Project Report
Project Report
Project Report
In industrial arena, if any industry to be successful, it has to be safe, reliable, and sustainable
in its operations. The industry has to identify the hazards and assess the associated risks and
to bring the risks to tolerable level.
Hazard Identification and Risk Assessment (HIRA) is carried for identification of undesirable
events that can lead to a hazard, the analysis of hazard of this undesirable event, that could
occur and usually the estimation of its extent, magnitude and likelihood of harmful effects. It
is widely accepted within industry in general that the various techniques of risk assessment
contribute greatly toward improvements in the safety of complex operations and equipment.
The objective of this work of hazards and risk analysis is to identify and analyze hazards, the
event sequences leading to hazards and the risk associated with hazardous events. Many
techniques ranging from the simple qualitative methods to the advanced quantitative
methods are available to help identify and analyze hazards. The use of multiple hazard
analysis techniques is recommended because each has its own purpose, strengths, and
weaknesses.
Keywords: Hazard Operability Studies (HAZOP), Failure Mode Effect Analysis (FMEA), Process
Hazard Analysis (PHA), Layer of Protection Analysis (LOPA).
HIRA Operation:
HIRA reviews may be performed at any stage in a works life cycle-conceptual design, detailed
design, construction, Commissioning, on-going operation, decommissioning or demolition. In
general, the earlier that a hazard is identified (eg during conceptual design). The more cost-
effectively it can be eliminated or managed. studies performed during the early design stages
are typically done at corporate or engineering offices. Studies performed once a process is
near start-up, during operation or before decommissioning are typically done in a plant
environment.
A HIRA study is typically performed by a team of qualified experts on the process, the
materials , and the work activities- personnel who have formal training on risk analysis
methods usually lead these teams, applying the selected analysis technique with subject
matter experts from engineering
,operations, maintenance and disciplines as needed. A simple early-in-life hazard
identification study may be performed by a single experts: However, a multidiscipline team
typically conducts more hazardous or complex process risk studies, especially during later life
cycle stages involving operating and maintenance personnel early in the review process will
help to identify hazards when they can be eliminated or controlled most cost- effectively.
When the study is complete, management must then decide whether to implement any
recommended risk reduction measures to achieve its risk goals.
HIRA Process:
HIRA Process it consist of four steps as follows:
I. Hazard identification
II. Risk assessment
III. Risk analysis
IV. Monitor and review
Hazard identification-
Once the hazard have been identified, it is necessary to assess what risk they pose to
employees in the workplace. In this way we can establish a measure of the risk and determine
what priority they should have for corrective actions. The risk assessment step is that part of
the process that assesses the probability (likelihood) and consequences (severity) of hazard
that have been identified. Once we have estimated the probability and consequences for each
hazard then we can allocate it a priority for corrective action. Generally, risk assessment is
estimating: what are the chances (probability) of an accident happening, and if it does happen,
what are the chances that someone will be hurt? What will be the extent of equipment or
environmental damage, and how bad will it be (severity)? The level of risk is dependent on the
exposure to the hazard and the probability and consequences of an event occurring.
Frequency:
The HIRA is not intended to be a scientific assessment of the frequency of the different
hazards, but is a risk assessment which must consider how likely it is that a hazard will occur
with enough strength to result in an emergency situation. Some hazards do not have a long
historical record and their frequencies can be only estimated based on the best sources
available. Ideally, the frequency would be calculated based on the number of times that the
event has occurred, rather than in years. Impact Different hazards have different potential
impacts. The information from this research was gathered and analyzed. Past impacts and
current mitigation measures were considered to determine to the extent possible whether
comparable damages could be expected in the future if similar events were to occur.
Impact was split into five groups:
Human Impacts - The direct negative effects of an incident on the health of people including;
fatalities, injuries or evacuations.
Property Impact - The direct negative effects of an incident on buildings, structures and other
forms of property.
Business Impact - The negative economic or social losses due to an incident.
Critical Infrastructure Service Disruptions/Impact - The negative effects of an incident on
the networks of institutions, services, systems and processes that meet vital human needs,
sustain the economy, protect public safety and security, and maintain continuity of and
confidence in government. This category is divided into two; Damage to Critical Facilities
and Damage to Lifelines.
Environmental Damage - The negative effects of an incident on the environment, including
the soil, water, air and/or plants and animals.
Review and monitor – A HIRA is part of the emergency management process. The risk
assessment will be used to prioritize which risks require further development of treatments
to prevent, mitigate, accept, or transfer the risks associated with hazards or threats.
Control- this stage is the process of determining and implementing appropriate measures
to control risk. practicable means considering Severity of the hazard in question State of
knowledge about the hazard or risk and ways of removing or mitigating it. Availability and
suitability of ways to remove or mitigate that hazard or risk
Cost of removing or mitigating the hazard.
Having identified the potential hazards, the team is further responsible for identifying
solutions to those hazards, the preferred hierarchy for developing solutions/controls is
provided below.
Elimination-eliminating toxic substances, hazardous equipment or processes that are not
necessary for a system of work.
Substitution-where hazardous materials /chemicals have been identified as a hazard, the
preferred option is to replace the material with a less hazardous one.
Engineering-the removal of potential hazards by reengineering the job is a preferred option.
This includes design modification, guards, permanently fixed physical barriers, interlocked
physical barriers, physical barriers, presence sensing systems, enclosures, ventilation,
automation and isolation.
Administrative controls-the application of administrative controls to hazards may include
such actions as limiting the time of exposure, rotating employees, and training of employees.
PPE-the provision of PPE does not eliminate the hazard, but only shields the individuals from
it. Such action may have to couple with training in the correct use of the equipment
Evaluation-this steps means checking to see whether the introduced changes reduce the risk
previously assessed. it may involve repeating the process of hazard identification, risk
assessment, and risk control to verify that all risks to health.
SITE OPERATIONS: The type of operations/activities carried out in a construction site are
many (See Fig.01) and they vary from site to site. However, all of them should be carried
out only with due regard to safe operations. Some of the routine work/operations carried
out in construction sites are listed below:
Scaffolding Work: Scaffolds are temporary structures of steel work, timber or bamboo. The
criteria for their erection are the same as those for permanent structures. The strength of the
scaffolding depends upon the combined strength of individual members. Failure of one or
two of them can result in the collapse of the entire structure. Modern scaffolds are invariably
made of steel tubes, pre-fabricated in convenient units.
They are safer and turn out good quality work. Of course, the steel scaffolds are too costly,
Hazard Identification & Risk Assessment in Construction Industries 10 | P a g e
but, it would be cheaper in the long run. In spite of the fact that the steel scaffolds are much
safer, many of the smaller and medium size builders in India, neglect the safety aspects and
prefer to use timber or bamboo scaffolds (See Fig.02) in order to cut the cost. In any case,
while erecting the scaffolds, the workers should be forced to wear necessary safety belts with
fall arrestors and helmets, so that the fall accidents can be avoided.
Crane Operations: Various type of cranes are used in construction sites, which includes (i)
Portable Cranes (See Fig.03) (ii) Tower Cranes (Sig Fig.04). A number of accidents are reported
in the use of cranes, and many of them could be averted by adopting safe methods of
operations. Some of the methods to be adopted for safe crane operations are given
below:
The weight of the load intended to be lifted by the crane must be carefully estimated.
The crane must be fitted with an automatic safe load indicator. The crane must always work
on a hard, level base.
The load must be properly fixed and secured.
The signal man must be trained to give clear signals.
The ropes, hooks, chains, slings, etc. used in the lifting operations, must be inspected
regularly for their worn out.
When mobile cranes are used, care must be taken to prevent overturning of cranes.
Wear appropriate personal protective equipment.
Hoisting Operations: Hoists are used to move heavy objects and equipment. The Fig. 05
shows various parts of hoists. As the hoists consists of various components, failure of any
one component can lead to disastrous accidents. Therefore these components should be
inspected daily.
Fork Lift Operations: Fork Lifts are very commonly used in construction sites for movement
of many construction materials and stacking them at heights. The Fig.06 shows a line
diagram of a Fork Lift with various parts. While operating the Fork Lifts, the following
general safety guidelines should be observed:
Do not walks, stand or work under the elevated portion of a fork lift even if it is not loaded?
Ensure that the fork lift has an overhead barriers to protect the operator from falling objects.
Do not allow riders on the fork lift. Do not raise people on a fork lift.
Always work within the capacity limits of your fork lift.
Before modifying the operation or capacity limits of a fork lift, consult with the
manufacturer.
Do not operate a fork lift in an area with hazardous concentrations of acetylene, butadiene,
hydrogen, ethylene or diethyl ether, or other explosive environment.
Never lift a load while moving a fork lift. Wait until you are completely stopped before raising
the mast.
Be sure, the top load sits squarely on the stack. Remember uneven load could topple the fork
lift.
When you want to travel with loads, slightly lift the loads back to provide stability.
Make sure that you travel with loads at the proper height. A stable clearance height is usually
4 to 6 inches at the tips and 2 inches at the heels of the fork blades.
When preparing to leave the fork lift unattended, lower the mast, neutralize the controls,
shut the power off, and set the brakes.
If you cannot see over the load, drive in reverse. Do not try to look around a load and drive
forward.
Ladder Safety: Ladders are one of the most popular item used in the construction sites for
working at heights. However, if not used safely, it can kill a lot of people. The Fig.07 &
Fig.08 will depict the wrong and right way of using the ladders. The following safe methods
should be adopted while operating ladders:
Always have a firm grip on the ladder and keep a good balance.
Never allow more than one person on a ladder.
Use tool belts or hand line to carry objects when you are climbing the ladder.
Do not lean out from the ladder in any direction.
If you have a fear of heights – don’t climb a ladder. Do not allow others to work
under a ladder in use. Do not use a defective ladder.
Electrical Safety: Electricity can cause great damage to both people working in the
construction sites and property. Contact with the electric current can trigger other accidents,
like falls from ladders or scaffolding. Electrical shocks or flashes can cause serious injuries
such as burns. Electric shock may also cause the victim to stop breathing and nerve centers
may be temporarily paralyzed.
The heart beat may fluctuate or the heat rhythm may actually be interrupted, thus causing a
stop in the circulation of blood throughout the body. Apart from human injuries like shock,
burns or falls, another major hazard is the situation in which an electrical fire or explosion
may occur. Fires and explosions generally cause extensive property & equipment damage.
Electrical Fires often start when an overloaded circuit becomes overheated – igniting the
insulation around the wires. If cords and cables are frayed or worn out, bare wires might
touch each other, thus causing a short circuit that could spark a fire.
Hazard Identification & Risk Assessment in Construction Industries 16 | P a g e
If the workers find a fault or malfunctioning piece of equipment, they should take it out of
operation, and make the necessary arrangements to have the equipment repaired. Make
sure that the workers at the construction site understand the importance of electrical
safety and recognize, that abusing or misusing electrical equipment is an invitation to an
accident. The workers should also make sure that the work area is safe and free from all
electrical hazards. Provide necessary personal protective equipment in particular,
electrical gloves & breathing apparatus
Electricity
Fire
Manual handling Noise
Chemical substance Dust
There are no fixed rules about how the risk assessment should be under taken. The
following steps could be used as guidance.
Initiating the HIRA
Step 3: Identify all parties affected by the hazard and determine how they can be affected
Next you need to identify who might be harmed; it will help you identify the best way of
managing the risk. That doesn’t mean listing everyone by name, but rather identifying groups
of people (e.g. people working in the storeroom or kitchen). In each case, identify how they
might be harmed, e.g. what type of injury or ill health might occur.
Remember:
Some workers might be more vulnerable like new and young workers, new or expectant
mothers and people with disabilities, lone workers.
Cleaners, visitors, contractors, maintenance workers etc, who may not be in the workplace all
the time.
Members of the public, if they could be hurt by your activities.
Hazard Identification & Risk Assessment in Construction Industries 20 | P a g e
If you share your workplace, you will need to think about how your work affects others
present.
As well as how their work affects your staff – talk to them; and ask your staff if they can
think of anyone you may have missed.
If the risk assessment is job-specific, use the individual's job title, not their name.
In order to do a ‘‘risk rating’’, we normally make use of a matrix scoring system. Numerical
scores are given to the different elements (e.g. consequence, exposure, likelihood) of risks and
these scores are added or multiplied to get a rating for the risk. For the initial risk evaluation,
consider the risks identified in the worst case scenario before any controls are applied.
Example: Electricity is a hazard, it can kill but the risk of it doing so in an office environment is
Elements of risk:
Consequence/ severity (How serious)
Consequences are the expected severity. The severity is expressed in terms of the effect on
the person, whether injury or ill health, and ranging from minor injury to death. Think about
how serious the likely outcomes would be if harm from a hazard was realized. The risks are
clearly higher if an accident is likely to result in serious injury or death, for example, than a
bruise or a scratch.
Sub Activity Hazard / Risk Initial Risk Actual Risk Priority Responsibility
Task Factor Existing Control Measures Factor
E S P R E S P R By By When
Whom
Shifting of structural 1.Unathorized 1. Area
Survey to be done
1. materials from yard Operation of Vehicle. before moving the crane
to blasting / painting 2.Carrying
area and back to Unauthorized 2.Designated persons are Execution Before / During
6 4 3 72 6 4 0.5 12 4
fabrication yard (By Passengers only allowed to travel in the Team Job
using of hydra, crane 3.Intoxicated Driving cabin of trailer / truck.
& trailer)
Manual Material 1. Hazards during 1. Don’tallow the person to lift
2. Handling / Material` manual materials more than 30 kg for materials
handing. 6 4 3 72 shifting from one place to
2. Pinching of other. Provide Trolley for Execution Before / During
6 4 0.5 12 4
leg/hands while materials shifting. Person Team Job
handing of materials. handing the material should
3. Improper stacking be physically fit to do work.
of Material.
2. Use
hand gloves during
material handing. All
mandatory PPE’s shall be use
at site..
3. 1.Unauthorized 1. medical Fitness of Crane
Operation of crane. 6 7 3 126 operators shall be check
2.Inadequate space for .
2. The space for access Execution Before / During
access/ egress.
&egress should be proper, 6 7 0.5 21 3
3.Improper Team Job
Hazard Identification & Risk Assessment in Construction Industries 25 | P a g e
illumination. clear & adequate.
4. Gas cutting Activity 1. Improper unloading 1. Cylinders should keeping at
Storage, Handing & process- damage of 6 7 3 126 upright direction only.
use of Gas Cylinders cylinder resulting fire
at site. & explosion, injury 2. Providing Flash back Execution Before / During
6 7 0.5 21 3
while handling. arrestor each side of gas Team Job
2. Improper Storage – cutting set.
Un tied cylinders.
3. Fire, burn injury
while using at site.
5. Grinding Work 1. Struck by grinding 1. All
the grinding m /c’s shall
wheel. be used with wheel guard.
2. breaking of wheel. 6 7 3 126
3.Poor electrical 2. Checkexpire date of Execution Before / During
6 7 0.5 21 3
connection. grinding wheel and use Team Job
approved product of wheel.
6. Welding Work 1. Electricutiondue to
improper electric 1. Welding
goggles shall be
connection. 6 7 3 126 provided to welder’s helper
2. Welding fumes / for eye protection. Execution Before / During
6 7 0.5 21 3
Health hazard. Team Job
3. Fire hazard due to 2. Area
shall be cleared of
welding spark. Flammables and
combustibles before
commencing welding.
The frequency of exposure indicates how often a dangerous situation can arise. It could be an exposure to a toxic chemical or working and handing
of a dangerous machine.
Factor Description
0.5 Very Rarely (less than one per year)
Risk
Score Priority INTERPRETATION
BASIC CONCEPTS:
Risk:
Risk is something that we as individuals live with on a day-to- day basis. People are constantly
making decisions based on risk. Simple decision in daily life such as driving, crossing the road
and money investment all imply an acceptance risk. Risk is the combination of the likelihood
and severity of a specified hazardous event occurring.
In mathematical term, risk can be calculated by the equation - Risk = Likelihood x Severity
Where,
Likelihood is an event likely to occur within the specific period or in specified circumstances
and, Severity is outcome from an event such as severity of injury or health of people, or
damage to property, or insult to environment, or any combination of those caused by the
event.
An occupational health hazard is any agent that can cause illness to an individual. A health
hazard may produce serious and immediate (acute) affects, or may cause long-term
(chronic) problems. All or part of the body may be affected. Someone with an occupational
illness may not recognize the symptoms immediately. For example, noise-induced hearing
loss is often difficult for the affected individual to detect until it is well advanced. Health
hazards include chemicals (such as battery acid and solvents), biological hazards (such as
bacteria, viruses, dusts and molds), physical agents (energy sources strong enough to harm
the body, such as electric currents, heat, light, vibration, noise and radiation) and work design
(ergonomic) hazards.
Safety hazards:
An environmental hazard is a release to the environment that may cause harm or deleterious
effects. An environmental release may not be obvious. For example, a worker who drains a
glycol system and releases the liquid to a storm sewer may not be aware, of the effect on the
environment. Environmental hazards cause harm when controls and work procedures are not
followed.
Severity of hazard:
Severity can be divided into five categories. Severity are based upon an increasing level of
severity to an individual’s health, the environment, or to property. Table B indicates severity
by using the following table:
To use this matrix, first find the severity column that best describes the outcome of risk. Then
follow the likelihood row to find the description that best suits the likelihood that the severity
will occur. The risk level is given in the box where the row and column meet.
The relative risk value can be used to prioritize necessary actions to effectively manage
work place hazards. Table D determines priority based on the following ranges:
Types of Control:
At the source of the hazard
Elimination - Getting rid of a hazardous job, tool, process, machine or substance is perhaps
the best way of protecting workers. For example, a salvage firm might decide to stop buying
and cutting up scrapped bulk fuel tanks due to explosion hazards.
Substitution - Sometimes doing the same work in a less hazardous way is possible. For
example, a hazardous chemical can be replaced with a less hazardous one. Controls must
protect workers from any new hazards that are created.
Engineering control:
Redesign - Jobs and processes can be reworked to make them safer. For example, containers
can be made easier to hold and lift.
Isolation - If a hazard cannot be eliminated or replaced, it can sometimes be isolated,
contained or otherwise kept away from workers. For example, an insulated and air-
conditioned control room can protect operators from a toxic chemical.
Automation - Dangerous processes can be automated or mechanized. For example,
computer- controlled robots can handle spot welding operations in car plants. Care must be
taken to protect workers from robotic hazards.
Barriers - A hazard can be blocked before it reaches workers. For example, special curtains
can prevent eye injuries from welding arc radiation. Proper equipment guarding will protect
workers from con tacking moving parts.
Hazard Identification & Risk Assessment in Construction Industries 39 | P a g e
Absorption - Baffles can block or absorb noise. Lockout systems can isolate energy sources
during repair and maintenance. Usually, the further a control keeps a hazard away from
workers, the more effective it is.
Dilution - Some hazards can be diluted or dissipated. For example, ventilation systems can
dilute toxic gasses before they reach operators.
Administrative controls:
Safe work procedures - Workers can be required to use standardized safety practices. The
employer is expected to ensure that workers follow these practices. Work procedures must
be periodically reviewed with workers and updated.
Supervision and training – Initial training on safe work procedures and refresher training
should be offered. Appropriate supervision to assist workers in identifying possible
hazards and evaluating work procedures.
Job rotations and other procedures can reduce the time that workers are exposed to a
hazard. For example, workers can be rotated through jobs requiring repetitive tendon and
muscle movements to prevent cumulative trauma injuries. Noisy processes can be
scheduled when no one is in the workplace.
Housekeeping, repair and maintenance programs - Housekeeping includes cleaning, waste
disposal and spill cleanup. Tools, equipment and machinery are less likely to cause injury if
they are kept clean and well maintained.
Hygiene - Hygiene practices can reduce the risk of toxic materials being absorbed by
workers or carried home to their families. Street clothing should be kept in separate lockers
to avoid being contaminated by work clothing. Eating areas must be segregated from toxic
hazards. Eating should be forbidden in toxic work areas. Where applicable, workers should
be required to shower and change clothes at the end of the shift.
Documenting process:
Instructions to team leader and persons conducting HIRA:
Complete HIRA Form. It is recommended to use a single form for each work process;
Record the names and designation of HIRAC team members;
Outline the process workflow and indicate in the form under ‘process/ location column;
List all activities (routine and non-routine) for each work process under the “Work Activity”
column;
Identify the hazards associated with each activity and record in “Hazard” column;
Determine the effect of each hazard identified and record in “Effect” column;
Record any existing hazard control measures;
Determine likelihood (L) from Table A and severity (S) from Table B for each hazard. Assign
P and C rating in respectively column. The existing control measures should be take into
consideration while determine (L) and (S);
By using Risk Matrix (Table C and D) assign one risk and record in “Risk” column;
Based on the risk assigned, recommend appropriate risk control measures (see Table D);
Assign a suitable person to implement the recommended risk control and indicate the
follow up action date and status;
Repeat the HIRA for other activities and process;
Conduct another round of HIRA after control measures have been implemented; and
Review HIRA for every three years or whenever there are changes in process or
Examples of Workplace Hazards:
Advantages:
Offers a creative approach for identifying hazards, predominantly those involving
reactive chemicals.
Thoroughly evaluates potential consequences of process failure to follow procedures.
Recognizes engineering and administrative controls, and consequences of their failures.
Provides a decent understanding of the system to team members.
Disadvantages
Requires a distinct system of engineering documentation and procedures.
HAZOP is time consuming.
Requires trained engineers to conduct the study.
HAZOP emphases on one event causes of deviations or failures.
Once the fault tree has been developed to the desired degree of detail, the various paths
can be evaluated to arrive at a probability of occurrence.
Disadvantages
Limited to one initiating event
Requires special treatment to account for system dependencies
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[5] Dziubinski, M., Fratczak, M. and Markowski, A. S., (2006), Journal of Loss Prevention in
the Process Industries, Vol. 19, pp 399-408.
[6] Khan, F. I. and Abbasi, S. A., (1998), Techniques and methodologies for risk analysis in
chemical process industries, Journal of Loss Prevention in the Process Industries, Vol.
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[7] Khan, F. I. and Abbasi, S. A., (2001), Risk analysis of a typical chemical industry using
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[9] Hazardhttp://www.uws.edu.au/ data/assets/pdf_file/
0020/12917/Hazard_Identification_Risk_Assessment
_and_control_Procedure_2008.pdf