SAFETY

MANAGEMENT

SYSTEM
Engr. M. Aslam
2
 SAFETY
• The opposite of risk (Harm Ringdahl :1993)

• The absence of danger from which harm could result

(Van Steem :1996)

• Freedom from danger or risk of injury. A Set-up

designed to prevent injury. ( Oxford Dictionary)

• In Mathematics Safety is “Inverse of Accident”

Safety = 1 / Accident
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 HAZARD
A hazard is something with the potential
to cause harm or loss to

Health, Life, Property, or Environment

General Hazards are,

Electricity, Fire, Chemicals, Elevations,
 RISK
A risk is the likelihood that the hazard
will actually cause that harm or loss.
Risk is combination of Probability &
Severity. It can be low or high, like

Higher Voltage, Higher Risk

Higher Elevation, Higher Risk
Higher Toxicity, Higher Risk
 GENERAL HAZARDS IN LIFE

ELECTRIC SHOCK FIRE

ROAD ACCIDENTS SLIPS
EXPOSURE TO HEAT FALLS
FALLING OBJECTS FUEL
SHARP OBJECTS ROITS
WIND STORMS, FLOOD, EARTHQUAKE
 HAZARDS IN INDUSTRIES

HIGH VOLTAGE CURRENT HIGH PRESSURE STEAM

CONDENSATE HIGH PRESSURE FUEL GAS

TOXIC GASES, CHEMICALS FLAMEABLE MATERIAL

BOILERS / FURNACES HIGH SPEED MACHINES

ELEVATIONS & FALLING HIGH PRESSURE

OBJECTS REACTORS / VESSELS

RUPTURES / LEAKAGES VERY LOW TEMP. FLUIDS

 BASIC SAFETY OBJECTIVE
Ensure Continuity of Operation/Production through;

• Personnel Protection

• Equipment Protection

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 SAFETY RULES ARE FOR

• EVERY ONE

• EVERY PLACE

• EVERY TIME
 PRIORITY IN SAFETY
• Priority of safety is generally in the following order;

1st ___ Safety of working personnel

2nd ___ Safety of equipment & material

3rd ___ Quality of product

4th ___ Quantity of product

 CAUSE OF ACCIDENTS
Ten-year study of all serious injuries
in all Du-Pont sites showed that:
ACCIDENTS JUST NOT HAPPEN,
THEY ARE CAUSED
95% Accidents are caused due to
Unsafe Acts & 5% Unsafe Conditions
TYPES OF INCIDENTS / ACCIDENTS
 ACCIDENTS ARE CAUSED
Work permit system.
• Cold work permit
• Hot work permit
• Confined Space Entry permit
• Long duration cold work permit
• Annual Hot work permit
• Scaffolding Fitness Certificate
• Radiography permit
• Fire Water permit
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 INCIDENTS / ACCIDENTS
• Accident
The HSE defines an Accident as any
unplanned event that resulted in

• Injury or ill health of people,

• or damage or loss to Property,
plant, Materials or the Environment
• or a loss of Business opportunity.
ACCIDENTS / INCIDENTS INVESTIGATIONS
All accidents & incidents should be thoroughly investigated
and remedial actions be taken accordingly.

Accidents & Incidents are ;

• LWI (Lost work injury) • Fires

• Minor Injuries • Works accidents

• Near Misses • Highway Accidents

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 TYPES OF INCIDENTS / ACCIDENTS
• Near-miss: An incident in which no injury or
damage results. Near Misses should be
reported & circulated which will result
in learning & preventing accidents.

• FAC: First Aid Case, an incident where minor

treatment is required at site

• MTC: Medical Treatment Case, an incident

where employ is shifted to Hospital for
a short period & later resumes his duty
 TYPES OF INCIDENTS / ACCIDENTS
• LTI: Lost Time Injury,

is an injury sustained by an employee

that will ultimately lead to the loss of
productive work time in the form of
worker absenteeism.

LTI is declared if the employ does not

resume his normal duty within 48 Hours
 TYPES OF INCIDENTS / ACCIDENTS

• FATALITY,

It is the death that results from

an Accident at Workplace.
TYPES OF INCIDENTS / ACCIDENTS
INJURIES: MATTER OF PROBABILITY

Fatal
x x

LTI x x x
Reaction
MTC

FAC

Near Miss

Anticipation
Learning's?
4%-unsafe condition

96%-unsafe behavior

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 SAFETY STANDARD
Litmus Test for Industry is
SAFE MAN-HOURS WITHOUT
LOSS TIME INJURY (LTI)

SMH = No of Employees X Hours worked

Severity = No of Days Lost

 WHY DO WE NEED
PROCESS SAFETY MANAGEMENT ?
Zeroth Law of Asset Productivity
• The Productivity of any facility drops
immediately to zero if it:
Blows up
Burns down
Impacts the community
Violates the Regulations
WHY DO WE NEED PSM?
WHY DO WE NEED PSM?
 SOME MAJOR INCIDENTS

CHERNOBEL NUCLEAR PLANT, RUSSIA

UNION CARBIDE, BHOPAL, INDIA

FUKUSHIMA NUCLEAR PLANT, JAPAN

DISASTERS OF CHERNOBYL NUCLEAR ACCIDENT
DISASTERS OF BHOPAL GAS ACCIDENT
FUKUSHIMA NUCLEAR PLANT, JAPAN
 ELEMENTS OF SAFETY SYSTEM
• HSE Policy (Management Commitment)
• Safety Meetings & Inspections
• Emergency Plans & Training
• Injury & Accident Investigation
• Safety Work Instructions
• Work Permits
• Safety Talks / Bulletins and MSDS Manual
• Fire Protection & Emergency Equipments
• Regulations Compliance
• New Employee Orientation
• Visitors Safety 34
 SAFETY MANAGEMENT
• There are two dimensional safety risks,
which are:

Personnel Safety Process Safety

• The purpose is to eliminate : • The purpose is to avoid:

• Personal injury • Fires
• Explosions
• Release of Hazardous
• Change Behaviours Materials
• Protect People and Assets
 THRESHOLD LIMIT VALUE (TLV)

It is the maximum average concentration of a

Hazardous Material floating in the workplace
to which workers can be exposed during an
eight-hour work day and 40-hour work week,
over a working lifetime, without experiencing
significant adverse health concerns.
 SAFETY IMPLEMENTATION
• Define the HSE Policy approved by CEO &
communicate
• Develop Area Ownership Map & communicate
• Develop behavioral observation (BO) procedure &
toolbox. Carry out TNA, train & implement.
• Encourage Incident Reporting (Open Culture)
• Develop Incident Reporting, Classification &
Investigation procedure & toolbox. Carry out TNA,
train & implement.
• Develop TRA (Task Risk Assessment) procedure &
toolbox. Carry out TNA, train & implement.
PERSONAL SAFETY

PPE’s
Personal Protective
Equipment
PERSONAL PROTECTIVE DEVICES
Personal Protective Devices are provided for;
• Head Protection Safety Hat
• Eye and Face Protection Safety Goggles
• Ear Protection Ear Plug/Muff
• Feet protection Safety Shoes
• Respiratory Protection Air Mask/Dust Mask
• Protective Clothing Uniform
• Hand Protection Gloves
• Fall Protection Safety Belt
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EMERGENCY EQUIPMENT
• Safety Showers & Eye Wash Fountains

• Supplied Air Masks

• SCBA (Self Contained Breathing Apparatus)

• First Aid Boxes

• Medical Oxygen Inhaling Unit

• Stretchers

• Ambulance
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PERSONAL & EQUIPMENT PROTECTION
Work permit system.
• Cold work permit
• Hot work permit
• Confined Space Entry permit
• Long duration cold work permit
• Annual Hot work permit
• Scaffolding Fitness Certificate
• Radiography permit
• Fire Water permit
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 WORK PERMIT SYSTEM

• Cold Work Permit

• Hot Work Permit
• Confined Space Entry Permit
• Scaffolding Fitness Certificate
• Radiography Permit
• Long Duration Work Permit

• Annual Hot Work Permit

• Fire Water Permit
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 SAFETY

Isolation (Lockout & Tagging)

 Electric Circuit
 Steam to Turbines
 Process Fluids
 Vessels / Reactors / Towers
EQUIPMENTS PROTECTION
Equipments protection is ensured by;

• Work Practices & procedures

• Work Instructions

• Safety meetings & inspections

• Safety talks/bulletins

• Fire prevention facilities

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 SAFETY TRAINING
• Safety Work instructions

• Use of Safety Equipment

• Fire Fighting Classes/Drills

• First Aid Training

• Refresher Courses on Use of Safety Equipment

• Safety Talks / Bulletins / MSDS

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 NEW EMPLOYEES
ORIENTATION

• Training for plant procedures like Cold work, Hot

Work, Confined Space Entry and lock out / Tag out.

• Training in how injuries and accidents are to be

reported and where first aid can be obtained.

• Training in Personal protective equipment including

where it is obtained and how it should be used.
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 SAFETY STANDARDS
• OHSAS – 18001 (Basic)

• OSHA (US Govt ) World-class Standard

• DUPONT Since 1903, Process & Behavior Safety

 COMBUSTION & FIRE

• Combustion is controlled

Oxidation to produce useful Heat

• Fire is rapid oxidation of a fuel

evolving heat, particulates & gases.

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 What is Fire
Triangle?
• The rapid oxidation of a fuel evolving
heat, particulates & gases.
 CLASSES OF FIRE
A - Free burning materials, Paper, wood, plastics

B - Flammable liquids, Petrol, solvents etc.

C - Flammable gases, Methane, Hydrogen etc.

D - Metals, Potassium, Sodium, Magnesium etc.

F - Edible Oils Cooking fats

Electricity can be involved in any class of fire

 SOURCES OF IGNITION
• Smoking
• Electrical equipment
• Welding
• Heaters
• Tools and equipment
• Arson
FIRE PREVENTION/ FIGHTING FACILITIES
 Water Supply System
• Water Storage Tank
• Fire Water Pumps
• Fire Water Loop
• Fire Hydrants
• Fire water sprinklers & fog Nozzles
• Fire Trucks
• Fire Alarm System

 Steam Guns 60
FIRE PREVENTION/ FIGHTING FACILITIES

 Fire Extinguishers

• Dry Chemical Powder

• Carbon dioxide
• Halotron
• AFFF Foam type
• Pressurized water type

 Emergency Equipment
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 Fire at Bradford
11th May 1985

• Time : first flame

(2-3 Minutes)

How many died? 57

• Very Poor standards of Fire Safety

 FUELS
• Gas
• Paper & Boxes
• Liquid Fuels
• Plastics
• Wood
• Solvents
• Electric Cables
• Furniture
• Waste materials
 4. OD

3. Implement
PSM Program

2. Build a Safety Culture

1. Management Leadership &

Commitment
EXTINGUISHERS - EUROPEAN CHANGES
 Fire Extinguishers - Water
• Red body
• Suitable for use on Class A Fires,
wood and paper etc.
• Not suitable for combustible liquids,
cooking fats etc.
• Not safe to use on fires involving
electricity
• Extinguishes by cooling
 Fire Extinguishers - Foam

• Cream body (Old type) or Red Body

with Cream label

• Suitable for Class A and B Fires.

• Not suitable for use on fires

involving electricity

• Extinguishes by cooling and sealing

the surface of a burning liquid
 Fire Extinguishers - Powder

• Blue body (Old type) or Red

body with blue label.

• Best on Class B fires but safe to

use on any type of fire.

• Works by chemically interfering

with the combustion reaction
FIRE EXTINGUISHERS -CARBON DIOXIDE
• Black body (Old type) or red body
with black label (New type)

• Best on Class B and C fires but safe to

use on any type of fire

• Safe to use on fires involving

electricity

• Extinguishes by reducing oxygen

levels and cooling