MODULE V

HAZARD IDENTIFICATION AND

ANALYSIS
S7 CE
SYLLABUS
HAZARD & RISK

• Hazard control is oriented

towards recognizing,
evaluating, and working
towards eliminating hazards
at the workplace
RISK = HAZARD X EXPOSURE
• A risk is the chance
(high/low) that any hazard
will cause
TYPES OF HAZARDS

/Electrical Mechanical hazard

hazard
TYPES OF HAZARDS:
[Link] HAZARDS

• Responsible for the majority of

accidents at work
• Equipment should be properly
examined for identifying and for
taking mitigating measures
TYPES OF HAZARDS:
[Link] HAZARDS
Common sources of mechanical hazards are:
(a) Unguarded or inadequately guarded moving parts
(b) Machine tools, hand tools, handling materials, lifting and other
appliances.
(c) improper ventilation, unsafe dress or apparel etc.,
(d) Improper use of tools.
TYPES OF HAZARDS:
[Link] HAZARDS

• This may be due to contact of the

body with wire, cable, or rail or
from the stroke of lightning.
• May cause death(electrocution)
depending on the strength of
current/path it takes.
• May cause burning especially with
higher voltage
TYPES OF HAZARDS:
2. ELECTRICAL HAZARDS
Common sources of electrical hazards are:
(a) Electrical shocks may be caused by an exposed live conductor or a
faulty piece of equipment.
(b) A mobile crane boom, a man carrying or climbing an aluminum
ladder, or vertical metal bars etc. can come in contact with overhead
power lines, electric crane rails, etc
TYPES OF HAZARDS:
2. ELECTRICAL HAZARDS
Common sources of electrical hazards are:
(c) Unskilled electricians, improper instructions, defective wiring which
may cause a short circuit, misuse, or overloading
(d) Ageing and attack by foreign materials cause insulation failures
which cause electrical fires or cases of electrocution
TYPES OF HAZARDS:
3. CHEMICAL HAZARDS

• usage of chemicals with the

resultant hazardous gases,
vapours and fumes is one of the
most dangerous industries.
TYPES OF HAZARDS:
2. CHEMICAL HAZARDS
The effects of noxious gases are:
(a) Simple asphyxiants, e.g., nitrogen gas, methane gas, carbon dioxide.
(b) Chemical asphyxiants, e.g., carbon monoxide, hydrogen sulphide,
hydro-cyanic acid.
TYPES OF HAZARDS:
2. CHEMICAL HAZARDS
The effects of noxious gases are:
(c) Irritant gases, e.g., nitrogen dioxide or peroxide, fluorine,
hydrogen fluoride, sulphur dioxide, ammonia.
(d) Organic metallic gases, e.g., assenic hydride.
(e) Inorganic metallic gases.
CLASSES OF FIRE
 CLASSES OF FIRE
• Class A fires are the most common type of fire and have relatively low
ignition temperatures, and once the fuel or oxygen has been depleted,
the fire will burn out.
• Generally speaking, if the fire leaves ash behind, it's likely a Class A Fire.
• Water and foam agents are most often used when fighting

• Class B fires are common in industrial settings and have a low flashpoint
and also spreads rapidly and produce thick black smoke as they burn.
• carbon Dioxide (CO2) or dry chemical agents are often used to fight
these fires
 CLASSES OF FIRE
• Class C is most common in industrial settings. However, they can also
occur in commercial or residential settings due to issues like faulty
wiring.
• A non-conductive chemical agent, including clean agents, should be
used to put out the flames

• Class D fire most often occurs in laboratories and in manufacturing.

• 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.
 CLASSES OF FIRE
• Class K are technically a type of liquid fire and is most common in
kitchens, food service and the restaurant industry
• Wet chemical agent are the best method to extinguish.
Structure of hazard identification and risk
assessment
To identify and assess hazards, employers and workers should:
• Collect and review information about the hazards present 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.
Structure of hazard identification and risk
assessment
To identify and assess hazards, employers and workers should:( cont..)
• Group similar incidents and identify trends in injuries, illnesses, and
hazards reported.
• Consider hazards associated with emergencies or nonroutine
situations.
• Determine the severity and likelihood of incidents that could result
from each hazard identified, and use this information to prioritize
corrective actions.
Structure of hazard identification and risk
assessment: HAZARD IDENTIFICATION
Action item 1: Collect existing information about the workplace
. hazards

Action item 2: Inspect the workplace for safety hazards

Action item 3: Identify health hazards

Action item 4: Conduct incident investigations

Action item 5: Identify hazards associated with emergency and

non routine situations
Action item 6: Characterize the nature of identified hazards,
identify interim control measures & prioritizehazards for control
Structure of hazard identification and risk
assessment: RISK ASSESSMENT TOOLS
.
The commonly used risk assessment tools are:
1. Risk matrix
2. Failure mode and effect analysis (FMEA)
3. Decision tree
4. Bowtie model
Structure of hazard identification and risk assessment:
RISK ASSESSMENT TOOLS – 1. Risk matrix

.
Structure of hazard identification and risk assessment:
RISK ASSESSMENT TOOLS – 2. FMEA

• Identify all possible issues or failures in a design, process, product,

and service
• Often used during a product or service’s design or proposal stage to
actively study possible risks and discover their effect.
• It has 2 parts:
1. Failure modes: the failure, problems, and issues that occur
2. Effect Analysis: analysis of the failure’s effects
Structure of hazard identification and risk assessment:
RISK ASSESSMENT TOOLS – 3. Decision tree

.
Structure of hazard identification and risk assessment:
RISK ASSESSMENT TOOLS – 4. Bowtie model
The Dow Fire and
Explosion Hazard Index

• It’s the method for ranking the relative fire

and explosion associated with a process.
• This index is developed by the Dow
chemical company and published by the
American Institute of Chemical Engineering,
Dow in 1994
The Dow Fire and Explosion Hazard Index

• It is developed to evaluate a process's potential risk and assess

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 final rating number (ie F&E) provides a relative ranking of
hazards. The larger value of the F&EI, the more hazardous the
process.
• It is also used for estimating damage radius (using Dow correlation)
and estimating the financial loss in the event of an accident (using
The Dow Fire and Explosion Hazard Index:
OBJECTIVES

Quantify the expected damage potential due to fire & explosion

incidents in realistic terms.

Identify the equipment that is likely to contribute to the

creation/escalation of an incident.

Communicate the fire & explosion potential, to design teams and

plant personnel.
The Dow Fire and Explosion Hazard Index:
ASSESSMENT OF HAZARD
Fire and explosion Degree of hazard
index range
1 – 60 Light
61 – 96 Moderate
97 – 127 Intermediate
128 – 158 Heavy
> 159 Severe
The Dow F& EI
CALCULATION
• The first step is to identify the units that would
have the greatest impact on the
the magnitude of any fire/explosion.
• The index is calculated for each of these
units.
The Dow F& EI
CALCULATION
• The Material Factor is a measure of the intrinsic
rate of energy release from the burning
explosion or other chemical reaction of
the material.
The Dow F& EI
CALCULATION
The Dow F& EI
CALCULATION
• The general process hazards are factors that
play a primary role in determining the
magnitude of the loss following an incident
 The Dow F& EI
CALCULATION
Penalty

Exothermic chemical reaction 0.3 – mild (eg: hydrogenation)

1.25 – sensitive (eg: nitration)
Endothermic processes 0.2 – reactors only
0.4 – if reactor is heated by combustion of fuel
Material handling and transfer This penalty takes account of hazard involved in the
handling, transfer and warehousing of material

Enclosed/indoor process units account for the additional hazard where

ventilation is restricted.
Access of emergency equipment Areas not having adequate access are penalised.
Minimum access is from 2 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.
The Dow F& EI
CALCULATION
• The special process hazards are factors that
are known from experience to
contribute to the probability of an incident
involving loss
 The Dow F& EI
CALCULATION
Toxic materials presence of toxic substances after an incident
will make the task of the emergency
personnel more difficult.
0 - non-toxic materials
0.8 - for substances that can cause death
after short exposure.
Sub-atmospheric pressure It is only applied for pressure less than 500
mmHg (9.5 bar).
Operation in or near flammable cover for the possibility of air mixing with
range material in equipment or storage tanks
Dust explosion 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 175µm, to 2.0 for
particles below 75µm.
 The Dow F& EI
CALCULATION
Relief pressure this penalty accounts for the effect of pressure on the
rate of leakage, should be a leak occur
Low temperature this factor allows for the possibility of brittle fracture
occurring in carbon steel, or other metals, at low
temperature.
Quantity of flammable The factor to apply depends on the physical state and
material hazardous nature of the process material, and the quantity of
material.
Corrosion and erosion: The factor to be applied depends on the anticipated
corrosion rate.
Leakage-joints and factor accounts for the possibility of leakage from gaskets
packing 1.5 – minor leaks
1.5 - process that have slight glasses, bellows or other
expansion joints.
 The Dow F& EI
CALCULATION
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.
Hot oil heat exchange The factor to apply depends on the quantity and
system 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:
The Dow F& EI
CALCULATION
The Unit hazard factor is found which is the
product of the two hazard factors
The Dow F& EI
CALCULATION
The MF is then multiplied by unit hazard factor
to determine the F & EI
for the process unit
 The Dow F& EI
CALCULATION: Simplified procedure

Determine Determine
Select units
Divide the penalty factor penalty factor Calculate F &
with highest Determine MF
process into (F1) for general (F2) for special EI = (F1 x F2) x
likelihood of from table
separate units process process MF
hazard
hazards hazards
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
• It is preceded by the preparation of a Preliminary Hazard List (PHL).
• Should be carried out in the early stages of a project and continue
throughout the system/ product’s life cycle
PRELIMINARY HAZARD ANALYSIS

• PHA focuses on identifying immediate hazards, assessing the

severity of potential accidents, and identifying safeguards.
• It aims to save time and money by identifying the weakness in the
early stage
• Format of PHA: Rapid Risk Ranking and Hazard Identification
(HAZID)
PRELIMINARY HAZARD ANALYSIS

• It provides a 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).
PRELIMINARY HAZARD ANALYSIS: Characteristics

• It relies on brainstorming and expert judgment to assess the

significance of hazards and assign a ranking to each situation.
• Typically performed by one or two people who are knowledgeable
about the type of activity in question.
• Applicable to any activity or system
• Used as a high-level analysis early in the life of a process.
PRELIMINARY HAZARD ANALYSIS: Characteristics

• Provides a qualitative ranking of the hazardous situations; this

ranking can be used to prioritize recommendations for reducing or
eliminating hazards
• 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.
PRELIMINARY HAZARD ANALYSIS

ADVANTAGES: DISADVANTAGES:

• Ensure that the system is safe • The effects of interactions

• Modifications are less between hazards are not
expensive and easier to easily recognized
implement in the earlier stages
of design
 PRELIMINARY HAZARD ANALYSIS: Procedure
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.

Define the accident categories of interest and the accident severity categories
e.g., health and safety concerns, environmental issues.

Conduct review
Identify the major hazards & associated accidents that result in undesirable consequences. Identify
design criteria to reduce/eliminate hazard

Use the results in decision making

Evaluate risk assessment recommendations and benefit they are intended to achieve
HAZARD AND 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 performed while:
• New facilities are being designed and constructed
• when new processes are added or
• when processes change.
HAZARD AND OPERABILITY STUDY (HAZOP)

• 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.
• .
Guidewords
CHEMICAL HAZARDS:
HAZARDOUS PROPERTIES OF
CHEMICALS
• Chemical substances that have the
ability to create a physical or health
hazard are considered hazardous.
• Due to their properties chemical
hazardous substances may be:
1. toxic
2. explosive
3. Flammable
4. self-reactive
5. oxidizing, or
CHEMICAL HAZARDS:
Hazardous properties of chemicals

1. Toxic: 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. 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.

✔gasoline can burn and its vapors can explode, gasoline is toxic and hazardous.
CHEMICAL HAZARDS:
Hazardous properties of chemicals
2. Explosive:
✔ Any substance/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
CHEMICAL HAZARDS:
Hazardous properties of chemicals
3. 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.
CHEMICAL HAZARDS:
Hazardous properties of chemicals
4. Self-reactive:

✔ Self-reactive chemicals are thermally unstable liquid or solid chemicals that can
undergo exothermic decomposition without interacting with oxygen.
✔ Self-reactive chemicals can start decomposing due to:

▪ Heat
▪ Contact with acids
▪ Contact with heavy metal compounds
▪ Contact with bases
▪ Friction
CHEMICAL HAZARDS:
Hazardous properties of chemicals
5. 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
• Nitrates
• Chlorates
• Permanganates
• Perchlorates

✔ Strong oxidizers are capable of forming explosive mixtures when mixed with
combustible, organic or easily oxidized materials.
 CHEMICAL HAZARDS:
Hazardous properties of chemicals
6. Corrosive: 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.
MSDS
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.
MSDS
• It is an essential starting point for the development of a complete
health and safety program.
• 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
MSDS
MSDS: The specific contents of the document vary depending on the nature
of the substance and the manufacturer. The typical information included are:

1. Product Information: product identifier (name), manufacturer and

suppliers names, addresses, and emergency phone numbers
2. Hazardous Ingredients
3. Physical Data
4. Fire or Explosion Hazard Data
5. Reactivity Data: information on the chemical instability of a product
and the substances it may react with
MSDS: The specific contents of the document vary depending on the nature
of the substance and the manufacturer. The typical information included are:

6. Toxicological Properties: health effects

7. Preventive Measures
8. First Aid Measures
9. Preparation Information: who is responsible for preparation and date
of preparation of MSDS
MSDS
• Employers and employees need information on MSDSs to protect
themselves from hazardous chemical exposures and work safely
with chemical products.
• The result will be a reduction in chemical source illness and injuries in
the workplace