SAFETY AND LOSS PREVENTION

DEPARTMENT OF CHEMICAL ENGINEERING

FACULTY OF ENGINEERING
UNIVERSITY OF BENIN
SUPERVISED BY: PROF. OBAHIAGBON

2013/2014 ACADEMIC SESSION

GROUP 6 MEMBERS
NAMES OF STUDENT

MATRIC NO.

AWOJULU TAIWO
OTUYA IFECHUKWUDE
ORANUSI RITA
OLEDHERE ALEX
ASOGWA UCHENNA
OBAMORUWA TEMIDAYO
OKOLIE JERRY
AMAIZE DANIEL
STEPHENSON

ENG0902082
ENG0902143
ENG0902138
ENG0902134
ENG0902081
ENG1002151
ENG1002165
ENG0902076
ENG0200602

TABLE OF CONTENT
1.0

INTRODUCTION

1.1
1.2
1.3

SAFETY
REASONS FOR SAFETY
INTRINSIC AND EXTRINSIC SAFETY
1.31 INTRINSIC SAFETY
1.32 EXTRINSIC SAFETY

1.4 THE CONCEPT OF RISK

1.4.1 TYPES OF RISK
1.4.1.1 ELECTRICAL RISK
1.4.1.2 MECHANICAL RISK
1.4.1.3 FIRE/EXPLOSION RISK
1.4.1.4 HIGH/ LOW TEMPERATURE EXPOSURE RISK
1.4.1.5 TOXIC/ CARCINOGENIC CHEMICAL RISK
2.0 RISK ASSESSMENT
2.1 DEFINITION OF RISK ASSESSMENT
2.2 IMPORTANCE OF RISK ASSESSMENT
2.3 DIFFERENCE BETWEEN RISK AND HAZARD
2.4 PROCESSES INVOLVED IN CARRYING OUT RISK ASSESSMENT
2.5 QUALITATIVE AND QUANTITATIVE RISK ASSESSMENT
2.51 QUALITATIVE RISK ASSESSMENT
2.52 QUANTITATIVE RISK ASSESSMENT
3.0 RISK MANAGEMENT
3.1 WHY MANAGE RISK
3.2 STAGES IN RISK MANAGEMENT
3.2.1 DEVELOP AND IMPLEMENT A RISK MANAGEMENT PLAN
3.2.2 IDENTIFY THE RISK
3.2.3 ANALYSE THE RISK
3.2.3.1 EVALUATION OF THE RISK
3.2.4 RISK CONTROL AND REVIEW

CHAPTER ONE
1.0 INTRODUCTION
1.1 SAFETY:
Safety is the prevention and control of accident through the use of appropriate technology
to identify hazard in a chemical plant and eliminate them before the accident occur. All
process industries are to an extent hazardous because they contain one hazardous chemical
or the other, hence, the idea of being safety conscious should not be overlooked, because a
whole lot depends on it.

1.2 REASONS FOR SAFETY

1. For our well being
2. Safeguard of properties
3. Productivity
4. Profitability
5. Environmental concerns

1.3 INTRINSIC AND EXTRINSIC SAFETY

Processes can be divided into those that are intrinsically safe, and those for which the
safety has to be engineered in.

1.31 INTRINSIC SAFETY: An intrinsically safe process is one in which safe

operation is inherent in the nature of the process; a process which causes no danger, or
negligible danger, under all foreseeable circumstances. Intrinsic safety strives to avoid
and remove hazards rather than to control them. The safe operation of such processes
depends on the design and good operating practices to prevent a dangerous situation
developing and to minimise the consequences of any incidence.

1.32 EXTRINSIC SAFETY: This is a means of controlling hazards rather than

avoiding it. It covers the provision engineering control systems, such as; pressure-relief
devices, automatic shut-down systems, sprinkler systems, blast walls, alarm, duplication
of key equipment services.

Safety should always come first and remain so despite cost, it should be included even
in the preliminary project design. The designer must be aware of the hazards, and
ensure through the use of sound engineering practice to reduce the risk to acceptable
levels if not completely eradicated.

1.4 THE CONCEPT OF RISK

The likelihood of a specific effect within a specified period is termed RISK. It is a
complex function of probability, consequences and vulnerability. It is defined as a
probability or threat of damage, injury, liability, loss or any other negative occurrence
that is caused by external or internal vulnerabilities and that may be avoided through
pre-emptive action.

1.4.1 TYPES OF RISK

There are several classifications of risk and they include;
1.
2.
3.
4.
5.

Electrical Risk
Mechanical Risk
Fire Risk/Explosion Risk
High/Low Temperature Exposure Risk
Toxic/Carcinogenic Exposure Risk

1.4.1.1 ELECTRICAL RISK

An electrical risk is a risk to a person of death, shock or other injury caused directly or
indirectly by electricity. The main hazards associated with these risks are;
1. Contact with exposed live parts causing electric shock and burns (for example
exposed leads or other electrical equipment coming into contact with metal
surfaces such as metal flooring or roofs).
2. Faults which could cause fires.
3. Fire or explosion where electricity could be the source of ignition in a potentially
flammable or explosive atmosphere.
4. Outdoors or in wet surroundings equipment may become wet and may be at
greater risk of damage.
5. In cramped spaces with earthed metalwork, such as inside a tank or bin it may
be difficult to avoid electrical shock if an electrical fault develops
The risks are greatest in harsh conditions such as those in point 4 and 5 above.

1.4.1.2 MECHANICAL RISK

This is a kind of risk which causative agent is a mechanical device that is either
electrically or manually driven. Depending on the nature of work in industries,
mechanical devices of various sizes are used. Examples of mechanical devices used in
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process industries are pumps, forklift, compressors, and etc. This risk can be classified
due to position or motion.
Possible examples of mechanical risk are listed below:
1) Throwing of metal objects at height in flammable regions
2) Discharge of high temperature stream through pipes containing condensate
thereby leading to hammering and vibrational movement of pipelines
3) Incessant disposal of banana peels in plant areas
4) Operational design of side-protruding thread of hand valve
5) Hard and portable working tools poses threat when improperly kept after usage
In ensuring minimal exposure to this kind of risk, the following measures must be
taken;
1. Routine check must be done before machines are used
2. Maintenance of process equipment must also be done
3. Various component joints of equipment must be properly screwed to avoid
dislocation of moving parts
4. Machines involving sharp edges must be lubricated to aid proper operation and
avoid possible fire out break

1.4.1.3 FIRE / EXPLOSION RISK

Fire and explosion can result in catastrophic consequences causing serious injuries or
death of workers and others as well as significant damage to property. It is important to
prevent the possibility of fire or explosion from an ignition or flammable substances
associated with a hazardous area which include wherever flammable liquids, vapour,
and gases as well as combustible dust are generated, used, stored and handled. For
places as this, all sources of ignition such as; naked flames, hot work activities,
mechanical spark, etc. must be identified either to eliminate them or to control
explosion.

1.4.1.4 HIGH/ LOW TEMPERATURE EXPOSURE RISK

Workers who are exposed to extreme cold or work in cold environments may be at risk
of cold stress. Extreme cold weather is a dangerous situation that can bring on health
emergencies in susceptible people such as outdoor workers. This weather-related
condition could lead to serious health problems such as hypothermia, frostbite, trench
foot, etc. Workers exposed to these extreme temperature conditions should wear
appropriate clothing.
Operations involving high air temperature, radiant heat sources and direct physical
contact with hot objects also have potential in for causing heat related illness.
Workplaces with these conditions may include iron and steel foundries, brick firing and
ceramic plants, bakeries, mining sites, steam tunnels, etc. Outdoor operations conducted
6

in hot weather such as construction also increase risk of heat related illness such as heat
rash and heat cramp in exposed workers. This can increase risk to injuries because of
sweaty palms and burns from hot surfaces or steam.

1.4.1.5 TOXIC/ CARCINOGENIC CHEMICAL RISK

These include exposure to substances designated as toxic, carcinogenic and those that
could impair fertility or harm unborn child. Exposure to substances such as benzene,
asbestos, formaldehyde, arsenic, etc at some level could cause cancer.

CHAPTER TWO
2.0 RISK ASSESSMENT
As part of managing the health and safety of a business enterprise, control measures
should be put in place for risks that could be encountered in the workplace. In order to
do this, there is need to think about what might cause harm to people and to decide
whether reasonable steps are taken to prevent the harm. This is what is referred to as
risk assessment and it is something that is required by law to be carried out.

2.1 DEFINITION OF RISK ASSESSMENT

Risk assessment can be defined as a systematic process of evaluating the potential risks
that may be involved in a projected activity. It can also be defined as where the severity
of hazards and its potential outcomes are considered in conjunction with other factors
including the level of exposure and the number of persons exposed and the risk of that
hazard being realized.

2.2 IMPORTANCE OF RISK ASSESSMENT

Risk assessment is very important because it forms an integral part of a good
occupational health and safety management plan. Others include
0. To create awareness of hazards and risk
1. To identify who may be at risk (employees, cleaners, visitors, contractors, the
public etc.).
2. Determining if existing control measures are adequate or if more should be done
3. To prevent injuries or illnesses when done at the design or planning stage.
4. To prioritize hazards and control measures
When should risk assessment be carried out?: Work places usually have generic
risk assessments in place, but can be carried out at any time required should the
need arise. E.g. if an employee is off with a physical injury, they may require a risk
assessment to assess the persons capability on returning to work. Also if an
employee is pregnant, a risk assessment should be carried out. It should also be
carried out for anything that has the potential to cause harm or injury to an
employee.
N.B The aim of risk assessment process is to remove a hazard or reduce the level of
its risk by adding precautions or control measures as necessary, by doing so you
have created a safer and healthier work place.

2.3 DIFFERENCE BETWEEN RISK AND HAZARD

Hazards in relation to occupational safety and health refers to a potential source of
harm or adverse health effect on a person while risk is the likelihood that a person may
be harmed or suffers adverse health effect or even death.

2.4 PROCESSES INVOLVED IN CARRYING OUT RISK ASSESSMENT

1). Identification of hazard: One of the most important aspects of risk assessment is
accurately identifying the potential hazards in work place. A good starting point is
inspecting the workplace for any hazards i.e checking the activities, processes or
substances that could cause injury or harm the health of the employees.
Tips to help identify the hazards that matter
Check manufacturers instruction or data sheet for chemicals and equipment as
they can be very helpful in explaining the hazards and putting them in their true
perspective.
Look back at accidents and ill health records because this often helps to identify
the less obvious hazards.
Take account of non-routine operations e.g. maintenance, cleaning operations or
changes in production cycles.
Remember to think about long term hazards to health e.g. high levels of noise or
exposure to harmful substances.
Visit the HSE website. HSE publishes practical guidance on hazards and how to
control them.
Ask employees about what they think the hazards are as they might notice things
that are not obvious. Hence, seek their ideas on how to control the risk.
For each hazard there is need to be clear about who might be harmed because it
will help in identifying the best way of controlling the risk. That doesnt mean
listing everyone by name but rather identifying groups of people (e.g. people
working in the store room or passers-by )
Examples of hazards with a recognized risk of harm are working at height and working
with chemicals and machinery depending on the kind of work you do there may be
other risks that are relevant to your business.
Take into consideration the following; New and young workers, new or expectant
mothers, contractors and members of the public by checking if they could be harmed by
the business work activities. In a situation where a workplace is shared with another
business, there is need to consider how the two business activities affect the other and
thereby making sure controls are in place.
2).Evaluation of risks: Having identified the hazards, you then have to decide how
likely it is that harm will occur i.e. the level of risk and what to do about it. Risk is a part
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of everyday life and you are not expected to eliminate all risks. What you must do is
make sure you know about the main risks and things you need to do to make sure you
manage them appropriately. Generally, you need to do everything reasonably
practicable to protect people from harm. This means balancing the level of risk against
the measures needed to control the real risk in terms of money, time or trouble.
However, you do not need to take action if it would be grossly disproportionate to the
level of risk.
N.B Risk assessment should only include what could reasonably be expected to know,
you are not expected to anticipate unforeseeable risk.
3) Record significant findings: Findings such as hazards, how people might be harmed
by them and measures put in place to control them should be recorded. Any record
produced should be simple and focused on control. Just note the main points down
about the significant risks and what you concluded when writing. If you have fewer than
five employees you dont have to write anything. But in a situation where you have five
or more employees, you are required by law to write it down. This is for you to be able
to review it at a later date. e.g; fumes from welding, control measure - local exhaust
ventilation used and regularly checked.
If your risk assessment identifies a number of hazards you need to put them in the
order of importance and address the most serious risk first. Identify long term solutions
for the risk with the largest consequences as well as those risks which are most likely to
cause accidents or ill health. You should also establish whether there are improvements
that can be implemented quickly, even temporarily until more reliable controls can be
put in place. Remember the greater the hazard the more robust and reliable the
measures to control the risk of an injury occurring will need to be.
4) Regularly review your risk assessment: in a situation where new equipment and
substances and procedures that could lead to new hazards are introduced into a work
place, it makes sense to review your risk assessment on an on-going basis.
Check if there has been any significant change in the work place. Hence, if there are
improvements still need to be made. Have the workers spotted any problems and if
anything has been learnt from recent accidents and near miss.

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2.5 QUALITATIVE AND QUANTITATIVE RISK ASSESSMENT

2.51 Quantitative risk assessment
Quantitative risk assessment is the use of measurable, objective data to determine asset
value, probability of loss and associated risk(s).
Quantitative risk assessment (QRA) is a formalised specialist method for calculating
individual, environmental, employee and public risk levels for comparison with
regulatory risk criteria.
Satisfactory demonstration of acceptable risk levels is often a requirement in, for
example, the approval of major hazard plant construction plans, or significant changes
to operations which may include areas such as plant modification and changes in
operational manning levels.
Facilities requiring QRA studies may include production and processing facilities, high
pressure pipelines or storage and importation sites including liquefied natural gas
(LNG).
QRA may be a requirement of applicable legislation and/or internal company
governance to show that risks are identified and controlled to an acceptable level. The
criteria for risk acceptability may be defined by local regulations or company / investor
policy.
Typically, a QRA can be defined as the formal and systematic approach of identifying
potentially hazardous events, estimating the likelihood and consequences of those
events, and expressing the results as risk to people, the environment or the business.
The method may include some or all of the following:

An analysis of the severity/consequence of accident scenarios

Predicted number of fatalities/casualties for each scenario
Individual risk
Group/societal risk
Potential loss of life
Location specific risk
Further analysis of accident scenarios that are ALARP (As Low As Reasonably
Practicable)
Preventative/mitigation measures
Sensitivity of results to uncertainties and assumptions.

The Purpose of Quantitative Risk Assessment are to;

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1. Identify and quantify hazards and risks related to the transport, use and storage
of hazardous materials.
2. Determine hazards or risks due to possible accident scenarios which will lead to
fire explosion or toxic release.
3. Recommends measures to be incorporated in the design and operation of plant
to keep hazards or risks to as low a level as practical.
4. Facilitate the development of emergency response plans to deal with all possible
accident scenarios.

2.52 Qualitative risk assessment

Qualitative risk assessment involves making formal judgement on the

consequence and probability using:
Risk = severity x likelihood

SEVERITY
When seeking to establish potential severity of harm, the following should be
considered

Parts of the body likely to be affected

Nature of the harm

Examples
The likely effect of a hazard may for example be rated:
1. Major: death or major injury or illness causing long term disability e.g.
amputations, poisonings, occupational cancer, etc.
2. Serious: injuries or illness causing short term disability e.g. lacerations,
burns, concussions, asthma, etc.
3. Slight: all other injuries or illnesses; superficial injuries; minor cuts and
bruises; eye irritation from dust; headaches, and so on

LIKELIHOOD
When seeking to establish likelihood of harm, the adequacy measure already
implemented and compiled with need to be considered. Other issues to be
considered include:

Number of personnel exposed

Frequency and duration of exposure to the hazard
Failure of services e.g. electricity and water
Exposure to the elements
Protection afforded by the personal protective equipment
12

Unsafe acts(unintended errors or unintentional violations of procedures)

The likelihood of harm may be rated:

1. High: where it is certain that harm will occur
2. Medium: where harm will often occur
3. Low: where harm will seldom occur
Risk = severity of harm x likelihood of occurrence
This simple computation gives a risk value of between 1 and 9 enabling a rough
and ready comparison of risks.
In this case we say the lower the number the greater the risk, and so prioritises
the hazards so that control action can be targeted at higher risk.

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CHAPTER THREE
3.0 RISK MANAGEMENT
Risk Management, the process of identifying, evaluating, selecting and
implementing actions to reduce risk to human health & the environment.
In a nut shell, risk management simply means that an organization has
carried out risk assessment, identified the possible risk and places them
on a scale of preference (prioritization of the task).

3.1 Why Manage Risk?

The primary reason therefore for managing risk is to enable agencies to
successfully achieve their goals, thereby averting every threat to potential
loss. A comprehensive understanding of the risk exposures facing an
organisation also facilitates effective pla nning and resource allocation,
and encourages a proactive management culture.

3.2 STAGES IN RISK MANAGEMENT

There are basically three stages in risk management, and they are;
1. Develop and implement a risk management plan
2. Identifying the risk
3. Analysis and evaluation of the risks
4. Where necessary, treatment of the risks{control}

3.2.1 Develop and Implement a Risk Management Plan

The first step to take in a risk management process is to develop and
implement a risk management plan. The purpose is to provide s tructure
for the covered entitys evaluation, prioritization, and implementation of
risk-reducing security measures.
For the risk management plan to be successful, the structure should
consist of key members of the organizational workforce, including senio r
management and other key decision makers.
An important component of the risk management plan is the plan for
implementation of the selected security measures.
The implementation component of the plan should address:
1. Risks being addressed
2. Security measures selected to reduce the risks
3. Implementation project priorities such as; required resources,
assigned responsibilities start and completion dates and
maintenance requirements.

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3.2.2 Identifying the risk

A risk is the chance or probability of a hazard (uncertainty) causing harm or damage to
people, property or the environment. From the type of risk discussed in chapter two,
one should know the kind of risk he is tring to control or manage.

3.2.3 Analysis of the risk

This is the process of considering the consequences and likelihood of a particular risk
scenario to determine the Level of Risk

Level of Risk Table

Level of Risk

Descriptor

1-3

Acceptable

With adequate
controls

4-5

Low

With adequate
controls

6-9

Moderate

With adequate
controls

10-14

Significant

Only acceptable
with excellent
controls

15-25

Critical

Only acceptable
with excellent
controls

3.2.3.1 Evaluation of the risk

Once the Level of Risk has been determined, the next step is to evaluate
the risk and see where the risk fits against the organisations overall risk criteria. An
example risk acceptance criteria table is shown below. The table gives guidance as to
the acceptability of the risk and who is responsible for the acceptance decision for that
risk.

15

Risk Acceptance Criteria Table

LEVEL OF RISK CRITERIA FOR
MANAGEMENT OF
RISK

REPORTING TO

WHO IS
RESPONSIBLE

13

Acceptable

With
adequate
Controls

Annual reporting to
Audit & RM Committee

Risk Owner

45
(excluding risk
with
consequence of
4 or 5)

Low

With
adequate
Controls

Annual reporting to
Audit & RM Committee

Risk Owner

69
(excluding
risk with
consequence of
4 or 5)
10 14
(including
any risk with
consequence of
4
or 5

Moderate

With
adequate
Controls

Quarterly Reporting to
Audit & RM
Committee/Director

Director if not
already the Risk
Owner

Significant

Only
acceptable
with
excellent
controls

Quarterly Reporting to
Audit & RM
Committee and
executive

Executive Director

15 25

Critical

Only
acceptable
with
excellent
controls

Immediate Reporting
to
Executive and Director
General

Director
General

3.2.4 Risk control and Review

Risk treatment involves identifying a range of options to reduce the consequences

and/or likelihood of a risk, or improve the controls, evaluating those options, preparing
treatment plans, and implementing them.
Controls need to be reviewed regularly but most especially when:
New plant or substances are introduced to the workplace
Before work of a type not previously performed at the workplace is commenced
16

When there is a change in the type of work, work practices or plant that may result in an
increased risk to workers or others
When information becomes available concerning work, work practices, plant or
substances that my impact of workers or others

Who is responsible for risk management?

Risk ownership
Each risk that is identified needs to be allocated a Risk Owner. This is the person
responsible for managing the risk, and is usually the person who is directly responsible
for the strategy, activity or function that relates to the risk. Some of the key
responsibilities of the Risk Owner include:
1. Responsible for the regular review of the risk
2. Responsible for the regular reporting on the risk
3. Monitoring of controls
4. Monitoring/implementation of any risk treatments
Assigning risk ownership ensures a specific person is responsible and accountable for a
particular risk.

17