HAZARD CONTROL SYSTEM

Hazard Control Programme:

Hazard (Definition): Hazards are causes of accidents. It is any existing or potential condition at the job site, which by itself or by interaction with other factors, can result in accident. Hazard Control Programme:The essential components of hazard control programme are:a) Hazard Identification i) By inductive method ii) deductive method. b) Ranking hazards by risk to prioritise preventive action. c) Establishing preventive and control measure.( Job safety analysis, developing safety culture, educating the worker, orienting new workers etc.) d) Monitoring e) Evaluating programme effectiveness and feedback. The last two are very important tools, without implementing this two-end result will not achieved.

HAZAN (Hazard Analysis): A Hazard Control System.

It has different types /components. Chose the type of analysis suitable for the system. Any one or all the following can be utilised for analysing the system/process. a) PHA (Preliminary Hazard Analysis): Define the SYSTEM (if required divide the system into sub-system) Identify TYPE of Hazards (Flammable, Explosive, Toxic etc.) in each step. Identify the System ELEMENTS (Storage Tanks, Reaction Vessels, Pipes, Valves etc.) Assess the RISK involved. Recommendation & Documentation. b) FHA (Fault /Failure Hazard Analysis) Identify whether any fault is there in the system. Identify the failure & cause of failure and its effect upon the system. Ask ? ?what will happen, if this component fails? What would be the result?? Examine the effect of the failure of a system /sub-system on another. Also examine the cause of any un-desired event. c) SCA (Sneak Circuit Analysis) [For any Electric/Electronic system] Identify any undesired / inhibited Electric/Electronic circuit function which occur without component failure. ASK ? ?Do we have circuit conditions that could produce unexpected Route/Timing/False display etc. d) OSHA (Operating and Support Hazard analysis) Identify Hazards due to implementation /Change of operational produce or Maintenance system. Identify the Hazards due to the task performed by an individual.

e) OHHA (Occupational Health Hazard Analysis ) Identify the Hazards from health point of view of the persons. Suggest reducing the Risk to an acceptable limit. Suggest protective measures. Give special consideration to: i) Toxic/Harmful substances. ii) Ergonomic designs. iii) Protective appliances/equipments.

HAZOP:(Hazard and Operability)- A tool for Hazard Control System.

HAZOP study is an important Hazard Analysis technique to examine critically, the process to discover the potential Hazards and operability problems. Advisable to start this study from the design stage of a project. Can be carried out in the existing Plant also, by examining the operational processes critically, studying the plant component design and existing standards and regulations. Study the original design and see wether the existing process devices from the recommended one. Identify the possible cause of deviation from the normal operation and their consequences. Identify any operational malfunction that could lead to the possible hazardous situation. Study the Inspection, maintenance/Repair & monitoring procedures. Eliminate / Control / Isolate the identified hazards. Consider alternate approach to minimise hazards. Minimise Human errors. Protect critical components by separation /guarding. Provide suitable Alarms (Audio/Visual/Audio-visual) Provide adequate safety requirements.

HAZOP Procedure:
HAZOP; It is a formal systematic & critical examination of a process/new facilities to assess the hazard potential involved at each stage. Important aspects: 1. All input data, Drawings must be accurate. 2. Team constituted for this must have adequate technical skill. 3. Team must have ability to maintain a sense of proportion. 4. Team should have ability to visualise deviations causing consequences. PROCEDURE TO GO FOR HAZOP STUDY Team Formation: It is a multi disciplinary team consisting of technical as well as supporting members. Leader Secretary 3 to 5 technical members 2 Supportive members Preparatory work: It consists of following-

1. 2. 3. 4.

Data collection Conversion of data in desired format Study of design/plan/sequence. Planned & scheduled meetings

Examination of system/practices:- Here discussion is done and solutions are found. Important thing to remember here is that -NO SOLLUTION TO BE STARTED FOR SEARCHING TILL ALL HAZARDS HAVE BEEN IDENTIFIED. FOLLOW UP WORK: Action should be taken as Process change(material etc ) Process condition change Operating method change Change in physical design During final review emphasis must be given on to club the actions in following categories:(a)Actions which remove hazards. (b)Actions, which reduce consequences. Note-Priority to be taken to remove HAZARDS, but in case there is no reasonable prospect, then The TEAM must consider to adequately protect persons with safety appliances.

Documentation of hazard control records:

1. Controlled Documents: A) It is such a document in which parameters are likely to be changed from time to time. B) It should be updated, from time to time, wherever there is some change in operational/Maintenance procedures. C) It should have restricted circulation amongst the end users only. D) The end users should have an updated document only. E) The documentations on Hazop/ Hazan etc. come into this category. 2. Un-Controlled Documents: a) This document can be circulated amongst all. b) This should contain the Basic/General rules, in which the parameters are not likely to be changed. c) The documentation on (say) Welding/Gas cutting / Road Safety etc. come into this category. The above Documents can be named and categorised as follows: i) Basic Safety Rules. ii) General plant safety rules. iii) Job safety instructions (may be depicted in DO?S & DON?T?S from. iv) Permit to work system. v) Standard/safe operational procedures. vi) Maintenance Safety Rules. vii) Safety Inspection checklists. viii) Safety Manual of the Dept.

Some definitions of OH&MS:

Conditions and factors that affect the well being of employees, temporary workers, contractor personnel, visitors and any other person in the workplace. OH&S Management System: Part of the overall management system that facilitates the management of the OH&S risks associated with the business of the organization. This includes the organizational structure, planning activities, responsibilities, practices, procedures, processes and resources for developing, implementing, achieving, reviewing and maintaining the organisation?s OH &S policy. Hazard: Source or situation with a potential for harm in terms of injury or ill health, damage to property, damage to the workplace environment, or a combination of these. Hazard identification: Process of recognizing that a hazard exists and defining its characteristics. Incident? Event that gave rise to an accident or had the potential to lead to an accident. Interested parties: Individual or group concerned with or affected by the OH&S performance of an organization. Non-conformance: Any deviation from work standards, practices, procedures, regulations, management system performance etc. that could either directly or indirectly lead to injury or illness, property damage, damage to the workplace environment, or a combination of these. Objectives: Goals, in terms of OH&S performance, that an organization sets itself to achieve. Risk: Combination of the likelihood and consequence(s) of a specified hazardous event occurring. Risk Assessment: Overall process of estimating the magnitude of risk and deciding whether or not the risk is tolerable. Safety: Freedom from unacceptable risk of harm. Performance: Measurable results of the OH&S management system, related to the organisation?s control of health and safety risks, based on its OH& S policy and objectives.

Occupational Health - A Global Issue:

Each year work-related injuries and diseases kill an estimated 1.1 million people worldwide, which roughly equals the global annual numbers of deaths from malaria. The International Labour Organization (ILO) has estimated that in 1977, the overall economic losses resulting from work-related diseases and injuries were approximately 4% of the world?s gross national product.

 Approximately 30% of the workforce in developed and between 50 and 70% in developing countries may be exposed to heavy physical work loads or ergonomically poor working conditions, which can lead to injuries and musculoskeletal disorders. Physical hazards, which can adversely affect health, include noise, vibration, ionizing and non-ionising radiation, heat and other unhealthy microclimatic conditions. Between 10 and 30% of the workforce in industrialized countries and up to 80% in developing and newly industrialized countries are exposed to variety of these potential hazards. Social conditions at work, which raise serious concerns about stress, include inequality and unfairness in the workplace; management style based on the exclusion of workers from decision-making process: lack of communication and poor organization of work:; strained interpersonal relationships between managers and employees. Stress at work has been associated with elevated risks of cardiovascular diseases, particularly hypertension, and mental disorders.