it is not suitable for use in
freezing conditions since the water inside will freeze and render the extinguisher
unusable.

❑ Certain types of water fire extinguishers contain antifreeze which will allow the
extinguisher to be used in freezing conditions.

❑ Water type fire extinguishers can also sometimes contain wetting agents which are
designed to help increase its effectiveness against fire (primarily for Class A fires).

❑ Water mist extinguishers are a type of water fire extinguisher that uses distilled
water and discharges it as a fine spray instead of a solid stream.

❑ Water mist extinguishers are used where contaminants in unregulated water

sources can cause excessive damage to personnel or equipment.

❑ Typical applications include operating rooms, museums, and book collections

 Film-forming foam type

• AFFF (aqueous film-forming foam) and FFFP (film-forming fluoroprotein)

fire extinguishers are rated for use on both Class A and Class B fires.

• As the name implies, they discharge a foam material rather than a liquid or
powder. They are not suitable for use in freezing temperatures.

• An advantage of this type of extinguisher when used on Class B

flammable liquid fires of appreciable depth is the ability of the agent to
float on and secure the liquid surface, which helps to prevent re-ignition.
 Carbon Dioxide type
❑ The principal advantage of Carbon Dioxide (CO2) fire extinguishers is that the agent
does not leave a residue after use.

❑ This can be a significant factor where protection is needed for delicate and costly
electronic equipment.

❑ Other typical applications are food preparation areas, laboratories, and printing or
duplicating areas.

❑ Carbon dioxide extinguishers are listed for use on Class B and Class C fires.

❑ Because the agent is discharged in the form of a gas/snow cloud, it has a relatively
short range of 3 ft to 8 ft (1 m to 2.4 m).

❑ This type is not recommended for outdoor use where windy conditions prevail or for
indoor use in locations that are subjected to strong air currents, because the agent
can rapidly dissipate and prevent extinguishment.

❑ The concentration needed for fire extinguishment reduces the amount of oxygen in
the vicinity of the fire and should be used with caution when discharged in confined
spaces.
 Halogenated agent types
1. Halon

❑ The bromo-chloro-difluoro methane (Halon 1211) fire extinguisher has an agent

that is similar to carbon dioxide in that it is suitable for cold weather installation and
leaves no residue.

❑ It is important to note that the production of Halon has been phased out because
of the environmental damage it causes to the earth's ozone.

❑ Some larger models of Halon 1211 fire extinguishers are listed for use on Class A
as well as Class B and Class C fires.

❑ Compared to carbon dioxide on a weight-of-agent basis, Halon 1211 is at least

twice as effective.

❑ When discharged, the agent is in the combined form of a gas/mist with about twice
the range of carbon dioxide.

❑ To some extent, windy conditions or strong air currents could make extinguishment
difficult by causing the rapid dispersal of the agent.
2. Halon Alternative Clean Agents

❑There are several clean agents that are similar to halon agents in that they
are nonconductive, non corrosive, and evaporate after use, leaving no residue.

❑Larger models of these fire extinguishers are listed for Class A as well as
Class B and Class C fires, which makes them quite suitable for use on fires in
electronic equipment.

❑When discharged, these agents are in the combined form of a gas/ mist or a
liquid, which rapidly evaporates after discharge with about twice the range of
carbon dioxide.

❑To some extent, windy conditions or strong air currents could make
extinguishing difficult by causing a rapid dispersal of agent.

❑Clean agent type extinguishers don't have detrimental effect on the earth's
ozone so these are more widely available than Halon type extinguishers
 Dry chemical types

1. Ordinary Dry Chemical

❑ The fire extinguishing agent used in these devices is a powder

composed of very small particulates.

❑ Types of agents available include sodium bicarbonate base and

potassium bicarbonate base.

❑ Dry chemical type extinguishers have special treatments that ensure

proper flow capabilities by providing resistance to packing and
moisture absorption (caking)
2. Multipurpose Dry Chemical

❑Fire extinguishers of this type contain an ammonium phosphate base agent.

❑Multipurpose agents are used in exactly the same manner as ordinary dry
chemical agents on Class B fires.

❑For use on Class A fires, the multipurpose agent has the additional
characteristic of softening and sticking when in contact with hot surfaces.

❑In this way, it adheres to burning materials and forms a coating that smothers
and isolates the fuel from air.

❑The agent itself has little cooling effect, and because of its surface coating
characteristic, it cannot penetrate below the burning surface.

❑For this reason, extinguishment of deep-seated fires might not be

accomplished unless the agent is discharged below the surface or the material
is broken apart and spread out.
 Wet chemical
The extinguishing agent can be comprised of solutions of water and potassium
acetate, potassium carbonate, potassium citrate, or a combination of these
chemicals (which are conductors of electricity).

❑ The liquid agent typically has a pH of 9.0 or less.

❑ On Class A fires, the agent works as a coolant.

❑ On Class K fires (cooking oil fires), the agent these forms a foam blanket to prevent
reignition.

❑ The water of the agent aids in cooling and reducing the temperature.
❑ The water content the hot oils and fats below their auto-ignition point.

❑ The agent, when discharged as a fine spray directly at cooking appliance reduces
the possibility of splashing hot grease and does not present a shock hazard to the
operator.

❑ Wet chemical extinguishers also offer improved visibility during firefighting as well
as minimizing clean up afterward
 Dry powder types

❑ These fire extinguishers and agents are intended for use on

Class D fires and specific metals, following special techniques
and manufacturer's recommendations for use.

❑ The extinguishing agent can be applied from a fire extinguisher

or by scoop and shovel.
STRUCTURE OF HAZARD IDENTIFICATION AND RISK ASSESSMENT

One of the "root causes" of workplace injuries, illnesses, and incidents is the failure to
identify or recognize hazards that are present, or that could have been anticipated. A
critical element any effective safety and health program is a proactive, ongoing process
to identify and assess such hazards.

To identify and assess hazards, employers and workers:

Collect and review information about the hazards present

Collect or likely to be present in the workplace.
Conduct initial and periodic workplace inspections of the workplace to identify new or
recurring hazards.

Investigate injuries, illnesses, incidents, and close calls/near misses to determine the
underlying hazards, their causes, and safety and health program shortcomings.

Group similar incidents and identify trends in injuries, illnesses, and hazards
reported.
Consider hazards associated with emergency or non routine situations.

Determine the severity and likelihood of incidents that could result for each hazard
identified, and use this information to prioritize corrective actions.
HAZARD IDENTIFICATION
 HAZARD IDENTIFICATION

Action 1: Collect existing information about workplace hazards

Collect, organize, and review information with workers to determine what types of
hazards may be present and which workers may be exposed or potentially exposed.
Information available in the workplace may include:

Equipment and machinery operating manuals.

Safety Data Sheets (SDS) provided by chemical manufacturers.
Self-inspection reports and inspection reports from insurance carriers, government
agencies, and consultants.
Records of previous injuries and illnesses.
Workers' compensation records and reports.
Patterns of frequently-occurring injuries and illnesses.

Exposure monitoring results, industrial hygiene assessments, and medical records

(appropriately redacted to ensure patient/worker privacy).

Existing safety and health programs (lockout/tagout, confined spaces, process safety
management, personal protective equipment, etc.).
Input from workers, including surveys or minutes from safety and health committee
meetings.
Results of job hazard analyses, also known as job safety analyses.
Information about hazards may be available from outside sources, such as:

National Safety Council, and Department of Labour & Employment websites,

publications, and alerts.

Trade associations.

Labor unions, state and local occupational safety and health committees/coalitions
and worker advocacy groups.

Safety and health consultants.

 Action 2: Inspect the workplace for safety hazards

•Hazards can be introduced over time as workstations and processes change,

equipment or tools become worn, maintenance is neglected, or housekeeping practices
decline.

Conduct regular inspections of all operations, equipment, work areas and facilities.
Have workers participate on the inspection team and talk to them about hazards that
they see or report.

Be sure to document inspections so we can later verify that hazardous conditions

are corrected. Take photos or videos of problem areas to facilitate later discussion and
brainstorming about how to control them, and for use as learning aides.

Include all areas and activities in these inspections, such as storage and
warehousing,facility and equipment maintanence, purchasing and office functions, and
the activities of on-site contractors, sub contractors and temporary employees.

Regularly inspect both plant vehicles (e.g., forklifts, powered industrial trucks) and
transport vehicles (e.g., cars, trucks).
 Use checklists that highlight things to look for. Typical hazards fall into several
major categories, such as those listed below:
o General housekeeping
o Slip,trip, fall hazards
o Electrical hazards
o Fire protection
o Work organization and process flow (including staffing and scheduling)
o Work practices
o Workplace violence
o Equipment operation
o Equipment maintenance
o Ergonomic problems
o Lack of emergency procedures

Before changing operations, workstations, or workflow; making major

organizational changes; or introducing new equipment, materials, or processes, seek
the input of workers and evaluate the planned changes for potential hazards and
related risks.
 Action 3: Identify health hazards

•Identifying workers' exposure to health hazards is typically more complex than

identifying physical safety hazards. For example, gases and vapors may be
invisible, often have no odor, and may an immediately noticeable harmful health
effect.
•Health hazards include chemical hazards (solvents, adhesives, paints, toxic
dusts, etc.), physical hazards (noise, radiation, .), biological hazards (infectious
diseases), and ergonomic risk factors (heavy lifting,repetitive motions, vibration).
•Reviewing workers' medical records (appropriately redacted to ensure
patient/worker privacy) can be useful in identifying health hazards associated with
workplace exposures.
 Identify chemical hazards -review SDS and product labels to identify chemicals in
the workplace that have low exposure limits, are highly volatile, or are used in large
quantities or in unventilated spaces. Identify activities that may result in skin exposure
to chemicals.

Identify physical hazards -identify any exposures to excessive noise (areas where
we must raise our voice to beheard by others), elevated heat (indoor and outdoor), or
sources of radiation (radioactive materials, X-rays, or radiofrequency radiation).

Identify biological hazards -determine whether workers may be exposed to sources

of infectious diseases, molds, toxic or poisonous plants, or animal materials (fur or
scat) capable of causing allergic reactions or occupational asthma.

Identify ergonomic risk factors -examine work activities that require heavy lifting,
work above shoulder height, repetitive motions, or tasks with significant vibration.
Conduct quantitative exposure assessments –when possible, using air sampling or
direct reading instruments.

Review medical records -to identify musculoskeletal injuries, skin irritation or

dermatitis, hearing loss, or lung disease that may be related to workplace exposures
 Action 4: Conduct incident investigations

•Workplace incidents -including injuries, illnesses, close calls/near misses, and

reports of other concerns- provide a clear indication of where hazards exist. By
thoroughly investigating incidents and reports, we can identify hazards that are likely
to cause future harm.

•The purpose of an investigation must always be to identify the root causes (and
there is often more than one) of the incident or concern, in order to prevent future
occurrences.

How to accomplish it ?

Develop a clear plan and procedure for conducting incident investigations, so that an
investigation can begin immediately when an incident occurs. The plan should cover
items such as:
o Who will be involved
o Lines of communication
o Materials, equipment, and supplies needed
o Reporting forms and templates
 Train investigative teams on incident investigation techniques, emphasizing
objectivity and open- mindedness throughout the investigation process.

Conduct investigations with a trained team that includes representatives of both

management and workers.

Investigate close calls/near misses.

Identify and analyze root causes to address underlying program shortcomings that
allowed the incidents to happen.

Communicate the results of the investigation to managers, supervisors, and

workers to prevent recurrence.
Action 5: Identify hazards associated with emergency and nonroutine situations

•Emergencies present hazards that need to be recognized and understood.

Nonroutine or infrequent tasks, including maintenance and startup/shutdown activities,
also present potential hazards.

•Plans and procedures need to be developedfor responding appropriately and safely

to hazards associated with foreseeable emergency scenarios and nonroutine
situations
How to accomplish:
Identify foreseeable emergency scenarios and nonroutine tasks, taking into account
the types of material and equipment in use and the location within the facility.
Scenarios such as the following may be foreseeable:
Fires and explosions
Chemical releases
Hazardous material spills
Startups after planned or unplanned equipment shutdowns
Nonroutine tasks, such as infrequently performed maintenance activities
Structural collapse
Disease outbreaks
Medical emergencies
Weather emergencies & natural disasters
Workplace violence
Action 6: Characterize the nature of identified hazards, identify interim control
measures, and prioritize the hazards for control

The next step is to assess and understand the hazards identified and the types of
incidents that could result from worker exposure to those hazards. This information
can be used to develop interim controls and to prioritize hazards for permanent
control.

How to accomplish
Evaluate each hazard by considering the severity of potential outcomes, the
likelihood that an event or exposure will occur, and the number of workers who might
be exposed.

Use interim control measures to protect workers until more permanent solutions
can be implemented.

Prioritize the hazards so that those presenting the greatest risk are addressed
first.
 Hazard inventory

•Hazard analysis is the process of identifying hazards that have the potential to arise
from a system or environment, documenting their unwanted consequences, and
analyzing their underlying causes.

•A hazardous inventory list is simply a list of all products your practice has that have
hazardous properties.

•All personnel who may have the potential of being exposed to hazards (chemical,
biological, radiological or physical) in the workplace must complete a Hazard
Inventory at the beginning of their employment or before working with a new hazard.

•What is hazard identification risk analysis?

Hazard Identification Risk Assessment (HIRA) is a process of defining and describing
hazards by characterizing their probability, frequency, and severity and evaluating
adverse consequences, including potential losses and injuries.
Hazard identification: The process of finding, listing, and characterizing hazards.

Risk A process for comprehending the nature of hazards and determining

Analysis: the level of risk.

Risk A process used to assign values to the likelihood and consequences

estimation: of a risk.

Risk
The process of comparing an estimated risk against given risk criteria to
evaluation
: determine the significance of the risk

Inventory analysis is the process of identifying and accounting Hazardous items to

find the risk involved.
RISK ASSESSMENT TOOLS

Risk assessment tools, sometimes called "risk assessment techniques," are

procedures or frameworks that can be used in the process of assessing and
managing risks. There are many ways to assess risk, making risk assessment
tools flexible and There are four commonly used risk assessment tools in
different businesses. All of them are used often and are easily applicable to
different situations.

These tools are:

1. Risk matrix
2. Failure Mode and Effects Analysis (FMEA)
3. Decision Tree
4. Bowtie Model
 1. Risk matrix

•A risk matrix is a visual representation of risks laid out in a diagram or a table,

hence its alternate name as a risk diagram. Here, risks are divided and sorted based
on their probability of happening and their effects or impact.

•A risk matrix is often used to help prioritize which risk to address first, what safety
measures and risk mitigation plans to take, and how a certain task should be done.
Risk matrices can come in any size and number of columns and rows,depending on
the project and risks being discussed.
 2.The Failure Mode and Effects Analysis (FMEA)

•The Failure Mode and Effects Analysis (FMEA) risk assessment tool was first
discovered in the 1940s by the US military to identify all possible issues or failures in
a design, process, product, and service.
•This tool is often used during a product or service's design or proposal
stage to actively study possible risks and discover their effects.

FMEA has two parts to it:

Failure Modes: the failures, problems, and issues that occur
Effects Analysis: the analysis of the failures' effects

3. Decision Tree
•The decision tree risk assessment tool works by providing project managers a
template to calculate and visualize the values of different results and the likelihood of
achieving them.
In some cases, a decision tree is also often used to help calculate the value of a
project, product, or service.

•To use this tool, one starts with one element, product, or service they want to
evaluate, and then creates different branches from it with different goals. When
carried out, the final product looks like a flowchart similar to a tree with different
branches, hence the name.
4. Bowtie Model
•The Bowtie Model risk assessment tool aims to show the causal links between
different sources of risks and their consequences. The left side of the diagram shows
what causes the risk, the right shows their potential outcomes, and then both sides
meet in the middle with a single risk called "Event."
•The left and right sides of the Event are larger and wider as many sources may lead
to different consequences, but still be centered around one risk. When drawn out, the
model starts to look like a bowtie.
 THE DOW FIRE AND EXPLOSION HAZARD (F &EI)
•It is a method for ranking the relative fire and explosion risk associated with a
process.
•The index is developed by the Dow Chemical Company and published by the
American Institute of Chemical Engineering, Dow for evaluating the potential risk from
a process and assessing the potential loss.
•A numerical "Fire and explosion index" (F&EI) is calculated, based on the nature of
the process and the properties of the process materials.
•The larger value of the F&EI, the more hazardous the process.
Objectives of Dow fire and explosion index

Quantify: The expected damage potential due to fire & explosion incidents in
realistic terms.

Identify: Equipment that is likely to contribute to the creation or escalation of an

incident.

Communicate: The fire & explosion potential, to design teams and also the plant
personnel.

It is tailored for the storage, handling, and processing of explosive and flammable
material in the chemical industry.
It uses a systematic approach based on the rating form.
Suitable to be used at an early stage of a project and for auditing the existing plant.
The final rating number (ie F&EI) provides a relative ranking of hazards.
It is also used for estimating damage radius (using Dow correlation) and estimate
the financial loss in the event of an accident (using consequence analysis form).
 Assessment of hazards:

•To assess the potential hazard of a new plant, the index can be calculated after the
Piping and Instrumentation and equipment layout diagrams have been prepared.

•In earlier versions of the guide, the index was then used to determine what
preventative and protection measures were needed.

•In the current version, the preventative and protection measures that have been
incorporated in the plant design to reduce the hazard-are taken into account when
assessing the potential loss: the form of loss control credit factors.
 Calculation of the Dow F & EI
•The first step is to identify the units that would have the greatest impact on the
magnitude of any fire or explosion. The index is calculated for each of these units.
•The basis of the F & EI is a Material Factor (MF). The MF is then multiplied by a
Unit Hazard Factor, F3 to determine the F & El for the process unit. The Unit
Hazard factor is the product of two factors which take account of the hazards
inherent in the operation of the particular process unit the general and special
process hazards.
Simplified procedure for calculating Dow F&EI
Modified procedure for calculating Dow F&EI
Material factor

•The material factor is a measure of the intrinsic rate of energy release from the
burning explosion or other chemical reaction of the material. Values for the MF
for over 300 of the most commonly used substances are given in the guide.

•The reactivity value is a qualitative description of the reactivity of the

substance, and ranges from 0 for stable substances, to 4 for substances that
are capable of unconfined detonation.
•In calculating the F&EI for unit the value for the material with the highest MF,
which is present in significant quantities is used.
General Process Hazards
The general process hazards are factors that play a primary role in determining the
magnitude of the loss following an:

Exothermic chemical reactions: the penalty varies from 0.3 for a mild exotherm,
such as hydrogenation, to 1.25 for a particularly sensitive exotherm, such as nitration.

Endothermic processes: penalty of 0.2 is applied to reactors only. It is increased to

0.4 if the reactor is heated by the combustion of a fuel.

Materials handling and transfer: this penalty takes account of the hazard involved
in the handling, transfer and warehousing of the material.

Enclosed or indoor process units: account for the additional hazard where
ventilation is restricted.

Access of emergency equipment. areas not having adequate access are penalised.
Minimum requirement is access from two sides.

Draining and spill control: penalises design conditions that would cause large spills
of flammable material adjacent to process equipment such as inadequate design of
drainage.
Special process hazards
The special process hazards are factors that are known from experience to contribute
to the probability of an incident involving loss.
Toxic materials: the presence of toxic substances after an incident will make the task
of the emergency personnel more difficult. The factor applied ranges from 0 for non-
toxic materials, to 0.8 for substances that can cause death after short exposure.

Sub-atmospheric pressure: allows for the hazard of air leakage into equipment. It is
only applied for pressure less than 500 mmHg (9.5 bar).

Operation in or near flammable range: cover for the possibility of air mixing with
material in equipment or storage tanks, under conditions where the mixture will be
within the explosive range.
Dust explosion: covers for the possibility of a dust explosion. The degree of risk is
largely determined by the particle size. The penalty factor varies from 0.25 for particles
above 175 μm, to 2.0 for particles below 75 μm.

Relief pressure: this penalty accounts for the effect of pressure on the rate of
leakage, should be a leak occur. Equipment design and operation becomes more
critical as the operating pressure is increased. The factor to apply depends on the relief
device setting and the physical nature of the process material.

Low temperature: this factor allows for the possibility of brittle fracture occurring in
carbon steel, or other metals, at low temperature.
 Quantity of flammable material: the potential loss will be greater the quantity of
hazardous material in the process or in storage. The factor to apply depends on the
physical state and hazardous nature of the process material, and the quantity of
material.
Corrosion and erosion: despite good design and materials selection, some corrosion
problems may arise, both internally and externally. The factor to be applied depends on
the anticipated corrosion rate.

Leakage-joints and packing: this factor accounts for the possibility of leakage from
gaskets. Pump and other shaft seals and packed glands. The factor varies from 0.1
where there is the possibility of minor leaks, to 1.5 for process that have slight glasses,
bellows or other expansion joints.

Use of fired heaters: the presence of boilers or furnaces, heated by the combustion of
fuels, increases the probability of ignition should a leak of flammable material occur
from a process unit. The risk involved will depend on the sitting of the fired equipment
and the flash point of the process material.
Hot oil heat exchange system: most special heat exchange fluids are flammable and
are often used above their flash points; so their use in a unit increases the risk of fire or
explosion. The factor to apply depends on the quantity and whether the fluid is above
or below its flash point.
Rotating equipment: this factor accounts for the hazard arising from the use of large
pieces of rotating equipment: compressors, centrifuges, and some mixers.
Basic preventative and protective measure
The basic safety and fire protective measures that should be included in all chemical
process design are listed below. This list is bases on that given in the Dow Guide,
with some minor amendments.

a) Adequate, and secure, water supplies for fire fighting.

b) Correct structural design of vessels, piping, steel work.
c) Pressure-relief devices.
d) Corrosion-resistant materials and adequate corrosion allowances.
e) Segregation of reactive materials.
f) Earthing of electrical equipment.
g) Safe location of auxiliary electrical equipments, transformers, switches gear.
h) Provision of backup utility supplies and services
i) Compliance with national codes and standards.
j) Fail-safe instrumentation.
k) Provision for access of emergency vehicles and the evacuation of personnel.
1) Adequate drainage for spills and fire-fighting water.
m) Insulation of hot surfaces.
n) No glass equipment used for flammable or hazardous materials, unless no suitable
alternative is available.
o) Adequate separation of hazardous equipment.
P) Protection of pipe racks and cable trays from fire.
q) Provision of block valves on lines to main processing areas.
r) Safe design and location of control rooms.
 PRELIMINARY HAZARD ANALYSIS

•The Preliminary Hazard Analysis (PHA) is usually the first attempt in the system safety
process to identify and categorize hazards or potential hazards associated with the
operation of a proposed system, process, or procedure.

•It provides rationale for hazard control and indicates the need for more detailed
analyses, such as the Subsystem Hazard Analysis (SSHA) and the System Hazard
Analysis (SHA). The PHA is usually developed using the system safety techniques
known as Failure Modes and Effects Analysis (FMEA) and/or the Energy Trace
and Barrier Analysis (ETBA).

•PHA development can be somewhat simplified through the use of a Preliminary Hazard
Matrix identifying a Generic Hazard Group. The PHA Report can be generated based
upon the evaluation and analysis of system hazard risk.

•Preliminary hazard analysis (PHA) is a semi-quantitative analysis performed with the

intention of identifying all potential hazards and accidental events that can cause an
industrial accident.
 Characteristics of PHA
It relies on brainstorming and expert judgment to assess the significance of
hazards and assign a ranking to each situation.

It is typically performed by one or two people who are knowledgeable about the
type of activity in question.

It is applicable to any activity or system

It can be used as a high-level analysis early in the life of a process.

It is used to generates qualitative descriptions of the hazards related to a

process. Provides a qualitative ranking of the hazardous situations; this ranking
can be used to prioritize recommendations for reducing or eliminating hazards in
subsequent phases of the life cycle.

Quality of the evaluation depends on the quality and availability of

documentation, the training of the review team leader with respect to the various
analysis techniques employed, and the experience of the review teams.
Advantages and Disadvantages of PHA

Advantages
Helps ensure that the system is safe.
Modifications are less expensive and easier to implement in the earlier stages of
design
Decreases design time by reducing the number of surprises

Disadvantages
Hazards must be foreseen by the analysts.
The effects of interactions between hazards are not easily recognized
Procedure for Preliminary Hazard Analysis

The procedure for conducting a preliminary hazard analysis consists of the following
steps.

1. Define the activity or system of interest: Specify and clearly define the
boundaries of the activity or system for which preliminary hazard information is
needed.

2. Define the accident categories of interest and the accident severity categories.
Specify the problems of interest that the risk assessment will address (e.g., health
and safety concerns, environmental issues). Specify the accident severity
categories that will be used to prioritize resources for risk reduction efforts.

3.Conduct review. Identify the major hazards and associated accidents that could
result in undesirable consequences. Also, identify design criteria or alternatives that
could eliminate or reduce the hazards.

4. Use the results in decision making. Evaluate the risk assessment

recommendations and the benefits they are intended to achieve (e.g., improved
safety and environmental performance, cost savings).
 HAZARD & OPERABILITY STUDY (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 of the 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.
 The HAZOP Study Process

A Hazard and Operability Study systematically investigates each element in a

process. The goal is to find potential situations that would cause that element to
pose a hazard or limit the operability of the process as a whole. There are four
basic steps to the process:

1. Forming a HAZOP team

2. Identifying the elements of the system
3. Considering possible variations in operating parameters
4. Identifying any hazards or failure points

Once the four steps have been completed, the resulting information can lead to
improvements in the such as adding caution signs or traffic signs. The best way to
apply the results of a HAZOP study will depend on the nature of the system.
1. Form a HAZOP Team : To perform a HAZOP, a team of workers is formed,
including people with a variety of expertise such as operations, maintenance,
instrumentation, engineering/process design, and other specialists as needed.
These should not be "newbies, but people with experience, knowledge, and an
understanding of their part of the system. The key requirements are a
understanding of the system, and a willingness to consider all reasonable variations
at each point in the system.

2. Identify Each Element and its Parameters : The HAZOP team will then create a
plan for the complete work process, identifying the individual steps or elements.
This typically involves using the piping and instrument diagrams (P&ID), or a plant
model, as a guide for examining every section and component of a process. For
each element, the team will identify the planned operating parameters of the
system at that point: flow rate, pressure, temperature, vibration, and so on.

3. Consider the Effects of Variation

For each parameter, the team considers the effects of deviation from normal. For
example, "What would happen if the pressure at this valve was too high? What if
the pressure was unexpectedly low? Would the rate of change in pressure pose its
own problems here?“

Don't forget to consider the ways that each element interacts with others over time; for
example, "What would happen if the valve was opened too early, or too late?"
 4. Identify Hazards and Failure Points

Where the result of a variation would be a danger to workers or to the production

process, we've found a potential problem. Document this concern, and estimate the
impact of a failure at that point. Then, determine the likelihood of that failure; is there a
real cause for the harmful variation? Evaluate the existing safeguards and protection
systems, and evaluate their ability to handle the deviations that we've considered.

Results of a HAZOP Study

•Because HAZOP is a mental exercise, it can be implemented as part of the planning of

a new work process, even before a facility is built. Existing facilities and processes can
also be assessed with HAZOP , Where a HAZOP study is performed in the planning
stage of a new process, completing the study means that all potential causes of failure
will be identified.

•The HAZOP team will write an assessment weighing the potential deviations, their
consequences, their causes, and the protection requirements. From this point, changes
to the plan can be made to prevent problems from arising, or to mitigate their effects.
•In existing facilities, a HAZOP may be ongoing, working to improve the process
without a any specific end date. Instead of a single, large assessment, the study's
results will be released a as a stream of action items, as each problem is identified and
a solution is created.

•In both cases, when a hazardous condition is identified, recommendations may be

made for process or system modifications, or further study by a specialist may be
required.

A HAZOP study might recommend these typical actions:

A review of existing protection system designs by a specialist

Adding or modifying alarms that warn of deviations
Adding or modifying relief systems
Adding or modifying ventilation systems
Increasing sampling and testing frequency
 CHEMICAL HAZARD

•A chemical hazard is any substance, regardless of its form- that

can potentially cause physical and health hazards to people, or
can result in harm to the environment.

•It
can also be defined as the actual risk associated with specific
chemicals, such as skin burns, long term negative impact to
health, lasting environmental damage, fires, or even explosions.
TYPES OF CHEMICAL HAZARDS
Health hazard : This symbol shows a person with damage Health hazard -
and pertains to chemicals that can cause serious and long-term negative
impacts on health. Carcinogens are also substances that are known to be
cancer-causing chemicals. They are categorized as either natural or
manmade, but it is crucial to note that even a small amount of this type of
chemical can severely damage human health.

Flammable: The symbol for this is a flame and it pertains to chemicals or

highly flammable gases that may catch fire or ignite once exposed to air or
other ignition sources or elements.

Irritant/hazardous/hazardous to the ozone layer: This is symbolized by a

big exclamation point and refers to chemicals that usually cause redness,
rashes, or inflammation of the affected area. Although the presence of
symptoms is normally short term, there are still instances where they create
long- lasting effects on others. It is also known to either cause harm to
individuals or pose a threat to public health by harming the ozone layer.
Gas under pressure - The symbol for this is a gas cylinder and it pertains to
gases that are stored under pressure and may explode if heated or
refrigerated gases that may cause burns or injury.
Corrosion - This pictogram shows corrosion of material and skin. It refers to
chemicals that can cause severe skin burns and damage to the tissue once
contacted with.
Explosives - This is symbolized by an exploding bomb and pertains to
chemicals that may explode or can cause a mass explosion
Oxidizers - This pictogram shows a flame over a circle and symbolizes
chemicals or substances that, under certain conditions or exposure to other
chemicals or elements, can cause severe physical hazards such as fires or
explosions.
Hazardous to environment – the symbol for this is a dead tree and fish. It
refers to chemicals that can cause lasting damage to the environment.
Toxic - This pictogram shows a skull and crossbones, and symbolizes
chemicals that even at a very low exposure-can cause irreversible changes or
mutations to a person's DNA, damage to health, or even fatality.
CONTROLLING OF CHEMICAL HAZARDS
•Once the hazards involved in the handling and use of chemicals are identified,
the next stage is to put control measures in place. This includes:
Elimination : options which get rid of the hazard altogether
Substitution- Replacing a hazardous chemical with a less hazardous one
wherever possible.
Engineering Controls- Fume Hoods, local exhaust ventilation, etc.
Administrative control- Standard Operating Procedures (SOP), caution
signages, etc. •
Personal protective equipment- Lab coats, safety glasses, hand gloves, etc.

1. Elimination
The risk control measure that has the greatest level of effectiveness is
elimination. Before any other control measures are considered, elimination
must be applied first. Elimination is the method of totally removing a hazard or
hazardous practice from the workplace.
2. Substitution
If we can't successfully eliminate the use of a hazardous chemical in our
business, we must then try to substitute it. Substitution is when we replace the
use of a hazardous chemical with another chemical that is less hazardous and
presents a lower level of risk.
3. Isolation
If it's not possible to substitute the use of a hazardous chemical with another
chemical that is less hazardous, we must then isolate the hazardous chemical
from people and other incompatible substances.
4. Engineering Controls
If isolation cannot be achieved, you can implement a range engineering
controls to reduce the risk associated with hazardous chemicals. Engineering
controls are physical in nature. They are devices or processes that eliminate
exposure to hazardous chemicals.
Engineering controls can be used to:
- Minimise the generation of hazardous chemicals
- Suppress or contain chemicals .
5. Administrative Controls
If there is still a chemical risk once higher order controls are implemented, then you
must
work to reduce this by developing administrative controls.

6. Personal Protective Equipment

Personal protective equipment (PPE) should not be relied on to control risk.
Instead, PPE should only be used as a last resort when other more effective control
measures have been used and the risk has not been eliminated.

Some examples of PPE can include:

Chemical resistant glasses
Face shields
Protective clothing
Chemical resistant gloves
Shoe covers
Respiratory equipment
 HAZARDOUS PROPERTIES OF CHEMICALS

•Chemical substances that have the ability to create a physical or health

hazard are considered hazardous, Due to their may be but are n properties
chemical hazardous substances may be, but are not limited to being

•Toxic,
•Explosive,
•Flammable,
•Self-reactive,
•Oxidizing,
•Corrosive.

•Exposure to these substances by different routes including inhalation, dermal

absorption, or ingestion can lead to adverse health effects, enhancing the
need to know about the hazards associated to these substances beforehand.
Toxic
•A toxic substance is a substance that can be poisonous or cause health effects.
•Chemicals can be toxic because they can harm us when they enter or contact the
body. Exposure to a toxic substance such as gasoline can affect your health. Since
drinking gasoline can cause burns, vomiting, diarrhea and, in very large amounts,
drowsiness or death, it is toxic.
•Some chemicals are hazardous because of their physical properties: they can
explode, burn or react easily with other chemicals Since gasoline can burn and its
vapours can explode, gasoline is also hazardous.
•A chemical can be toxic, or hazardous, or both.

Explosive
•Explosive, any substance or device that can be made to produce a volume of rapidly
expanding gas in an extremely brief period.
•Basically, chemical explosives are of two types: (1) detonating, or high explosives
and (2) deflagrating, or low explosives.
•Detonating explosives, such as TNT and dynamite, are characterized by extremely
rapid decomposition and development of high pressure,
•Deflagrating explosives, such as black and smokeless powders, involve merely fast
burning and produce relatively low pressures.
Flammable
•Flammability is the ability of a chemical to burn or ignite, causing fire or combustion.
The degree of difficulty required to cause the combustion of a chemical is quantified
through fire testing.

Self-reactive
Self-reactive chemicals are thermally unstable liquid or solid chemicals that can
undergo exothermic decomposition without interacting with oxygen.

Oxidizing
•Oxidizing chemicals are materials that spontaneously evolve oxygen at room
temperature or with slight heating or promote combustion.
•This class of chemicals includes:
∙ Peroxides
∙ Chlorates
∙ Perchlorates
∙ Nitrates
∙ Permanganates
Corrosive

•Corrosive chemicals are defined as chemicals that can cause damage to

body tissues. These chemicals can be dangerous if they come into
contact with user's skin, tissues, eyes, and body parts.

•Corrosive materials can irritate eyes, burn skin, irritate and burn the inner
lining of the nose and throat if inhaled, and have other negative effects if
users are not careful when handling these chemicals.

•Common corrosive chemicals include acids and bases. Hydrochloric acid,

sulfuric acid, and hydrofluoric acid are examples of common corrosive
acids, while ammonium hydroxide, potassium hydroxide, and sodium
hydroxide are examples of bases.
 MATERIAL SAFETY DATA SHEET (MSDS)

•A Material Safety Data Sheet (MSDS) is a document that contains information

on the potential hazards (health, fire, reactivity and environmental) and how to
work safely with the chemical product.

• It is an essential starting point for the development of a complete health and

safety program.
•It also contains information on the use, storage, handling and emergency
procedures all related to the hazards of the material.

The MSDS contains much more information about the material than the label.

•MSDSs are prepared by the supplier or manufacturer of the material.

• It is intended to tell what the hazards of the product are, how to use the
product safely, what to expect if the recommendations are not followed, what to
do if accidents occur, how to recognize symptoms of overexposure, and what to
do if such incidents occur.
•The purpose of a safety data sheet is to act as a quick reference for safely
storing, handling, and transporting the chemical product.

The specific contents of the document vary depending on the nature of the
substance and the manufacturer. It will, however, typically include :

Product Information: product (name), manufacturer and suppliers names,

addresses, and emergency phone numbers

Hazardous Ingredients
Physical Data

Fire or Explosion Hazard Data Reactivity Data: information on the chemical

instability of a product and the substances it may react with

Toxicological Properties: health effects

Preventive Measures

First Aid Measures Preparation Information: who is responsible for

preparation and date of preparation of MSDS
•Employers and employees need the information contained on MSDSs to
protect themselves from hazardous chemical exposures and to work
safely with chemical
products. The result will be a reduction in chemical source illness and
injuries in the workplace.

•The use and distribution of MSDSs have proven to be an effective and

efficient way to ensure that employers and employees can obtain
necessary information on the hazards associated with exposure to
chemicals in the workplace.