ISE

Module 5
 Hazard
• Existing or Potential
Condition That Alone or
Potential Condition That
Alone or Interacting With
Other Factors Can Cause
Harm Factors Can Cause
Harm
• Factors Can Cause Harm

• A Spill on the Floor

• Broken Equipment
 Risk
• A measure of the probability and
severity of a hazard to harm human
health, property, or the environment
• A measure of how likely harm is to occur
and an indication of how serious the
harm might be

Risk ≠
0
 Types of Hazards
• Physical Hazards
• Chemical Hazards
• Biological Hazards
• Fire and Explosion Hazards
• Ergonomic Hazards
• Environmental Hazards
 Physical Hazards
A physical hazard is a factor, agent, or circumstance that can cause harm
through contact. Some examples of physical hazards include:
• Noise: Loud noises can damage hearing over time, or cause tinnitus,
stress, irritability, and sleep disorders.
• Vibration: Whole-body vibration occurs when the body is supported on
a vibrating surface, like in a vehicle or near vibrating machinery.
Hand-arm vibration occurs when vibrating tools or work pieces are
grasped or pushed by the hands or fingers.
• Radiation: Exposure to radiation can cause cataracts, thyroid damage,
cardiovascular damage, DNA damage, and more.
• Electricity: Electrical damage can be a physical hazard.
• Extreme temperatures: Elevated heat can be a physical hazard.
• Confined spaces: Confined spaces can be a physical hazard.
• Heights: Working at heights can be a physical hazard.
• Sharps: Sharps must be disposed of in approved sharps containers and
not in municipal waste.
 Chemical Hazards
Chemical hazards are substances that can be toxic or
irritating to the body, and can cause a range of health
and physical hazards:
• Health hazards: Can include irritation, sensitization,
and carcinogenicity. Long-term exposure to chemical
hazards can increase the risk of heart disease, stroke,
and high blood pressure.
• Physical hazards: Can include flammability, corrosion,
and explosibility.
• Exposure: Can occur through inhalation, ingestion or
dermal contact
 Biological Hazards
• Biological health hazards include bacteria,
viruses, parasites or fungi. They can pose a
threat to human health when they are
inhaled, eaten or come in contact with skin.
 Environmental Hazards
Environmental hazards are events or substances in
the environment that can harm people and things
they value. Some examples of environmental hazards
include:
• Chemical hazards: These can be a threat to the
safety of people in the workplace and nearby
areas.
• Physical hazards: These include wet floors,
improper lighting, noise pollution, and extreme
weather.
• Biological hazards: These include exposure to
viruses or bacteria that can threaten health.
 Fire and Explosion Hazard
• Fire and explosive hazards include
combustible and flammable liquids and
substances, and/or when hot work is
performed.
• Fire and explosion can occur when the
temperature has reached the flash point
of the volatile material, and where there
is sufficient vapour present in the
atmosphere.
 Ergonomic Hazards
• Ergonomic hazards are physical factors around
the workplace that can lead to musculoskeletal
issues. Common in office environments,
ergonomic hazards are attached to workstations
and performing standard tasks.

• Actions like lifting and carrying heavy boxes can

trigger musculoskeletal issues. But so too can
simple activities such as sitting at a desk
incorrectly.
Fire Triangle
❑ Every fire involves a chain reaction
in which a multitude of chemical
reactions generate chemical
compounds or elements that
sustain the process.

❑ Removal or elimination of one of

the parameters prevents or ceases
fire
 HAZARD IDENTIFICATION & RISK
ASSESSMENT (HIRA)
A Hazard Identification and Risk Assessment (HIRA) is a
systematic risk assessment tool that can be used to assess
the risks of various hazards. There are three reasons why a
HIRA is useful to the emergency management profession:
• It helps emergency management professionals prepare
for the worst and/or most likely risks.
• Allows for the creation of exercises, training programs,
and plans based on the most likely scenarios.
• Saves time and resources by isolating hazards that
cannot occur in the designated area.
 HIRA
• Risk is the unwanted consequence of an event or series of events.
Risk occurs when multiple risk causing factors occur at the same
time causing an accident manifesting in an event like a fire or
explosion.
• Risk Assessment (RA) is a method that has proven its value as an
all-round tool for improving the safety standards prevalent in
every hazardous industry.
• With advancements in in-built and inherent safety systems,
accidents rates have come down, but still persist at unacceptable
levels for newer technology, new plants and chemical handling
facilities.
• RA is a structured safety assessment tools designed for high
hazard industries such as chemical, petrochemical, pesticides
pharmaceuticals, sea ports, etc., supplementing other safety
systems tools such as HAZOP, safety audit, and regular incident
analysis to identify the potential for incidents (near-misses,
unsafe conditions) and to evaluate the necessary control
measures.
 Objectives of HIRA study:
• Carryout a systematic, critical appraisal of all
potential hazards involving personnel, plant, services
and operation methods.
• Identify the existing safeguards available to control
the risks due to the hazards.
• Suggest additional control measures to reduce the
risk to acceptable level.
• Prepare a Risk register that will help in continuously
monitoring these risks, detect any changes and
ensure the controls are effective.
 Step 1: Identification of the Hazard
• Hazard Identification is a critical step in Risk
Analysis.
• Many aids are available, including experience,
engineering codes, checklists, detailed process
knowledge, equipment failure experience, hazard
index techniques, What-if Analysis, Hazard and
Operability (HAZOP) Studies, Failure Mode and
Effects Analysis (FMEA), and Preliminary Hazard
Analysis (PHA).
• In this phase all potential incidents are identified
and tabulated. Site visit and study of operations
and documents like drawings, process write-up etc.
are used for hazard identification.
 Step 2: Assessment of the Risk
• Consequence Estimation is the methodology used to
determine the potential for damage or injury from specific
incidents. A single incident can have many distinct incident
outcomes.
• Likelihood assessment is the methodology used to estimate
the frequency or probability of occurrence of an incident.
Estimates may be obtained from historical incident data on
failure frequencies or from failure sequence models, such as
fault trees and event trees.
• Risks arising from the hazards are evaluated for its tolerability
to personnel, the facility and the environment. The
acceptability of the estimated risk must then be judged
based upon criteria appropriate to the particular situation.
 Step 3: Elimination or Reduction of the
Risk
• This involves identifying opportunities to reduce the likelihood
and/or consequence of an accident Where deemed to be
necessary. Risk Assessment combines the consequences and
likelihood of all incident outcomes from all selected incidents to
provide a measure of risk.
• The risk of all selected incidents are individually estimated and
summed to give an overall measure of risk. Risk-reduction
measures include those to prevent incidents (i.e. reduce the
likelihood of occurrence) to control incidents (i.e. limit the
extent and duration of a hazardous event) and to mitigate the
effects (i.e. reduce the consequences).
• Preventive measures, such as using inherently safer designs and
ensuring asset integrity, should be used wherever practicable. In
many cases, the measures to control and mitigate hazards and
risks are simple and obvious and involve modifications to
conform to standard practice.
 The general hierarchy of risk
reducing measures is:

• Prevention (by distance or design)

• Detection (e.g. fire and gas, Leak detection)
• Control (e.g. emergency shutdown and
controlled depressurization)
• Mitigation (e.g. fire fighting and passive fire
protection)
• Emergency response (in case safety barriers fail)
 Inventory Analysis
• This method proceeds to analyse quantity of
hazardous material and to reduce it to the
minimum possible level, to find out its safe
substitute if any, and to find out necessary
control measures to prevent or contain any
accident due to it.
 Inventory Analysis
• Steps suggested by the World Bank and IFC
Guidelines to prevent major accident and to
limit their consequences are: Proper design,
construction, inspection, maintenance and
operation of storage vessels and process plants,
alarms, trips, dump-tanks, scrubbers, water
curtains, emergency procedures; information,
training and protective equipment to workers,
and on-site and off-site emergency plans.
 Fire and Explosion Hazard rating of
Process plants
Dow Fire and Explosion Index
• The Dow Fire and Explosion Index is a technique for
measuring the total hazards of a plant or part of its
services. The index can be used to identify
inconsistencies and provide guidelines for reducing
damage.
Fire and Explosion Risk Assessment (FERA)
• This structured process assesses the probability of fire
and explosion accidents and their consequences. The
results can be used to ensure safe facility layouts and
specify fire protection requirements
 Fire and Explosion Hazard Rating
Fire and Explosion Inherent Environmental Risk Index
(F&E-IERI)
• This risk-based index ranks chemical process routes
based on the environmental impacts of fires and
explosions. It considers factors like the magnitude of
environmental impact, the frequency of fire and
explosion events, and the vulnerability of affected
environmental elements.
Fire and Explosion Hazard Analysis (FEHA)
• This systematic evaluation identifies and assesses
potential fire and explosion risks. It's important for
safeguarding against catastrophic incidents, protecting
personnel, and ensuring operational continuity.
Dow Fire and Explosion Index(FEI)
The Dow FEI is a ranking system that gives a
relative index to the risk of individual
process units due to potential fires and
explosions.

Introduced by Dow Chemicals

 Dow FEI
■ V1.0 was first Issued in 1964 By Bill Braise
■ V7.0 was last issued in 1994 and is now
marketed by the AIChE
■ FEI is widely used outside of Dow.
■ FEI is the leading hazard index
methodology recognized by the chemical
industry.
 What is the Primary Purpose of
the Dow FEI?
• It serves as a guide for the selection of
fire and explosion protection methods.
• It assists in determining the spacing
between adjacent process units within
the ISBL.
• It is a guide for insurance agencies to
set insurance rates.
• It ranks individual process units where
special safety attention can be focused.
 When should one perform an FEI?

• Late in Phase III Engineering after:

– P&IDs have been completed,
– Equipment has been sized,
– A trial equipment layout has been done,
– A DFC estimate has been completed.
Who Usually Performs the FEI?

• Generally a senior process engineer,

who is acquainted with the details of
the project, is assigned the task.
• Occasionally, different groups tackle the
assignment and results are compared
for consensus building.
 What Does the FEI Consider?

• Six general process hazards.

• Twelve special process hazards.
• Nine process control credit factors.
• Four material isolation credit factors.
• Nine fire protection credit factors.
General Process Hazards
• Exothermic reactions.
• Endothermic processes.
• Material handling and transfer
• Enclosed or indoor process units.
• Access.
• Drainage and spill control.
Special Process Hazards

• Toxic materials.
• Sub-atmospheric pressure (<500 mmHg).
• Operating in or near flammable range.
– Tank farm storage flammable liquids.
– Process upset or purge failure.
– Always in flammable range.
• Dust explosion.
• Pressure.
 Special Hazards Cont’d

• Low temperature.
• Quantity of flammable/unstable
material.
– Liquids or gases in process.
– Liquids or gases in storage.
– Combustible solids in storage.
• Corrosion and erosion.
Special Hazards Cont’d

• Leakage – joints and packing.

• Use of fired equipment.
• Hot oil heat exchanger system.
• Rotating equipment.
Process Control Credit Factors

• Emergency power.
• Cooling.
• Explosion control.
• Emergency shutdown.
• Computer control.
Process Control Factors Cont’d

• Inert gas.
• Operating instruction
procedures.
• Reactive chemical review.
• Process hazard analysis.
Material isolation Credit Factors
• Remote control valves.
• Dump or blow down control.
• Drainage.
• Interlocks.
Fire Protection Credit Factors
• Leak detection.
• Structural steel .
• Fire water supply.
• Special systems.
• Sprinkler systems.
• Water curtains.
• Foam.
• Hand extinguishers.
• Cable protection.
 Preliminary Hazard Analysis
• This is an initial study to determine hazard causes, effects
and controls.
• Facts of proposed product, process or operation are to be
known to determine hazards.
• For example, for the product using electric power the
hazards to be presumed are: electric shock, burns, fire,
sparking, hot surface, inadvertent starts of equipment,
failure of the equipment to operate at a critical time to
cause accident, radiation effects, electrical explosions etc.
• Similarly adverse effects of foreseeable causes like chemical
exposures, reactions, acceleration, mechanical effects,
pressure etc. can be listed. Then appropriate remedies are
selected and applied.
 PHA
Since the PHA is fast, cost effective and not complicated
like other methods of hazard assessment, it should be
adopted as the first step. Its basic steps are as under:
1. Assume a type of accident or hazard possible (e.g.
fire, explosion, toxic release, finger cutting etc.)
2. Find out which plant component, system or
machine can cause this accident (e.g. storage
vessel, reactor, pipeline, circular saw etc.).
3. Find out the event (result) initiating the hazard or
accident (e.g. release of explosive or toxic gas,
runaway reaction, leakage, running without guard
etc.).
 PHA
• This will naturally suggest the corresponding
safety devices (safety valve, rupture disc,
alarms, gauges, guards, interlocks, trips etc.).
• The component system or part in step-2 can
then be further examined and analysed for
details of failure and how to remove them.
• This study indicates which system is more or
less important from major hazard point of view
and to limit the assessment to priority
problems and screening less important ones.
 PHA
Preliminary hazard identification is required at
different stages of project as under :
1. R & D : Chemicals, reactions, impurities and pilot
plant.
2. Pre Design : Hazard indices, hazard studies.
3. Design : Process design checks, HAZOP, Failure
mode and effects.
4. Commissioning : Safety audits, mechanical
commissioning tests, NDT, emergency planning.
5. Operation : Condition and corrosion monitoring.
 PHA

PHA is generally used for early identification

of hazards. It is based on -
Raw materials Operating environment
Intermediates Operations
Final products Other facilities
Plant equipment Safety equipment etc
Interface among system components.
 HAZard and OPerability Study
• HAZOP is defined as 'The application of a formal
systematic critical examination to the process and
engineering intentions of the facilities to assess the
hazard potential of mal-operation or malfunction of
individual items of equipment and the
consequential effects on the facility as a whole'.
• In HAZOP a multidisciplinary team searches
deviations from design intent through fixed sets of
guide words or checklists or knowledge.
 HAZOP
• HAZOP can be conducted to check the designs or
operating procedures for a new project or an existing
one. It can also be conducted to improve safety of
existing facilities. 'It is also useful before implementing
significant modifications or for other operational or legal
reasons. After carrying out the Preliminary Hazard
Analysis (PHA) as explained earlier, the plant
component, system or machine/equipment part which
can cause 'major hazard' becomes known to us. Now to
find out deviations or malfunctions leading to such
event and its mode of operation, HAZOP helps us. Thus
HAZOP is complimentary to PHA.
 HAZOP
❑ HAZOP study is carried out to determine deviations from
normal operation and operational malfunctions which
could lead to uncontrolled events.
❑ Although the HAZOP study was developed to supplement
experience-based practices when a new design or
technology is involved, its use has expanded to almost all
phases of a plant's life.
❑ It is based on the principle that several experts with
different backgrounds can interact and identify more
problems when working together than when working
separately and combining their results.
❑ Therefore HAZOP study is performed by a
multidisciplinary expert group always including workers
familiar with the installation.
 HAZOP
• The examination procedure takes a full description of
the process, systematically questions every part of it to
discover how deviations from the intention of design
can occur and decides whether these deviations can
give rise to hazard.
• Each part of design is analysed with questions
formulated around a number of guide words, which
ensure that the question posed to test the integrity of
each part of design will explore every conceivable way
in which that design could deviate from design
intention and then each deviation is considered for
what the consequences it could lead to.
• The potential hazards are noted for remedial action.
• Trivial or meaningless consequences are dropped out.
 HAZOP
Stages at which HAZOP can be carried out are
1. At an early stage of development to decide the site and
identify major hazards.
2. At design freeze stage i.e. when design is completed and
construction is to be started.
3. At pre-start-up stage i.e. when construction is completed
and the operation is to be started.
4. Studies on existing plants.
5. Studies prior to plant modification.
6. Studies prior to taking a plant, out of service.
7. Studies on research facilities.
 Chemical Hazards
People working in chemical factories and dwelling nearby are exposed to
various types of chemical hazards.
• Inflammable, explosive, toxic, corrosive, reactive, radio active, oxidising,
reducing, decomposing, compatible and hidden hazardous nature of
chemicals pose material or property hazards.
• In process, chemical and physical change, chemical reaction, pressure,
temperature, level, flow, quantity and other parameters create process
hazards.
• The vessels and equipment in which the chemicals are stored, handled or
processed, pose vessel hazards.
• The inadequate, defective, under-designed or wrongly modified control
devices or failure thereof cause control hazards.
• Fire or explosion causes fire hazards.
• Effluent disposal and gaseous emissions bring pollution and toxic
hazards.
• Leaks, spills and splashes cause handling hazards. Absence, non-use or
failure of fire fighting equipment, personal protective equipment,
emergency control devices reveal accident and emergency hazards.
• All other unsafe working conditions and unsafe actions pose a variety of
 Classification of Chemical Hazards

• Categorization of chemicals as substances

and mixtures according to their physical,
health, and environmental properties
followed by,
• Employment of pictograms, signal words,
hazard statements, and precautionary
statements to convey critical information
about the hazards posed by the chemicals.
 Physical Hazards
• Explosives • Pyrophoric liquids
• Flammable gases • Pyrophoric solids
• Aerosols and chemicals • Self-heating substances and
under pressure • mixtures
• Oxidizing gases • Substances and mixtures
• Gases under pressure which, in contact with water,
• Flammable liquids emit flammable gases
• Flammable solids • Oxidizing liquids
• Self-reactive substances • Oxidizing solids
and mixtures
• Organic peroxides
• Corrosive to metals
• Desensitized explosives
 Health Hazards
• Acute toxicity
• Skin • Reproductive toxicity
corrosion/irritation • Specific target organ toxicity –
• Serious eye Single exposure
damage/eye irritation • Specific target organ toxicity –
• Respiratory or skin Repeated exposure
sensitization • Aspiration hazard
• Germ cell mutagenicity
• Carcinogenicity
 Environmental Hazards
• Hazardous to the aquatic environment
(acute and chronic)

• Hazardous to the ozone layer

 Control of Chemical Hazards
• Identification of contents, properties, hazards and quantity
of chemicals, their content minimisation, proper storing,
handling and packing;
• auto control, recording and warning devices for level,
pressure, vacuum, temperature, flow, feed, speed, cooling,
heating, stirring, discharge, contamination;
• remote control devices, proper ventilating, exhaust,
scrubbing, neutralising, inactivating and incinerating
devices;
• monitoring, measuring, recording, tripping, correcting and
controlling system, fire fighting and personal protective
equipment, emergency and disaster planning, controls and
all engineering well designed process and plant layout and
fully safe actions of workpeople are utmost necessary to
fight these hazards and to control over them.
 Flammable and Combustible
❑ These chemicals are easily ignited and may present a serious
fire and explosion hazard.
❑ Flammable Liquids: Flash Point Below 100F
❑ Combustible Liquid Flash Point Between 100 F and 200 F
❑ Flammable Solids : Ignition Temperature Below 212 F

❑ Keep away from all ignition sources

(Open flames, hot surfaces, direct
sunlight and spark sources)
❑ Approved safety containers and
cabinets
 Corrosives
❑ Strong acids and bases can destroy human tissues and
corrode metals
❑ Acids and bases are incompatible with one another and may
react with many other classes
❑ Acids react with some chemicals and produce toxic gases.

❑ Segregate acids from, bases, water and

reactive metals like sodium, potassium
and magnesium
❑ Use PPEs (goggles, gloves, and closed toe
shoes while handling)
❑ Store in polyethelyne containers, on
lower shelves with proper ventilation
 Toxics
❑ Overexposure can cause injury or death
❑ Toxics are chemicals with lethal dose (LD50) of more than 50
or less than 500 mg per kg body weight or a lethan
concentration (LC50) in air of more than 200 ppm and less
than 1000 ppm.

❑ Segregate toxics from other hazards

❑ Store in a cool, well ventilated area away
from light and heat.
❑ Containers should be tightly sealed
 Highly Toxics
❑ Can cause injury or death at low concentrations.
❑ Highly toxics are chemicals with lethal dose (LD50) of less
than or equal to 50 per kg body weight or a lethan
concentration (LC50) in air of less than or equal to 200 ppm.

❑ Maintain the lowest possible quantities.

❑ Segregate toxics from other hazards
❑ Store in a cool, well ventilated area away
from light and heat.
❑ Use in a designated area or laboratory.
❑ Highly toxic chemicals that produce
fumes or dusk should always be handled
within a chemical fume hood.
 Oxidizers
❑ Oxidizers are fire hazards.
❑ They will readily decompose under certain conditions to
yield oxygen or react to promote or initiate the combustion
of flammable or combustible materials.

❑ Segregate oxidizers from flammable and

combustible materials (paper, wood),
reducing agents( zinc, alkaline metals,
formic acid) and from organic peroxides
❑ Store in a cool, and dry place.
❑ Do not store under sink.
❑ Do not store on wooden shelves or
cardboard boxes.
 Compressed Gases
❑ Large amount of energy is stored in the cylinder.
❑ Dropping or knocking over a cylinder can cause the energy to
be rapidly released.
❑ Toxicity, flammability, corrosivity or reactivity may cause
additional hazards.

❑ Secure cylinders with chains, so that they

will not fall.
❑ Keep cylinders away from heat and open
flames.
❑ Leave the valve protection cap on unless
it is in use.
 Cryogens
❑ Extremely low temperature (-100 to -270 C)
❑ Living tissues can freeze and become brittle enough to
shatter upon contact with cryogenic materials.
❑ Rapid pressure buildup, oxygen enrichment and
asphyxiation.

❑ Store and handle in a well ventilated

area.
❑ Use only approved storage vessels with
pressure relief mechanisms.
❑ Use insulated holders, eye goggles, face
shields, aprons and cryogenic gloves
while handling cryogenic materials.
 Pyrophorics
❑ Pyrophorics are air reactive substances.
❑ Substances that ignite spontaneously upon contact with air.

❑ Store in a cool dry place

❑ Prevent contact with air.
❑ Treat like highly toxic gases
 Water Reactive
❑ These substances often react violently with water
and may ignite or generate toxic, inflammable or
corrosive gases.

❑ Store in a cool dry place

❑ Keep away from water
❑ Incase of fire do not use water.
 Explosive and Potentially explosive
chemicals
❑ Explosive chemicals can rapidly release tremendous amounts of destructive
energy. And can cause death, injury or severe property damage.
❑ Heat, shock, friction or even static electricity can initiate explosions.
❑ The family include pure chemicals (eg. TNT) and mixtures (eg. Ammonium
nitrate/fuel mixtures)
❑ Potentially explosive chemicals are the substances that become explosive on
how they are handled.

❑ Keep away from all ignition sources such as open

flames, hot surfaces, spark sources, and direct
sunlight.
❑ Designate a special area for use.
❑ Store in an explosive magazine,
Material Safety Data Sheet (MSDS)
❖ A Material Safety Data Sheet (MSDS) is designed
to provide both workers and emergency
personnel with the proper procedures for
handling or working with a particular substance.
▪ MSDS's include information such as physical data
(melting point, boiling point, flash point etc.),
toxicity, health effects, first aid, reactivity,
storage, disposal, protective equipment, and
spill/leak procedures.
▪ These are of particular use if a spill or other
accident occurs.
 MSDS
• Material Safety Data Sheets (MSDSs) are documents
prepared by the manufactures/suppliers of the chemicals
and contain information on physical and chemical
properties of the material, potential hazards of the material
and how to work safely with these materials.
• They also contain information on usages, storage, handling
and emergency procedures related to the hazards of the
materials.
• In fact, they provide a single reference for all information
about hazardous substances.
• MSDSs provide information on chemicals, chemical
compounds and chemical mixtures and are primarily
intended for use by the personnel working with hazardous
chemical substances.
 MSDS
• MSDSs need to be updated every three years, but if
any significant new information becomes available
about the material, then it should be incorporated
into MSDS even before lapse of three years.
• The revised (Material) Safety Data Sheets (SDS)
contains Sixteen (16) Sections, however, different
countries provide for 9 to 16 sections and their
format varies from country to country. As per purple
book on GHS, the information in the SDS should
normally be presented using the following
16headings.
 Sections in MSDS
● (1) Identification
● (2) Composition/ information on ingredients
● (3) Hazard (s) identification
● (4) First-aid measures
● (5) Fire-fighting measures
● (6) Accidental release measures
● (7) Handling and Storage
● (8) Exposure controls/personal protection
● (9) Physical and Chemical Properties
● (10) Stability and reactivity
● (11) Toxicological information
● (12) Ecological information
● (13) Disposal Considerations
● (14) Transport information
● (15) Regulatory information
● (16) Other information