07/04/2021

School of Chemical Engineering

College of Engineering
Universiti Teknologi MARA

Hazards Identification and

the Control of Hazards

Hasnora Jafri
PROCESS SAFETY - CPE615
FKK UiTM

What have you learned

about hazard……..???
It is a physical situation which has the potential to
cause:
▪ Human injury
▪ Damage to property
▪ Damage to the environment
▪ Production losses
▪ Business harm
▪ Increased liability
▪ Combination of the above

Hasnora Jafri
PROCESS SAFETY - CPE615
FKK UiTM

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Categories of Hazards
• Chemical hazards • Thermodynamics hazards
• Acidity • High pressure
• Alkalinity • Vacuum
• Corrosivity • Heat transfer
• Explosiveness • High temperature
• Flammability • Low temperature
• Toxicity • Fluid jets
• Asphyxiation
• Electrical &
• Compressed or liquified
gas electromagnet hazards
• Dust • High voltage
• Oxidizers • Radiation
• Static electricity
• Electrical current
• Poor insulation
Hasnora Jafri
PROCESS SAFETY - CPE615
FKK UiTM

Categories of Hazards
• Health hazards • External threats
• Noise • Accidental damage by missile
• Pollution and vehicles
• Vibration • Act of God and natural
• Radioactivity causes
• Temperature extremes • Abnormal environmental
extremes
• Mechanical hazards • External interference
• Mechanical energy • Instability of structures
• Stresses • External releases of energy
• Impact and forces or toxin, etc.
• Contact laceration
Hasnora Jafri
PROCESS SAFETY - CPE615
FKK UiTM

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Sources of Hazards
The work environment

Equipment/plant/process
Man
Substances/materials Machine
Method
Work system
Material
Milieu
People
(Environment)
Hasnora Jafri
PROCESS SAFETY - CPE615
FKK UiTM

Examples of Hazards and Their

Effects
Table 1
Workplace Hazard Example of Hazard Example of Harm Caused
Thing Knife Cut
Substance Benzene Leukemia
Mycobacterium
Material Tuberculosis
tuberculosis
Source of Energy Electricity Shock, electrocution
Condition Wet floor Slips, falls
Process Welding Metal fume fever
Practice Hard rock mining Silicosis
Behaviour Bullying Anxiety, fear, depression
https://www.ccohs.ca/oshanswers/hsprograms/hazard_risk.html

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Elimination of hazards
(unsafe conditions) may help
eliminating accidents…….

But, before you can do something about a

hazard you must identify and recognise it
first.

Hasnora Jafri
PROCESS SAFETY - CPE615
FKK UiTM

Hazard Identification
The identification and understanding of hazards is a fundamental requirement
for all businesses, ranging from offices through to major hazard installations.
Should be viewed as an integral part of securing the long term profitable
development of the business.
Hazard identification is to identify:
◦ The hazards that will exist
◦ The consequences that may occur due to these hazards
◦ The likelihood that these events may take place
◦ The likelihood that safety system and emergency system will function
properly

Hasnora Jafri
PROCESS SAFETY - CPE615
FKK UiTM

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Why do it?
The requirement is a key element of OSHA 1994.

What makes people want to look for

hazards?
• The fear of getting hurt when the risk of doing a job is not minimized
by mitigating the hazards.
• The pressure applied by the Company to identify hazards or else a
negative performance review.
• The desire to meet behavioral expectations.
• Personal integrity or the personal pride that one has in doing the
right job.

Hasnora Jafri
PROCESS SAFETY - CPE615
FKK UiTM

Before you can do something

about a hazard

you must see

the
hazard.

Hasnora Jafri
PROCESS SAFETY - CPE615
FKK UiTM

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Hazards identification objectives:

To improve the safety reliability and operability of a project by recognising
and eliminating or reducing potential hazards at the design stage as well as
through the whole project lifecycle,
To avoid endangering the health and safety of the plant employees and
nearby public, and
To avoid loss of properties which will cause serious financial and economic
loss.

Hasnora Jafri
PROCESS SAFETY - CPE615
FKK UiTM

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When to carry out hazard

identification…???
• Before and during :
• Introduction of new plant, equipment, process, materials
• Alteration to the plant, equipment, workplace
• Change to the way the plant, equipment and area is used
• Change to the work system
• Change in location of the plant, equipment or people

• If new or additional health or safety information associated with plant,

equipment, materials or other item becomes available.

• After an incident, accident or workplace illness.

Hasnora Jafri
PROCESS SAFETY - CPE615
FKK UiTM

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When to carry out hazard

identification…???
The whole plant lifecycle

Hasnora Jafri
PROCESS SAFETY - CPE615
FKK UiTM

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When to carry out hazard

identification…???
Process safety must be integrated into the entire life
cycle of the plant.

Hasnora Jafri
PROCESS SAFETY - CPE615
FKK UiTM

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Basic approach to hazard

identification and risk assessment
1) Identify the types of hazards – these may be chemical, electrical,
physical, mechanical, fire/explosion or health hazards or a combination
of these.
Identify the individual hazards which might arise and under what
conditions this might happen.
2) Evaluate the possible consequences arising from this hazard (to
people, the environment, financial impact or any combination of these).
3) Evaluate the likelihood of the consequence arising.
4) Identify the prevention, control and mitigation measures in place to
limit the consequences and / or reduce the likelihood.

Hasnora Jafri
PROCESS SAFETY - CPE615
FKK UiTM

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Basic approach to hazard

identification and risk assessment
5) Assess if these measures are adequate and reduce the risk to “as
low as reasonably practicable (ALARP)”.
6) Introduce additional measures if required and have a plan of action
to deliver these.
7) Review the assessment periodically to ensure it remains valid in the
light of regulatory changes, new technology and changes in risk levels
considered “tolerable” by society.

Hasnora Jafri
PROCESS SAFETY - CPE615
FKK UiTM

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The process of hazard

identification can also assist in:
1. Revealing hazards which were overlooked in the original design &
installation of plant, equipment, operating procedures & setting-up of
associated work systems;
2. Detecting hazards which have developed after the plant, equipment or
work system has been established;
3. Highlighting any ergonomics problems associated with the plant,
equipment, operating procedures;
4. Indicating any environmental factors e.g. poor lighting, that may
contribute to an accident.
5. Determining methods for ongoing monitoring to achieve optimum OHS
standards.
6. Highlighting any training requirements.

Hasnora Jafri
PROCESS SAFETY - CPE615
FKK UiTM

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Components of Hazard Identification

1. Develop a register for all hazardous items
1. Must list all items with details on the location and usage.
2. One person must be given responsibility for maintaining the
register in each area.
2. Analyse available information about the potential
hazards associated with each item and work system,
e.g.:
1. Check accident/incident reports
2. Check breakdown/maintenance records
3. Check recommended training information, instructions
4. Check codes of practice/standards

Hasnora Jafri
PROCESS SAFETY - CPE615
FKK UiTM

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Components of Hazard Identification

3. Inspect the workplace to identify hazards.
Analyse:
1. The environment.
2. The system of work.
3. The piece of plant, equipment, chemicals or other item itself

4. Record the hazard identification on:

1. Hazard identification checklist, and/or
2. Hazard identification worksheet, and/or
3. Register.

Hasnora Jafri
PROCESS SAFETY - CPE615
FKK UiTM

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Hazard Control Hierarchy

No. Control Method Description/Example

1. Eliminate Completely remove the hazard from the workplace so that

it is not there.
2. Substitute Replace the material or process with a less hazardous one.

3. Isolate Place a barrier or similar between the hazard and people

within the workplace (e.g. a fence surrounding the hazard).
4. Engineering Install or using additional machinery. (e.g ventilation
controls system, guarding on machinery, sensor system).
5. Administrative Safety briefings, safety trainings, work procedure, safety
controls awareness signage.
6. PPE “Last line of defence” to protect a worker if the above
measures have failed.

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Level 1 - Elimination

Level 2 – Minimise the Risk

- Substitute
- Modify
- Isolate
- Engineering

Level 3 – Back Up
- Administrative
- PPE

HIERARCHY OF CONTROLS

Process Safety - CPE615 Hasnora Jafri

FKK UiTM

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Layers of Protection in Process Plant

Layer 1:Basic Process Control
Maintain variables at set points
Layer 2: Alarms
Alert operators
Layer 3: Safety Interlock System
Automatic action usually stops part of plant operation to
achieve safe conditions.
Layer 4: Relief
Automatically provide exit path for fluids

Hasnora Jafri
PROCESS SAFETY - CPE615
FKK UiTM

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Layers of Protection in Process Plant

Layer 5: Containment
Use to moderate the impact of a spill or an escape
(e.g. bunding for storage tank, diversion to temporary
storage)
Layer 6: Emergency Response
Moderate the impact of incidents. A must for every workplace.

Hasnora Jafri
PROCESS SAFETY - CPE615
FKK UiTM

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LAYER OF
PROTECTION
& BARRIER
HIERARCHY

https://www.slideshare.net/ChandrashekharKulkar11/keeping-bowties-alive

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LAYER OF
PROTECTION
& BARRIER
HIERARCHY

http://search.abb.com/library/Download.aspx?DocumentID=3BUS095673&La
nguageCode=en&DocumentPartId=&Action=Launch

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Inherent Safety
As perfect safety cannot be achieved, common practice is to talk about inherently
safer design. “An inherently safer design is one that avoids hazards instead of controlling
them, particularly by reducing the amount of hazardous material and the number of
hazardous operations in the plant.”
Relies on the chemistry and physics to prevent accidents rather than on control
systems, interlocks, etc.
Major approach to inherently safer process design:
▪ minimise (to replace intensification)
▪ substitute (substitution)
▪ moderate (to replace attenuation and limitation of effects)
▪ simplify (to replace simplification and error tolerance)

Hasnora Jafri
PROCESS SAFETY - CPE615
FKK UiTM

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Inherent
Safety
Techniques

Hasnora Jafri
PROCESS SAFETY - CPE615
FKK UiTM

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Risk Analysis Screening Tool (RAST)

https://www.aiche.org/ccps/resources/tools/risk-analysis-screening-tool-rast-and-chemical-hazard-engineering-
fundamentals-chef

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Toxic Release Fire

Explosion

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Hazard from Toxic Substances

1. There are no harmless substance, only harmless ways of using
substances
2. Toxicants
• A chemical agents
• A physical (dusts, fibers, noise, and radiation) agents, e.g.
asbestos
• Toxicity is a property of toxicant that describe its effect on
biological organism.
• Toxic hazards is the likelihood of damage to biological
organism based on exposure resulting from the
use/transport/storage of the toxicants (hazardous material).

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Hazard from Toxic Substances

4. Effects that are Irreversible
• Carcinogen-cause cancer
• Mutagen-cause chromosome (gene) damage
• Teratogen- cause birth defects
5. Effects that may or may not be irreversible
• Dermatotoxic – affects skin
• Hemotoxic – affects blood
• Hepatotoxic - affects liver
• Nephrotoxic – affects kidneys
• Neutotoxic – affects nervous system
• Pulmonotoxic - affects lungs

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Types of Fire
Flash Fire Pool Fire

Jet Fire

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Jet Fire
1. A jet fire is the combustion of material emerging with significant
momentum from an orifice, from a source under pressure, e/g.a
flammable liquid or gas is ignited after its release from a
pressurized, punctured vessel or pipe.
2. The pressure release generates a long flame which is stable
under mostconditions.
3. The duration of a jet fire is determined by the release rate and the
capacity of the source.

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4. Flame length increase directly with flow rate.

5. Crosswinds affect flame length (crosswind velocity)
6. An increase in crosswind velocity causes the flame to bend over
quickly and be convected by the wind.
7. A jet flame is similar to a Bunsen burner flame

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https://www.youtube.com/watch?v=24zDU7GnhYc

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Flash Fire/Vapor Cloud Fire

1. Occurs when a vapour cloud forms from a leak and is ignited, but
without creation of significant overpressure.
2. Released a flammable vapour from a process equipment or pipe
followed by ignition
3. If the ignition is prompt, the cloud may be modest in size. But if the
cloud has time to spread over an appreciable part of the siteand is
then ignited, a major vapour cloud fire may result.
4. It is a quick and short phenomenon which can be accompanied by
mechanical effects (blast).

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https://www.youtube.com/watch?v=Q4cqV34xe0E

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POOL FIRE
1. A pool fire is the combustion of flammable vapor evaporating from a
layer of liquid at the base of the fire.
2. It occurs on ignition of an accumulation of liquid as a pool on the
ground or on water or other liquid.
3. A steadily burning fire is rapidly achieved as the vapor to sustain the
fire is provided by the evaporation of the liquid by heat from the
flames.

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https://www.youtube.com/watch?v=ci9GayOcUp0

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Important terms
Shock wave: An abrupt pressure wave (energy front)
generated due to sudden release of energy, which move in the
medium.
Blast wave: A shock wave in open air generally followed by
strong wind, the combined shock and wind is called blast
wave
Overpressure: The pressure on an object as a result of an
impacting shock wave
Deflagration: An explosion in which the reaction front
(energy front) moves at a speed less than the speed of the
sound in the medium.
Detonation: An explosion in which the reaction front
(energy front) moves at a speed greater than the speed of the
sound in the medium.

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Types of Explosion

1. Vapor Cloud Explosion

2. BLEVE
3. Dust Explosion

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Vapor Cloud Explosion

1. The most dangerous and destructive explosions in the chemical process
industries

2. When flammable vapour is released to the atmosphere, it will form a cloud

suspended inthe air, filling the atmosphere to a height limited by its density.

3. If it is ignited at some early stages, flash fire will be formed.

4. However if ignition is delayed and triggered within the explosive limit, it

will generate more devastating effect known as theVCE.

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https://www.youtube.com/watch?v=bKkpyKFjpNw&t=3s

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Phillips Pasadena, USA

• 23rd Oct. 1989

• 23 Deaths 130 Injuries
• Vapour Cloud explosion
• Loss US$ 500 Millions

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BLEVE
B L E V E
O I X A X
I Q P P P
L U A O L
I I N R O
N D D S
G I I
N O
G N
S

BLEVE is a consequence of holding a pressurized flammable liquids above its

boiling point.

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Causes of BLEVE
• A BLEVE can be defined as a major failure of container at a moment in
time when the contained liquid is at a temperature well above its
atmospheric pressure boiling point.

• The most common type of BLEVE occurs when apressure vessel that is
partially filled with liquid is exposed to afire.

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Mechanism of BLEVE
• The fire weakens the portion ofthe tank shell that is
contacted by the flame and that is not in contact
with liquid.

• Simultaneously, the flame heat the liquid in the

tank, increasing the equilibrium pressure and
ultimately the tank pressure.

• At some point the tank weakens so much that

internal pressure is sufficient to cause the vessel to
rupture.

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Mechanism of BLEVE
• Fragments of the tank are propelled away from the
tank location with great force.

• The liquid remaining in the tank at the time of

ruptureis subject to rapid flash vaporization that
atomizes much of the liquid.

• A fireball is created by burning vapour and liquid at

it expands outward.

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https://www.marineinsight.com/tech/what-is-boiling-liquid-expanding-vapour-explosion-bleve-on-gas-carrier-ships/

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• Second type of BLEVE is that which occurs mechanically

damage tanks.

• In some cases, the damage done to a pressurized tank of liquefied gas

in a transportation accident has been sufficient to cause an
immediate catastrophic failure of the tank.

• In other cases, the damage to the tanks appeared to be minor, but

the stresses imposed on the mechanically damaged areas were
sufficient tocause the tank to fail catastrophically at a later time.

• In this instances, BLEVE’s can occur with out the presence of a fire and
might or might not followed by fireball.

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• A third type of BLEVE can occur if a pressure vessel is allowed to

become completely filled with liquid.

• As the temperature rises, the pressure relief capacity is

insufficient to keep the internal pressure from exceeding the
strength of the tank.

• This type of BLEVE can occur without the presence of a fire

and might or might notbe followed by a fireball.

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https://www.youtube.com/watch?v=UM0jtD_OWLU

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DUST EXPLOSION
• Any combustible material (and some materials normally
considered non-combustible) can burn rapidly when in a
finely divided form.
• If such a dust is suspended in air in the right
concentration, it can become explosive.
• The force from such an explosion can cause employee deaths,
injuries, and destruction of entire buildings.

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• Materials that may form combustible dust include metals (such as

aluminium and magnesium), wood, coal, plastics, bio solids, sugar,
paper, soap, dried blood, and certain textiles.
• In many accidents, employers and employees were unaware that a
hazard even existed.

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https://www.youtube.com/watch?v=70fZqHsEdMo

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