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8/9/2019 000 HSE - Ch 1 - Overview
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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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HSEM 3 /Ch. 1HSE management View Part I - Dr. Attia Gomaa - 2007
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.
8/9/2019 000 HSE - Ch 1 - Overview
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HSEM 4 /Ch. 1HSE management View Part I - Dr. Attia Gomaa - 2007
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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HSEM 5 /Ch. 1HSE management View Part I - Dr. Attia Gomaa - 2007
8/9/2019 000 HSE - Ch 1 - Overview
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HSEM 6 /Ch. 1HSE management View Part I - Dr. Attia Gomaa - 2007
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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HSEM 7 /Ch. 1HSE management View Part I - Dr. Attia Gomaa - 2007
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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HSEM 8 /Ch. 1HSE management View Part I - Dr. Attia Gomaa - 2007
Cost&
Resources
Ma inten a nce
HSE&
RCADesi g n
&HAZOP
ProcessInputs & Outputs
Critical Equipment
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HSEM 9 /Ch. 1HSE management View Part I - Dr. Attia Gomaa - 2007
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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HSEM 10 /Ch. 1HSE management View Part I - Dr. Attia Gomaa - 2007
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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HSEM 11/Ch. 1HSE management View Part I - Dr. Attia Gomaa - 2007
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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HSEM 12 /Ch. 1HSE management View Part I - Dr. Attia Gomaa - 2007
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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HSEM 13 /Ch. 1HSE management View Part I - Dr. Attia Gomaa - 2007
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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HSEM 14 /Ch. 1HSE management View Part I - Dr. Attia Gomaa - 2007
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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HSEM 15 /Ch. 1HSE management View Part I - Dr. Attia Gomaa - 2007
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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HSEM 16 /Ch. 1HSE management View Part I - Dr. Attia Gomaa - 2007
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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HSEM 18 /Ch. 1HSE management View Part I - Dr. Attia Gomaa - 2007
> 5 millionEgyptian areaffected by
asthma.
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HSEM 19 /Ch. 1HSE management View Part I - Dr. Attia Gomaa - 2007
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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HSEM 20 /Ch. 1HSE management View Part I - Dr. Attia Gomaa - 2007
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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HSEM 21/Ch. 1HSE management View Part I - Dr. Attia Gomaa - 2007
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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HSEM 22 /Ch. 1HSE management View Part I - Dr. Attia Gomaa - 2007
%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
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.
Critical Items
(A Rule 80/20)
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HSEM 23 /Ch. 1HSE management View Part I - Dr. Attia Gomaa - 2007
80%
12%5% 3%
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
Human factors Process
factors
Enviromental
factors
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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HSEM 24 /Ch. 1HSE management View Part I - Dr. Attia Gomaa - 2007
Ca use o f injuries
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HSEM 25 /Ch. 1HSE management View Part I - Dr. Attia Gomaa - 2007
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HSEM 26 /Ch. 1HSE management View Part I - Dr. Attia Gomaa - 2007
Accident Prevention
M anagement Systems
Technology
Human Factors
AccidentRate
Time
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HSEM 27 /Ch. 1HSE management View Part I - Dr. Attia Gomaa - 2007
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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HSEM 28 /Ch. 1HSE management View Part I - Dr. Attia Gomaa - 2007
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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HSEM 29 /Ch. 1HSE management View Part I - Dr. Attia Gomaa - 2007
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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HSEM 31/Ch. 1HSE management View Part I - Dr. Attia Gomaa - 2007
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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HSEM 32 /Ch. 1HSE management View Part I - Dr. Attia Gomaa - 2007
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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HSEM 33 /Ch. 1HSE management View Part I - Dr. Attia Gomaa - 2007
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