Mcn 401 - Industrial Safety Enginering Module 5

HAZARD AND RISK

Hazard : A hazard is any source or situation with the potential to cause harm, injury, or ill
health. It represents the inherent danger present in substances, processes, or conditions,
such as chemicals, electricity, sharp tools, or unsafe environments.

Examples:

▪ A wet floor (hazard of slipping)

▪ High voltage wire (hazard of electrocution)
▪ Toxic chemical (hazard of poisoning)

Risk : Risk is the likelihood that a hazard will actually cause harm, considering both the
probability of occurrence and the severity of consequences. Even if a hazard exists, proper
safety measures can reduce the overall risk to minimal levels.

Examples:

▪ Walking on a freshly mopped floor in smooth shoes = high risk of slipping.

▪ A high-voltage wire properly insulated and out of reach = low risk
▪ A toxic chemical locked in a sealed container = low risk, but hazard remains.

In short:

❖ Hazard = potential for harm

❖ Risk = probability + severity of that harm happening

Types of hazards

➢ Mechanical Hazard
➢ Electrical Hazard
➢ Chemical Hazard

Mechanical Hazard

Mechanical hazards arise from moving machinery parts, tools, or equipment that may cause
cuts, crushing, entanglement, or impact injuries. They are common in manufacturing,
construction, and workshops where rotating, sharp, or fast-moving elements pose risks to
workers’ safety without adequate guarding. Sources are,

▪ Gears and rotating shafts, Conveyor belts, Cutting machines, Press machines,
Forklifts and cranes

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 Mcn 401 - Industrial Safety Enginering Module 5

Electrical Hazard

Electrical hazards occur due to exposure to live wires, faulty circuits, or improper grounding,
which may lead to shocks, burns, fires, or electrocution. Working near power lines,
overloaded systems, or damaged insulation significantly increases the danger if proper safety
measures are ignored. Sources are,

▪ Overloaded circuits, Damaged insulation, Exposed live wires, Improper grounding,

Wet electrical equipment

Chemical Hazard

Chemical hazards result from exposure to harmful substances in liquid, solid, or gaseous
form, which may cause burns, poisoning, respiratory problems, or long-term illnesses. Risks
increase through inhalation, ingestion, or skin contact, especially in industries handling toxic,
flammable, or corrosive chemicals. Sources are

▪ Acids and alkalis, Pesticides and insecticides, Solvents and paints, Toxic fumes and
gases, Cleaning agents

CLASSES OF FIRE

Fire classes are important because they categorize fires based on the type of fuel involved
and it can determine how quickly it burns and how dangerous it is. This helps in selecting the
correct extinguishing method or extinguisher. Using the wrong method can worsen the fire,
cause re-ignition, or increase danger to people and property.

Different Classes of Fire

1. Class A – Fires involving ordinary combustibles like wood, paper, cloth, rubber,
plastics.
2. Class B – Fires involving flammable liquids like petrol, diesel, oils, paints, solvents.
3. Class C – Fires involving fire due to electric failure from appliances and wiring
4. Class D – Fires involving combustible metals like magnesium, sodium, potassium,
aluminum powder.
5. Class E (Electrical) – Fires caused by live electrical equipment, circuits, appliances.
(Often combined with other classes once power is cut off.)
6. Class K (or F in some systems) – Fires involving cooking oils and fats, common in
kitchens.

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Class A Fire : Class A fires are the most common type of fire. They are produced from
common combustible materials including wood, paper, fabric, rubber, and plastic. Class A
fires have relatively low ignition temperatures, and once the fuel or oxygen has been
depleted, the fire will burn out. A garbage fire is one example of Class A fires. 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 A fires.

Class B Fire : Class B fires occur when flammable liquids or gases such as alcohol, kerosene,
paint, gasoline, methane, oil-based coolants, or propane ignite. Class B fires are most
common in industrial settings, but they may also occur in residential or commercial settings.
Class B fires 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

Class C Fire : Class C fires are those fires that have live electrical currents or electrical
equipment as a source of fuel. Such fuel sources could include electric tools, appliances,
motors, and transformers. Class C fires are most common in industrial settings that deal with
energy or electrically-powered equipment, like wind turbines. However, Class C fires can also
occur in commercial or residential settings due to issues like faulty wiring.
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.

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.

Class K Fire : Class K fires are cooking fires that occur as a result of the combustion of a
cooking liquid like grease, oil, vegetable fat, or animal fat. Class K fires are technically a type
of liquid fire, but they are separated out as their own class because of their unique setting.
Class K fires are most common in the food service and restaurant industry, but can occur in
any kitchen.
Like other liquid fires, water should not be sprayed onto Class K fires. Instead, wet chemical
agents are the best method to use.

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 Mcn 401 - Industrial Safety Enginering Module 5

TYPES OF FIRE EXTINGUISHERS

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.

Five main types of fire extinguishers

➢ Water, water mist or water spray fire extinguishers

➢ Foam fire extinguishers
➢ Dry Powder – standard or specialist fire extinguishers
➢ Carbon Dioxide (‘CO2’) fire extinguishers
➢ Wet Chemical fire extinguishers

1. Water Type
Water extinguishers are suitable for Class A fires involving ordinary combustibles like wood,
paper, and cloth. They work by cooling the burning material and soaking it to prevent re-
ignition. These extinguishers are not suitable for electrical fires or flammable liquids as water
can conduct electricity and spread the fire.

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2. Film-Forming Foam (FFF) Type

Film-forming foam extinguishers are effective on Class A and B fires. They create a foam layer
that smothers flames and prevents oxygen from reaching the fuel. The foam also forms a
cooling barrier over flammable liquids, reducing the risk of reignition. These are commonly
used in industries, fuel storage areas, and flammable liquid spills.

3. Carbon Dioxide (CO₂) Type

CO₂ extinguishers are ideal for Class B and electrical fires. Carbon dioxide displaces oxygen
around the fire, smothering it without leaving residue. They are especially useful in electrical
equipment, offices, and laboratories. CO₂ extinguishers are not suitable for Class A fires, as
they do not cool the burning material and may allow re-ignition.

4. Dry Chemical Type

Dry chemical extinguishers are multipurpose and can handle Class A, B, and C fires depending
on the formulation (ABC or BC type). They interrupt the chemical reaction of fire, effectively
stopping flames. These extinguishers are versatile, widely used in commercial, industrial, and
domestic settings, and safe for electrical fires, though they leave a powder residue.

5. Wet Chemical Type

Wet chemical extinguishers are designed for Class K (or F) fires, mainly involving cooking oils
and fats in kitchens. They work by cooling the oil and forming a soapy layer on the surface
(saponification), preventing re-ignition. These extinguishers are essential in commercial
kitchens, restaurants, and food processing areas for safe fire control.

6. Dry Powder Type

Dry powder extinguishers are specifically used for Class D fires involving combustible metals
such as magnesium, sodium, and potassium. The powder smothers the fire, absorbs heat,
and prevents oxygen from reaching the burning metal. They are designed to avoid violent
chemical reactions and are commonly used in laboratories, workshops, and metal processing
industries.

Toxic Gas Release Due to Chemical and Fire Explosions

Toxic gas release during chemical and fire explosions is a serious industrial hazard. When
certain chemicals combust or react violently, they can produce harmful gases such as carbon
monoxide (CO), hydrogen sulfide (H₂S), chlorine (Cl₂), ammonia (NH₃), or phosgene (COCl₂).
These gases can spread rapidly, posing immediate health risks including respiratory distress,
poisoning, or even death. In addition, toxic gas clouds can contaminate air, water, and soil,
causing long-term environmental damage. Proper safety protocols, early detection systems,
and emergency response plans are crucial to minimize risks associated with such incidents

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 Mcn 401 - Industrial Safety Enginering Module 5

HAZARD IDENTIFICATION AND RISK ASSESSMENT.

Hazard identification and risk assessment are critical components of an effective safety and
health program in any workplace. These processes aim to proactively identify and assess
potential hazards to prevent injuries, illnesses, and accidents.

Steps in Hazard Identification and Risk Assessment

1. Collect Existing Information About Workplace Hazards

Gather all available information about hazards in the workplace from both internal and
external sources and records to understand known hazards and operational risks.

How to Accomplish:

▪ Review equipment and machinery manuals, safety data sheets (SDS), and inspection
reports.
▪ Analyze past injury and illness records.
▪ Collect exposure monitoring data and industrial hygiene assessments.
▪ Utilize safety programs and input from workers (e.g., surveys, safety committee
meetings).

2. Inspect the Workplace for Safety Hazards

Physically examine work areas, machinery, and processes to detect unsafe conditions,
behaviours or any new or recurring hazards that may cause harm.

How to Accomplish:

▪ Conduct regular inspections of all operations, equipment, work areas, and facilities,
involving workers in the process.
▪ Use checklists to assess major hazard categories (e.g., slip/trip hazards, electrical
hazards, fire protection).
▪ Document inspections and take photos for reference and improvement discussions

3. Identify Health Hazards

Evaluate exposure to chemical, biological, and physical agents that may cause acute or
chronic health effects in workers, which can be more complex than safety hazards.

How to Accomplish:

▪ Review chemical hazards through SDS, product labels, and exposure limits.
▪ Identify physical hazards (e.g., excessive noise, heat) and biological hazards (e.g.,
infectious diseases).
▪ Examine ergonomic risk factors (e.g., heavy lifting, repetitive motions).
▪ Conduct quantitative exposure assessments (e.g., air sampling)

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 Mcn 401 - Industrial Safety Enginering Module 5

4. Conduct Incident Investigations

Investigate past workplace incidents to identify hazards and prevent future occurrences.

How to Accomplish:

▪ Develop a clear plan for incident investigations, involving both management and
workers.
▪ Focus on identifying the root causes of incidents rather than blaming individuals.
▪ Document findings and communicate them to improve safety protocols.

5. Identify Hazards in Emergency and Non-Routine Situations

Recognize hazards associated with emergency scenarios or non-routine tasks like during
maintenance, shutdowns, or emergencies when normal operations are disrupted and
hazards may increase unexpectedly.

How to Accomplish:

▪ Identify foreseeable emergencies (e.g., fires, chemical spills, workplace violence) and
non-routine tasks.
▪ Develop plans for responding safely to these hazards, ensuring workers are prepared

6. Characterize the Nature of Identified Hazards and Prioritize for Control

Evaluate hazard severity and likelihood, and prioritize risks to focus control efforts on the
most critical threats first.

How to Accomplish:

▪ Evaluate hazards based on potential outcomes, exposure likelihood, and number of

exposed workers.
▪ Implement interim controls to protect workers until permanent solutions are in place.
▪ Prioritize the hazards based on risk levels.

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 Mcn 401 - Industrial Safety Enginering Module 5

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 easy to use for a variety of jobs,
industries, and needs.
There are four commonly used risk assessment tools in different businesses
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. 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
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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.

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 Mcn 401 - Industrial Safety Enginering Module 5

Uses of Risk Assessment Tools

Risk assessment tools are an essential part of performing risk assessments and risk
management tasks. Not only do they make risk assessments easier, but they also help put
different risks into perspective and help create contingency plans better.

Risk assessment tools help make workplaces safer. They are used to
➢ Raise awareness about different hazards and risks
➢ Identify who is most at risk
➢ Decide what safety measures are needed
➢ Prevent injuries, illnesses, or deaths
➢ Meet legal safety requirements for specific industries

1. Assessing the Consequences of a Hazard

This involves evaluating how severe an injury would be if a worker is exposed to a hazard,
assuming the injury happens. It focuses only on injury severity

We assume the injury will happen and just look at how severe it would be. Injuries are usually
grouped like this:

▪ Fatality – the injury causes death

▪ Major/Serious Injury – serious or permanent damage, needs medical care
▪ Minor Injury – small injury, may need some medical care but short recovery
▪ Negligible Injury – very minor, only needs first aid

Example: For a task like metal shearing, a flying piece of metal could cause serious injury
such as broken bones. So, the consequence is "Major or Serious Injury.

2. Assessing the Likelihood of Injury

This evaluates how likely a worker is to be injured if exposed to a hazard. It doesn’t
measure how likely the hazard is, only the injury risk.

Likelihood levels:

▪ Very likely – the worker is exposed to the hazard all the time
▪ Likely – the worker is exposed to the hazard sometimes
▪ Unlikely – it could happen, but not often
▪ Highly unlikely – very rare, probably won’t happen

Example: If workers stay at a safe distance from the metal shearing machine and wear proper
PPE (Personal Protective Equipment), injury might be "Unlikely."

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