Industrial Safety &

Risk Assessment
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HSE management View Part I - Dr. Attia Gomaa - 2007

1/Ch. 1

Why HSE & RA?

Current
Pollution
Accidents

Brain-storming
not
Blame-storming

Targets

Future

1. HSE & Risk Ass. Tools

2. Awareness programs
3. HSE Systematic
SC
approach
RC A
A
R
HA CFA
FM ZO
P
RB EA
RC I
O
IS SH M
O
OH ISO 90 A
SA 140 01
S 1 00
80
01

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HSE management View Part I - Dr. Attia Gomaa - 2007

2/Ch. 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

Dr. Attia Hussien Gomaa
attiagomaa@yahoo.com
1) American Unv. in Cairo (AUC) Eng. Service.
2) RCM & HSE Consultant for Industrial Companies.
3) Head of Industrial Eng. Department- Fayoum University.

Safety
First

Course Outline:
Introduction
Chapter 1: Importance of Industrial Safety & Risk Assessment
Chapter 2: HSE Management
Chapter 3: Problem Solving Techniques
Chapter 4: Risk Assessment
Chapter 5: Global Performance Evaluation
Chapter 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 10: International Standards Overview (ISO 14001 & OHSIS 18001)
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HSE management View Part I - Dr. Attia Gomaa - 2007

3/Ch. 1

Let us be a Team Approach

Your Participation
Will Make This Presentation
More Applicable & Successful

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4/Ch. 1












5/Ch. 1

HSE management View Part I - Dr. Attia Gomaa - 2007

HSEM

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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HSE management View Part I - Dr. Attia Gomaa - 2007

6/Ch. 1

Systematic Approach for Critical Systems

Process &
Performance

Design
& HAZOP

Critical
System or Project

PMIS

Inventory
Control

HSEM

HSE
& Risk

Cost
Analysis

Maintenance

Critical
Resources

HSE management View Part I - Dr. Attia Gomaa - 2007

7/Ch. 1

Process
Inputs & Outputs

Design
&
HAZOP

HSE
&
RCA

Critical
Equipment
Cost
&
Resources

Maintenance
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8/Ch. 1

Engine Overhaul:
Item

Replace

Repair

Replace
(New)

Repair
(010,020,030)

Cost ratio

Duration ratio

Reliability ratio

MTBF ratio

CM/PM ratio

Performance ratio

Manpower ratio

Job Safety Analysis

Medium

High

Equipment Criticality
(HSE, Process, Standby)

Critical

Normal
(with standby)

In normal conditions: Repair policy if (repair cost <40%Replace cost)

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HSE management View Part I - Dr. Attia Gomaa - 2007

9/Ch. 1

Turbine Overhaul:
Item

Replace

Repair

Replace

Repair

Cost ratio

Duration ratio

Reliability ratio

MTBF ratio

CM/PM ratio

Performance ratio

Manpower ratio

Job Safety Analysis

Medium

High

Equipment Criticality
(HSE, Process, Standby)

Critical

Normal
(with standby)

HSEM

HSE management View Part I - Dr. Attia Gomaa - 2007

10/Ch. 1

Systematic Approach for Engineers

Maintenance

Information &
Planning

Managerial
View

HSEM

Process

HSE

Design &
Materials

Engineer

Spare parts
& Stock

Process &
Down
Losses

HSE management View Part I - Dr. Attia Gomaa - 2007

11/Ch. 1

Basic Aspect of Any Business

Quality
Process

Business
Success
Cost
Safety
Employee
Relations

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HSE management View Part I - Dr. Attia Gomaa - 2007

12/Ch. 1

Safety
(Accidents, Fire, .. etc.)

Team
Approach

HSE
Analysis

Health

Environment

)People)

(Air, Water, Land)

Time

HSE
Management

Specs

Resources
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13/Ch. 1

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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( )

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14/Ch. 1

Hazard :
Anything which has the potential to cause Harm

Hazards types:
1- Physical Hazards
2- Engineering Hazards:

Hazards Substances

- Mechanical Hazards

1.

Flammable

- Electrical Hazards

2.
3.
4.
5.

Explosive
Toxic
Irritant
Corrosive

3- Chemical Hazards
4- Ergonomics Hazards
5- Biological Hazards

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15/Ch. 1

Chapter 1
Importance of Industrial Safety & Risk Assessment

In 1995, 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
Source: National Safety Council, Accident Facts, 1997 Edition.
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16/Ch. 1

Cairo - Egypt
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17/Ch. 1

> 5 million
Egyptian are
affected by
asthma.
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18/Ch. 1

Serious Health Impacts of Asthma

Asthma is a potentially fatal, chronic disease
Responsible for over 1.8 million emergency room
visits per year,
Over 460 thousand hospitalizations per year and
Over five thousand deaths per year
(Department of Health and Human Services, 2002).

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19/Ch. 1

Facts About Vehicle Accidents in Egypt

Causes of Road/Traffic incidents in Egypt

12,000 road accidents:

24 % of all hospital fatalities
28% of childrens deaths in
hospitals.
Over 5000 people were killed
Over 20,000 injured
Very high fatalities rate per
100million kilometers driven (44 )

Most Common Human Errors:

- Over speeding
- Driving on wrong direction
- Sudden stop
- Sleeping while driving
- Horse playing
- Speaking on the mobile phones while driving
- Eating , drinking or smoking while driving
- Driving under the influence of drugs
HSEM

How to Prevent Accidents:

Observation techniques
Space
Concentration
Pre Departure Checks

HSE management View Part I - Dr. Attia Gomaa - 2007

20/Ch. 1

Egyptian Oil & Gas Industries - Nature of

Accidents

Causes Of Incidents %:
30% Poor Maintenance

25% Backlog, 20% Quality, 15% Spares, 20% Planning & Feedback,
5% Poor housekeeping, 15% Others

25% Process & Operator error

90% Unsafe acts & 10% Unsafe conditions such as poor layout

20% Poor Management (Process, HSE, Maintenance, .. etc.)

70% Information, Planning & Control, 20% Awareness & Culture, 10% others

15% Design Deficiency

50% Design error, 35% Materials, 15% others

10% Others
Based on data from 5 Egyptian Companies
Last 10 years Accident & Incident History & Brain Storming
Prepared by Dr. Attia Gomaa, 2007, Inprint.
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21/Ch. 1

Egyptian Oil & Gas Industries - Nature of

Accidents
Main Equipment/Item

1) Piping systems

30

2) Tanks

25

3) Heat Exchangers

4) Valves

5) Towers

6) Compressors

7) Pumps

8) Gages

2
Others

Critical Items
(A Rule 80/20)

16
Total

100

Based on data from 5 Egyptian Companies

Last 10 years Accident & Incident History & Brain Storming
Prepared by Dr. Attia Gomaa, 2007, Inprint.
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22/Ch. 1

Egyptian Oil & Gas Industries - Nature of

Accidents

Based on data from 5 Egyptian Companies

Last 10 years Accident & Incident History & Brain Storming
Prepared by Dr. Attia Gomaa, 2007, Inprint.
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23/Ch. 1

Cause of injuries

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24/Ch. 1

HSEM

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25/Ch. 1

Accident Prevention
Accident
Rate
Technology

Management Systems

Human Factors

Time
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26/Ch. 1

Direct cost is Less than 10% of the global costs

Accident

or

CM

or

Unplanned job

Accident
Incident
Unsafe Conditions
Unsafe Acts
You only see the tip of the iceberg
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27/Ch. 1

Deaths
Lost Time Injuries

Medical
Treatment

First Aid Cases

Unsafe conditions

Unsafe Acts
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28/Ch. 1

What do accidents cost your company?

Direct Costs

Unseen costs can

sink the ship!

Insured

Just the tip of the iceberg

1. Workers compensation premiums
2. Miscellaneous medical expenses.

Indirect Costs
A few examples:
1.
2.
3.
4.
5.
6.
7.
8.
9.

Hidden - Uninsured - Out of pocket

Cost of wages paid for for working time loss by other workers.
Net cost to repair, replace, or straighten up material or damaged equipment.
Extra cost due to overtime work.
Cost of wages paid supervisor activities required by injury.
Wage cost due to decreased output of injured worker after return to work.
Cost-of-learning period of new worker.
Uninsured medical costs.
Cost of time to investigate accidents, process claims.
Miscellaneous unusual costs. (over 100 other items may impact the employer).
Ref: Grimaldi and Simons, Safety Management, 1989.

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29/Ch. 1

What is HSE Systematic Approach ?

HSE
Policy
Inventory

Process

HSE
Review as
Necessary

Maintenance

Strategic Plan
Strategic
Plan

Annual

HSE

Social

Annual Plan
Annual
Plan

Review
Plan
Plan
Modification
Modification

Cost

Documentation &&
Documentation
Records
Records

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HSE management View Part I - Dr. Attia Gomaa - 2007

30/Ch. 1

Equipment
Safety

HR
Safety

HSE

Down
Losses

Environmental
(Air, Water, Land)
Safety

HSEM

Process
Safety

Visitors
Safety

Material
Safety

Contractors
Safety

HSE management View Part I - Dr. Attia Gomaa - 2007

31/Ch. 1

WHAT DOES HSE and Risk

Assessment REQUIRE?

1. Policy
2. Goals & Targets

Team
Approach

3. Constraints & Problems

4. Team Approach
5. Organization Structure & Responsibility
6. Project Management Information System
7. Awareness & Training programs
8. Global Performance Evaluation
9. Management Support & Commitment & Review
10. Long Term Continues Improvement
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32/Ch. 1

Melt the Iceberg!

Injury
Accidents

96% of all injuries

are due to
Unsafe Acts

Safe Work Practices

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33/Ch. 1