9/7/2010

Introduction to 
Introduction to
Industrial Safety
Prof. Ir. Dr. Mohd Sobri Takriff
Dept. of Chemical & Process Engineering
Universiti Kebangsaan Malaysia

Learning Outcomes
At the end of the course you are expected to
i. Understand the importance of safety and risk
management in the process industry and aware of its
legsilative requirements
ii. Understand hazard system and types of hazards that exist
in the industry
iii. be able to aply various hazard identification and analysis
techniques (CHA, PHA, Dow’s indices, HAZOP, FMEA,
FTA, ETA)
iv. Be able to apply simple risk assessment technique

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Course Content
• The objective of this course is to impart knowledge and understanding on
aspects of safety so that students can gain skills to handle and manage a
process plant safely for the workers, the public, property and the
environment. Students will be introduced to methods of identifying
potential hazards at the work place, evaluate the adverse consequences if
there are realization of the identified hazards and to estimate the
frequency of such hazard realizations so that appropriate decisions can be
made to produce working conditions that are much safer. Students are
also introduced to state legislations pertaining to occupational safety and
health together with regulations under these legislations that have to be
complied.

Texas City, USA
March 23, 2005 Flixboro, UK
Explosion at oil Refinery June 1st, 1974
15 Death & 170 injuries p y
Explosion at Nylon Plant
Loss more than USD 1.5 Billion 28 Death & 36 injuries

Toulouse, France
Bhopal India Sept 21st, 2001
03 Dec 1984 AZF Fertilizer Plant
AZF Fertilizer Plant
Toxic gas, Union Carbide Plant 29Death & 2500 injuries
2000 deaths, 20,000 injuries Damages exceeding Euro 1.5 Billion

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Bright Sparkles, Sg Buloh
• Explosion at 
fi
fireworks factory
k f t
– May 7, 1991
– Consequences
• 22 deaths
• 103 injuries

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Hazards & Industrial Safety
• Hazards are always associated with industrial 
activities
– Process materials,  operating conditions, industrial 
machineries, workplace, etc
• Hazardous materials If not managed could 
lead to major accidents such as
– Fire, explosion, release of toxic gas, etc
Fire explosion release of toxic gas etc
that would results in injury, fatality, property 
damages, environmental damages, etc

Major Industrial Accidents
• Fires
• Explosions
• Release of toxic materials

Types of Accident Probability of  Potential for Potentail for 

Fire High Low Intermediate

Ref: Crowl & Louvar 2002

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Accident Consequences
• Human  • Property
– Loss of life
Loss of life
– Damages 
– injury 
– Permanent disability  – Disruption of life

• Environment • Economy
– Pollution
• Air 
– Loss of employment
Loss of employment
• water – Loss of income
– Damages
– Loss of investment

Accident Consequences
• Company
– Difficulty for new investments
Difficulty for new investments
• Financing
• Resistance from local residents
– e.g.  Union Carbide Inc.
• Established in 1917
• International company in chemical and petrochemical 
businesses all over the world
• 1984 –
1984 Bhopal accident ( thousands kills & few hundred 
Bhopal accident ( thousands kills & few hundred
thousand injured)
– Company image severely damage & face legal action
– Difficulty for new investment
• Sold to Dow Chemicals in 2001

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Engineering Code of Ethics
Engineers, in the fulfillment of their professional 
d ti
duties, shall  
h ll
– hold paramount the safety, health, and welfare of 
the public.
– Perform services only in areas of their 
competence
– ….
– ….

Legislative Requirements
Environmental Quality Act 1974
– During planning stage is required  to 
carryout an Environmental Impact 
Assessment (EIA)  the to ensure that the 
safety of the public is safeguarded, the 
environment is protected  and sustainability 
p y
criteria is considered

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Legislative Requirements
OSHA 1994
– It shall be the duty of every employer and every 
It h ll b th d t f l d
self‐employed person to ensure, so far as is 
practicable, the safety, health and welfare at work 
of all his employees and It shall be the duty of 
every employer and every self‐employed person 
to conduct his undertaking in such a manner as to 
ensure, so far as is practicable, that he and other 
f i ti bl th t h d th
persons, not being his employees, who may be 
affected thereby are not thereby exposed to risks 
to their safety or health 

Legislative Requirements
OSHA 1994 ‐ CIMAH (Control Of Industrial Major 
A id t H
Accident Hazards) Regulation 1996
d ) R l ti 1996
– states that every manufacturer who undertakes an 
industrial activity shall as soon as he becomes 
aware of an imminent danger which may affect 
the safety of persons or the environment, take 
i
immediate action to rectify the situation and 
di t ti t tif th it ti d
establish and maintain a good management 
system for controlling any major accident.

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Risk Management

HIRARC – Hazards indentification, Risk Assessment

Important terminology
• Hazard ‐ chemical or physical conditions that has the 
potential for causing damage / harm to people, property, 
or the environment. 
• Risk ‐ A measure of human injury, environmental 
damage or economic loss in terms of both the incident 
likelihood and the severity or magnitude of the loss or 
injury.
• Risk management ‐ The systematic application of 
management policies, procedures, and practices to the
management policies, procedures, and practices to the 
tasks of analyzing, assessing, and controlling risk in order 
to protect employees, the general public, and the 
environment as well as company assets while avoiding 
business interruptions.

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Summary
• Hazards are assoaciated with industrial activities
• Hazard has numerous consequences to
Hazard has numerous consequences to
– Human, Property, Environment, Economy, Company 
image, etc
• It is a moral and legal responsibility of engineers 
to ensure the well being of workers and the 
general public are safeguarded
general public are safeguarded
• Industrial risk must be managed properly
– Indentify hazard, Assess risk, Control risk, 
Communicate risk