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HSEM 1/Ch. 1HSE management View Part I - Dr. Attia Gomaa - 2007

Industrial Safety &Risk Assessment

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HSEM 2 /Ch. 1HSE management View Part I - Dr. Attia Gomaa - 2007

Why HSE & RA?

TargetsTargets

PollutionPollution

AccidentsAccidents 1 . HSE & Risk Ass. Tools2. Awareness programs

3. HSE Systematic approach

Brain-storming

not Blame-storming

Current Current

FutureFuture

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Course Outline:IntroductionChapter 1 : Importance of Industrial Safety & Risk Assessment Chapter 2: HSE Management Chapter 3: Problem Solving TechniquesChapter 4: Risk Assessment Chapter 5: Global Performance EvaluationChapter 6: Hazard Classification & Hazard Control Chapter 7: Job Hazard Analysis (About 70 Real Case Studies)Chapter 8: Risk Based Inspection (RBI) Overview (API 580)Chapter 9: Reliability Centered Maintenance Overview (RCM)Chapter 1 0: International Standards Overview (ISO 1 400 1 & OHSIS 1 800 1 )

Course Outline:IntroductionChapter 1 : Importance of Industrial Safety & Risk Assessment Chapter 2: HSE Management Chapter 3: Problem Solving TechniquesChapter 4: Risk Assessment Chapter 5: Global Performance EvaluationChapter 6: Hazard Classification & Hazard Control Chapter 7: Job Hazard Analysis (About 70 Real Case Studies)Chapter 8: Risk Based Inspection (RBI) Overview (API 580)Chapter 9: Reliability Centered Maintenance Overview (RCM)Chapter 1 0: International Standards Overview (ISO 1 400 1 & OHSIS 1 800 1 )

"In the name of Allah The All Merciful The most Merciful - Useful Science for the Sake of God

Industrial Safety & Risk Assessment for Engineers

Safety First

Dr. Attia Hussien Gomaaa tti ag om aa@ya hoo .com

1) Americ a n Unv . in Ca iro (AUC) En g . Service .2) RCM & HSE Consult a nt f or Industri a l Comp a nies .

3) He a d o f Industri a l En g . Dep a rtment- F ay oum Universit y.

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Your P a rticip a tionWill Mak e This Present a tion More Applic ab le & Success f ul

Let us be a Team Approach

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Safety first Safety is a value

Safety is our business If it is not safe, make it safe

Safety is everyone responsibility Believe that you can make a difference

There is nothing permanent except change Any worker is one of the following:

Trouble-maker, Reactive, Preventive, or Proactive Try to be Proactive

"Never cut what you can untie" Dont Fix the problem, fix the system Do not do more than one critical job at a time

Fire can kill you but the risk assessment can kill the Fire

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Critical System or Project

Desi g n & HAZOP

Process &Per f orm a nce

CostAn a lysis

Critic a lResources

Ma inten a nce

HSE& Ris k

P MIS

Inventor yControl

Systematic Approach for Critical Systems

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Cost&

Resources

Ma inten a nce

HSE&

RCADesi g n

&HAZOP

ProcessInputs & Outputs

Critical Equipment

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En g ine Over ha ul: Repl a ce : Rep a ir Item Replace

(New)

Repair (0 1 0,020,030)

Cost ratio 3 1Duration ratio 1 3

Reliability ratio 2 1

MTBF ratio 2 1CM/PM ratio 1 2Performance ratio 2 1Manpower ratio 1 2

Job Safety Analysis Medium HighEquipment Criticality (HSE, Process, Standby)

Critical Normal (with standby)

In norm a l conditions: Rep a ir polic y if (rep a ir cost

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Tur b ine Over ha ul: Repl a ce : Rep a ir Item Replace Repair

Cost ratio 3 1Duration ratio 1 3

Reliability ratio 2 1

MTBF ratio 2 1

CM/PM ratio 1 2Performance ratio 2 1Manpower ratio 1 2Job Safety Analysis Medium High

Equipment Criticality (HSE, Process, Standby)

Critical Normal (with standby)

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Systematic Approach for Engineers

Engineer

Ma inten a nce Process

Sp a re p a rts & Stoc k

Process &DownLosses

Desi g n &Ma teri a ls

HSE

In f orm a tion &Pl a nnin g

Ma n ag eri a lView

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Basic Aspect of Any Business

Q u a lity

Cost

Emplo yee Rel a tions

Sa f et y

Process

Business Success

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Sa f et y (Accidents, Fire, .. etc .)

Environment(Air, Wa ter, La nd )

He a lth(People )

HSE Analysis

Time

Resources

Specs HSE Management

Team Approach

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Incident:Bad Event that degrade the efficiency of an operation.

Accident:Bad Event that results in physical harm to people

or damage to facility.

Accident types:Struck Against Struck By Fall To Below Fall On Same Level Caught In Caught Between Contact with Overload (Overexertion) )(

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Hazards types:1- Physic a l Haza rds2- En g ineerin g Haza rds:

- Mec ha nic a l Haza rds- Electric a l Haza rds

3- Chemic a l Haza rds

4 - Er g onomics Haza rds5 - Biolo g ic a l Haza rds

Hazards Substances1. Flammable2. Explosive3. Toxic

4. Irritant5. Corrosive

Hazard : Anything which has the potential to cause Harm

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Source: National Safety Council, Accid ent Fa c ts, 1997 E di t io n.

Chapter 1Importance of Industrial Safety & Risk Assessment

In 1 995, National Safety Council (NSC) estimated that:

Workplace accident cost > 75 billion $

Killed workers > 11 ,0000 worker

Injured workers > 7 million worker

Lost workdays > 70 million day

Lost workforce > 35,000 worker

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HSEM 17 /Ch. 1HSE management View Part I - Dr. Attia Gomaa - 2007 Cairo - Egypt

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> 5 millionEgyptian areaffected by

asthma.

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Serious He a lth Imp a cts o f Ast hm a

Ast hm a is a potenti a lly f a ta l, c hronic dise a seResponsi b le f or over 1.8 million emer g enc y room visits per ye a r,Over 4 6 0 thous a nd hospit a liza tions per ye a r a ndOver f ive thous a nd de a ths per ye a r

(Dep a rtment o f He a lth a nd Hum a n Services, 200 2).

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Facts About Vehicle Accidents in Egypt 12, 000 ro a d a ccidents:24 % o f a ll hospit a l f a ta lities28 % o f c hildrens de a ths in hospit a ls .Over 5000 people were killedOver 20 ,000 injuredVer y hig h f a ta lities r a te per 100 million kilometers driven (44 )

Ca uses o f Ro a d /Tr a ff ic incidents in Egy pt

V 0% %

8 %Most Common Human Errors:- Over speedin g- Drivin g on wron g direction

- Sudden stop- Sleepin g while drivin g- Horse pl ay in g- Spe ak in g on the mo b ile p hones w hile drivin g- Ea tin g , drin kin g or smo kin g w hile drivin g- Drivin g under the in f luence o f dru g s

How to Prevent Accidents:

Ob serv a tion tec hniquesSp a ce

Concentr a tion

Pre Dep a rture Chec ks

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Causes Of Incidents %:

30% Poor Maintenance25% Ba cklo g, 20% Qua li ty, 1 5% Spares, 20% P l ann i ng & Fee db a ck ,5% P oo r h o use k eep i ng, 1 5% Others

25% Process & Operator error 90% Unsafe a c ts & 1 0% Unsafe co n di t io ns su c h as p oo r l ay o ut

20% Poor Management (Process, HSE, Maintenance, .. etc.) 7 0% Inf o rmat io n, P l ann i ng & C o ntr ol , 20% Aw areness & Cu l ture, 1 0% o thers

1 5% Design Deficiency 50% Des i gn err o r, 3 5% Mater i a l s, 1 5% o thers

1 0% Others

Egyptian Oil & Gas Industries - Nature of Accidents

Based on data from 5 Egyptian CompaniesLast 1 0 years Accident & Incident History & Brain Storming

Prepared by Dr. Attia Gomaa, 2007, Inprint.

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%Ma in Equipment /Item301) Pipin g s ystems252) Ta n ks83) He a t Exc ha n g ers74 ) Va lves55 ) Towers46 ) Compressors37 ) Pumps28 ) Gag es

16Ot hers100Tot a l




Critical Items

(A Rule 80/20)

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80%

12%5% 3%

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

Human factors Process

factors

Enviromental

factors

Others




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Ca use o f injuries

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Accident Prevention

M anagement Systems

Technology

Human Factors

AccidentRate

Time

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Direct cost is Less than 1 0% of the global costs

Accident or CM or Unplanned job

You only see the tip of the iceberg

Accident

Incident

Unsafe Acts

Unsafe Conditions

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Lost Time Injuries

Medic a l Tre a tment

De a ths

Uns a f e conditions

Uns a f e Acts

First Aid Ca ses

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1. Workers compensation premiums2. M iscellaneous medical expenses .

Direct CostsInsured

Indirect CostsHidden - Uninsured - Out of pocket

J ust the t i p o f the ic eb erg

A few examples:

1. Cost of wages paid for for working time loss by other workers .

2. Net cost to repair, replace, or straighten up material or damaged equipment . 3. E xtra cost due to overtime work .4. Cost of wages paid supervisor activities required by injury .5. Wage cost due to decreased output of injured worker after return to work .

6. Cost-of-learning period of new worker .7. U ninsured medical costs .8. Cost of time to investigate accidents, process claims . 9. M iscellaneous unusual costs . (over 100 other items may impact the employer) .

What do accidents cost your company?

Unseen costs c a n sin k the s hip!

Ref: Grimaldi and Simons, Safety Management, 1 98 9.

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HSE

HRSa f et y

EquipmentSa f et y

VisitorsSa f et y

Contr a ctorsSa f et y

Ma teri a lSa f et y

Process Sa f et y

DownLosses

Environment a l(Air, Wa ter, La nd )

Sa f et y

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WHAT DOES HSE and Risk Assessment REQUIRE? 1 . Policy

2. Goals & Targets

3. Constraints & Problems

4. Team Approach

5. Organization Structure & Responsibility 6. Project Management Information System

7. Awareness & Training programs

8. Global Performance Evaluation9. Management Support & Commitment & Review 1 0.Long Term Continues Improvement

Team Approach

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Melt the Iceberg! Injur yAccidents

96 % o f a ll injuriesa re due to

Uns a f e Acts

Sa f e Wor k Pr a ctices

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