Hazard Analysis, Control & Correction

1. Hazard Analysis, Control & Correction (Unit-I)

2. Hazard control Policy statements • Should clearly address an organization’s philosophy and objectives related to accident prevention. • Written in precise and unambiguous language • Senior leadership must sign and disseminate all organizational members.

3. Hazard control Plan • Hazard control managers can take planning tips from emergency and disaster planners. • Using results obtained from a hazard vulnerability analysis (HVA), Hazard control managers should develop their master hazard control directive. • Conducting a thorough hazard vulnerability assessmentwould provide a solid foundation to build PPE. • Developing a master hazard control plan • can provide direction to all accident prevention efforts. • must hold all operational policies, procedures, and job practices • stress the importance of establishing procedures for the immediate reporting of accidents, incidents, mishaps, and other close-call events. • Hazard control practicerequiresindividuals to take responsibility for doing the right thing. • Plans, procedures, and policies can’t identify and correct hazards—people do

4. During Inspection? • What is your most flammable substance? • how much do you store on-site? • how and where do you store it? • which departments use the substance? • Flammable substance created fire load hazard at several locations throughout the facility. • This situation created other hazard control issues such as human exposure risks, sprinkler system coverage, proper storage room configuration, and portable fire extinguisher assessments.

5. Objectives and goals • Organizations and hazard control managers must ensure the development of realistic objectivesand goals. • Develop and implement written documents that direct or requirespecifichazard control–related actions and behaviors.

6. HAZARD ANALYSIS • Organizations can use a variety of processes to analyze workplace hazards and accident causal factors. • Hazard evaluations and accident trend analysis can help improve the effectiveness of established hazard controls. • Routine analysis enables to implement appropriate controls for unsafe operations. • Analysisprocesses rely on information collected from hazard surveys, inspections, hazard reports, and accident investigationsthat providea snapshotof hazard information. • Effective analysis can then take the snapshotsand create viable pictures of hazards and accident causal factors. • Types: Change Analysis, Creative Hazard Analysis, Risk Analysis, Phase Hazard Analysis, Process Hazard Analysis

7. Change Analysis • Works as a proactive problem-solving technique. • Helps to identify hazards inherent in new processes and job related tasks, and to identify all anticipated hazards and concerns generated by the change. • To solve a problem, hazard control personnel must look at situations using some type of logic process. • Begin by defining a problem & to determine what happened. • Next, determine the norm or standard. • Ask the question, what should have happened? • Attempt to identify, locate, and describe the change by focusing on what, where, when, and to some extent how. • Describeexactly the things impacted and things not affected by the change. • Identify distinctive features of any change and list all possible causes. • Finally, select and validate all causes before continuing with corrections or controls.

8. Creative Hazard Analysis • Combines innovation with human expertise to identify, discover, and analyze hazards of a process. • Ensure the analysis team understands the problem statement. • Providethe team with sufficient information such as known hazards, related technologies, operational procedures, equipment design issues, instrumentation controls, and necessary historical information. • As the team works through each step of the hazard process, collectively generate a list of what or why questions related to hazards. • After completing this list of probing questions, the team must systematically answer each question to achieve consensus. • The answers can also generate additional questions that seek to clarify important information. • The answers that achieve consensus form the foundation for developing recommendations or dictating the requirement for additional action to reduce operational hazards.

9. Risk Analysis • Helps to assess the probability of an uncontrolled hazard could contribute to an accident event with resulting organizational losses. • Considerthe potential severity associated with an adverse event occurrence. • Analysis personnel use available empirical data when attempting to determine probability of a risk-related event. • Severity consideration become the controlling issue when other factors indicate a low probability of an event. • Risk personnel can consider hazards with acceptable risks as safe and those with unacceptable risks as unsafe. • “safety first” implies safety becomes primary objective and not job accomplishment. In very hazardous jobs and operations, a more appropriate slogan should read, “accomplish the job with safety.”

10. Phase Hazard Analysis • Processes work very well for construction projects and other settings with rapidly changing work environments. • Considered as a new or unique set of hazards not present during operations. • Prior to transitioning to a new phase, conduct an analysis to identify and evaluate new or potential hazards. • Use the information gained through analyses to develop action plans that ensure implementation of appropriate controls.

11. Process Hazard Analysis • The OSHA Process Safety Management standard requires completion of a process hazard analysis for any activity involving the use of highly hazardous chemicals. • The OSHA standard applies to entities using (storing, manufacturing, handling, or on-site moving) of highly hazardous chemicals. • Process hazard analysis permits employers to accomplish detailed studies to identify every potential hazard. • Include all tools and equipment, each chemical substance, and every job-related task. • The analysis must show that each element of the process poses no hazard, poses an uncontrolled hazard, or poses a hazard controllable in all foreseeable circumstances. • Apply process hazard analysis during the design and development phases of any hazardous operation under development.

12. JOB HAZARD ANALYSIS (JHA) • Permits the examination of job-related tasks to discover and correct inherent risks and hazards. • JHA does require an understanding of potential job hazards. • Personnel conducting the analysis must possess knowledge of hazard control including use of PPE. • An effective analysis provides the basis for implementing appropriate control measures. • Step A: Break the job down—Examine each step in the process for hazards or unsafe conditions. • Step B: Identify hazards—Document process hazards, environmental concerns, and any anticipated human issues • Step C: Evaluate hazards—Assess identified hazards and behaviors to determine their potential roles in an accident event • Step D: Develop and design hazard controls—Develop or design the best hazard control by evaluating each hazard. • Step E: Implement required controls—Coordinate and obtain management approval for implementation • Step F: Revise and publish the JHA information—Update the JHA and then communicate implementation actions with the organizational members

13. Job Design • Creating well-designed jobs, tasks, and processes can help reduce worker fatigue, reduce repetitive motion stress, isolate hazardous tasks, and control human factor hazards. • Safe work area design reduces static positions and minimizes repetitive motions and awkward body positions. • Consider the importance of human factor issues when designing work processes.

14. HAZARD CONTROL AND CORRECTION • Use the concept hierarchy of controls to reduce, eliminate, and control hazardous processes. • Hazard controls include actions such as using enclosure, substitution, and attenuationto reduce human exposure risks. • An enclosure keeps a hazard physically away from humans. For example, completely enclosing high-voltage electrical equipment prevents access by unauthorized persons. • Substitutioncan involve replacing a highly dangerous substance with a less hazardous one. • Attenuation refers to taking actions to weaken or lessen a potential hazard. Attenuation could involve weakening radioactive beams or attenuating noise to safer levels. • The use of system safety methods, traditional hazard control techniques, and human factors must begin at the initial stages of any design process. • Active hazard controls –require users to accomplish a task at some point during the operation to reduce risks and control hazards.

15. Hazard Correction Monitoring System • Implement a system to report and track hazards correction actions. • Establish a timetable for implementing hazard controls. • Prioritize hazards identified by inspections, reporting, and accident investigations. • Require employees to report hazards using established processes. • Provide quick feedback about the status of hazard correction. • Delegate responsibility for correcting and documenting completion actions. • Permit supervisors and experienced employees to initiate hazard correction actions.

16. Common Never-Ever Hazards • Obstacles preventing the safe movement of people, vehicles, or machines • Blocked or inadequate egress routes and emergency exits • Unsafe working and walking surfaces • Using damaged tools and equipment or misusing tools • Failing to identify hazards and provide proper equipment including PPE • Operating equipment with guards removed or bypassed • Permitting the presence of damaged, or unguarded electrical wiring, fixtures, or cords • Lack of or inadequate warning, danger, or caution sign in hazardous areas

17. Engineering Controls • The design of machine guards, automobile brakes, traffic signals, pressure relief valves, and ventilation demonstrates engineering controls at work. For example, proper ventilation can remove or dilute air contaminants in work areas, Air cleaning devices. • Seek to eliminate hazards by using appropriate engineering controls. Make the modifications. • Using engineering, design, and technical innovation remains the top priorityfor controlling or eliminating hazards. • Establishing preventive and periodic maintenance processes can help ensure tools and equipment operate properly and safely.

18. Administrative Controls • Use administrative controls such as scheduling to limit worker exposure to many workplace hazards Eg: working in hot areas. • OSHA prohibits employee scheduling to meet the requirement of air contaminant exposure limits. • The scheduling of maintenance and other high exposure operations during evenings or weekends can reduce exposures. • Use job rotation to limit repetitive motion tasks or reduce the exposure time to occupational noise hazards. • Use a work–rest schedule for very hazardous or strenuous tasks.

19. Work Practice Controls • Development of standard operating procedures (SOPs) reduce hazard exposure. • Conducting training and education about the safe use of tools and equipment. • Practices can also include • knowing emergency response procedures for spills • fire prevention principles • dealing with employee injuries • Must address task accomplishment and ensure workers understand all job-related hazards

20. Hierarchies for Controlling Hazards • Engineeringand technological innovation are preferred type of hazard control. • Substitution results in using a less hazardous substance or piece of equipment. • Isolation moves either workers or hazardous operations to reduce risks. • Work practices such as policies or rules can reduce human exposure to the hazard. • Administrative controls limit human exposures through the rotation and scheduling. • Consider PPE when other controls prove inadequate.