Guidelines for Hazard Identification, Risk Assessment and Risk Control (HIRARC) 2008 PDF

HIRARC Guidelines for Hazard Identification, Risk Assessment and Risk Control Guidelines for Hazard Identification, Risk Assessment...

HIRARC Guidelines for Hazard Identification, Risk Assessment and Risk Control Guidelines for Hazard Identification, Risk Assessment and Risk Control (HIRARC) Department of Occupational Safety and Health Ministry of Human Resources Malaysia 2008 JKKP DP 127/789/4-47 ISBN 978-983-2014-62-1 D e p ar tment of O c c up ati on a l S afe ty an d He a lt h HIRARC Guidelines for Hazard Identification, Risk Assessment and Risk Control Guidelines for Hazard Identification, Risk Assessment and Risk Control (HIRARC) Department of Occupational Safety and Health Ministry of Human Resources Malaysia 2008 JKKP DP 127/789/4-47 ISBN 978-983-2014-62-1 D e p ar tment of O c c up ati ona l S afe ty and He a lt h HIRARC Guidelines for Hazard Identification, Risk Assessment and Risk Control Preface I n recent years, Hazard Identification, Risk Assessment and Risk Control (HIRARC) has become fundamental to the practice of planning, management and the operation of a business as a basic of risk management. The organizations that have carried out risk assessment at the work place have noted numerous changes in their working practice. Those who have already carried out risk assessment in their work, have reported positive changes in their working practice, they recognize substandard act and working condition as they develop and take necessary corrective action. Legislation requires that this process should be systematic and be recorded so that the results are reliable and the analysis complete. The risk assessment process should be continuous and should not be regarded as a one-off exercise. In line with the Department approach of PREVENTIVE MEASURES as a way of enforcing the law on Occupational Safety and Health (OSH), it seems that HIRARC has became extremely important. With HIRARC, one will be able to identify hazard, analyze and assess its associated risk and then apply the suitable control measures This Guideline is supposed to provide guidance on methodology of conducting HIRARC, it should be simple enough to be used by small and medium industries and should be versatile enough to be used by all in various economic sectors, either in the manufacturing sector, construction sectors or any other economic sectors. The methodology of HIRARC as proposed in this Guidelines is intended for the assessment of physical hazards. Those who intend to assess health hazards in their workplaces, should make use of other risk assessment guidelines designed specifically for such purposes. The Department would like to thank all the staff from Major Hazard Division for their effort and contribution in the preparation of this guideline. Director General Department of Occupational Safety and Health, Malaysia 2008 2 D e p ar tment of O c c up ati on a l S afe ty an d He a lt h HIRARC Guidelines for Hazard Identification, Risk Assessment and Risk Control Page Numbers Table of PREFACE 1. Purpose 5 Contents 2. Term and Definitions 3. Basic Concepts 3.1 What is risk? 4. Planning And Conducting Of HIRARC 6 4.1 Purpose of HIRARC 4.2 Planning of HIRARC Activities 4.3 Process of HIRARC 4.3.1 Classify Work Activities 7 4.3.2 Hazard Identifications 4.3.2.1 Health Hazards 4.3.2.2 Safety Hazards 8 4.3.2.3 Environmental Hazards 4.3.2.4 Hazard Identification Technique 4.3.2.5 The hazard identification and assessment methodology 9 4.3.3 Analyze and Estimate Risk 4.3.3.1 Probability of an Occurrence 10 4.3.3.2 Severity of Consequence 11 4.3.3.3 Risk assessment 12 5. Control 5.1 Selecting a Suitable Control 13 5.2 Types of Control 5.2.1 At the source of the hazard 5.2.2 Engineering control 14 5.2.3 Administrative controls 5.2.4 Personal Protective Equipment 15 5.3 Monitoring Controls 5.4 Safe work Procedures 5.5 Personal Protective Equipment 16 D e p ar tment of O c c up ati ona l S afe ty and He a lt h 3 HIRARC Guidelines for Hazard Identification, Risk Assessment and Risk Control Table of 6. Documenting HIRARC 6.1 Responsibility and Accountability 16 Contents 6.2 Documenting Process 17 7. Consultation 18 8. Training APPENDIX A 19 Examples of Workplace Hazards APPENDIX B 22 Checklist for Workplace Hazard Examples APPENDIX C HIRARC Form 23 APPENDIX D Worked examples: Scenario 1 Worked examples: Scenario 2 25 APPENDIX E Example of Hazard Identification Technique 26 Example of Job Hazard Analysis 31 4 D e p ar tment of O c c up ati on a l S afe ty an d He a lt h HIRARC 1.0 Purpose Guidelines for Hazard Identification, Risk Assessment and Risk Control The purpose of this guideline is to provide a systematic and objective approach to assessing hazards and their associated risks that will provide an objective measure of an identified hazard as well as provide a method to control the risk. It is one of the general duties as prescribed under the Occupational Safety and Health Act 1994 (Act 514) for the employer to provide a safe workplaces to their employees and other related person. 2.0 Term And Definitions Hazard means a source or a situation with a potential for harm in terms of human injury or ill health, damage to property, damage to the environment or a combination of these. Hazard control means the process of implementing measures to reduce the risk associated with a hazard. Hierarchy of control means the established priority order for the types of measures to be used to control risks. Hazard identification means the identification of undesired events that lead to the materialisation of the hazard and the mechanism by which those undesired events could occur. Risk means a combination of the likelihood of an occurrence of a hazardous event with specified period or in specified circumstances and the severity of injury or damage to the health of people, property, environment or any combination of these caused by the event. Risk assessment means the process of evaluating the risks to safety and health arising from hazards at work. Risk management means the total procedure associated with identifying a hazard, assessing the risk, putting in place control measures, and reviewing the outcomes. 3.0 Basic Concepts 3.1 What is 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, D e p ar tment of O c c up ati ona l S afe ty and He a lt h 5 HIRARC Guidelines for Hazard Identification, Risk Assessment and Risk Control 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. 4.0 Planning And Conducting Of Hirarc 4.1 Purpose of HIRARC The purpose of HIRARC are as follows:- a. to identify all the factors that may cause harm to employees and others (the hazards); b. to consider what the chances are of that harm actually be falling anyone in the circumstances of a particular case and the possible severity that could come from it (the risks); and c. to enable employers to plan, introduce and monitor preventive measures to ensure that the risks are adequately controlled at all times. 4.2 Planning of HIRARC Activities HIRARC activities shall be plan and conducted – a. for situation – i. where hazard appear to pose significant threat; ii. uncertain whether existing controls are adequate; or/and iii. before implementing corrective or preventive measures. b. by organization intending to continuously improve OSH Management System. It should be the duty of the employer to assign a trained personnel to lead a team of employees associated with one particular process or activity to conduct HIRARC. 4.3 Process of HIRARC Process of HIRARC requires 4 simple steps - a. classify work activities; b. identify hazard; c. conduct risk assessment (analyze and estimate risk from each hazard), by calculating or estimating - i. likelihood of occurrence, and ii. severity of hazard; d. decide if risk is tolerable and apply control measures (if necessary). 6 D e p ar tment of O c c up ati on a l S afe ty an d He a lt h HIRARC Guidelines for Hazard Identification, Risk Assessment and Risk Control Flowchart of HIRARC Process Classify work activities Employer Representative Consultation Worker Representative Identify Hazards Risk Assessment Review Prepare Risk Control Action Plan (If Necessary) Implement 4.3.1 Classify work activities Classify work activities in accordance with their similarity, such as - i. geographical or physical areas within/outside premises; ii. stages in production/service process; iii. not too big e.g. building a car; iv. not too small e.g. fixing a nut; or v. defined task e.g. loading, packing, mixing, fixing the door. 4.3.2 Hazard identification The purpose of hazard identification is to highlight the critical operations of tasks, that is, those tasks posing significant risks to the health and safety of employees as well as highlighting those hazards pertaining to certain equipment due to energy sources, working conditions or activities performed. Hazards can be divided into three main groups, health hazards, safety hazards, and environmental hazards. 4.3.2.1 Health hazards 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 D e p ar tment of O c c up ati ona l S afe ty and He a lt h 7 HIRARC Guidelines for Hazard Identification, Risk Assessment and Risk Control 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. 4.3.2.2 Safety hazards A safety hazard is any force strong enough to cause injury, or damage to property. An injury caused by a safety hazard is usually obvious. For example, a worker may be badly cut. Safety hazards cause harm when workplace controls are not adequate. Some examples of safety hazards include, but are not limited to - i. slipping/tripping hazards (such as wires run across floors); ii. fire hazards (from flammable materials); iii. moving parts of machinery, tools and equipment (such as pinch and nip points); iv. work at height (such as work done on scaffolds); v. ejection of material (such as from molding); vi. pressure systems (such as steam boilers and pipes); vii. vehicles (such as forklifts and trucks); viii. lifting and other manual handling operations; and ix. working alone. 4.3.2.3 Environmental 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. 4.3.2.4 Hazard identification technique The employer shall develop a hazard identification and assessment methodology taking into account the following documents and information - i.any hazardous occurrence investigation reports; ii.first aid records and minor injury records; iii.work place health protection programs; iv. any results of work place inspections; v. any employee complaints and comments; vi. any government or employer reports, studies and tests concerning the health and safety of employees; vii. any reports made under the regulation of Occupational Safety and Health Act,1994 viii. the record of hazardous substances; and ix. any other relevant information. 8 D e p ar tment of O c c up ati on a l S afe ty an d He a lt h HIRARC Guidelines for Hazard Identification, Risk Assessment and Risk Control 4.3.2.5 The hazard identification and assessment methodology The hazard identification and assessment methodology shall include - a. Steps and time frame for identifying and assessing the hazards. One must define the steps for the identification of hazards and a time frame for this identification. The following information should be included - i. who will be responsible for the identification:  for example, it may be the work place health and safety committee, or an individual or individuals appointed by the committee; ii. the way in which the identification reports are processed: for example, they may be compiled and processed by the commit tee, or by individuals appointed by the committee; and iii. the identification time frame:  for example, the identification of hazards for workshop A must be completed in December, for workshop B in April and for workshop C in November. b. The keeping of a record of the hazards. After having identified the hazards, one must establish and maintain an identification record, either in print or electronic format. c. A time frame for reviewing and, if necessary, revising the methodology. The date for the review of the identification:  for example, the review of the identification method will be carried out every three years. To complete hazard identification, one can use techniques to identify hazards. Some examples of techniques include, but are not limited to - i. work place inspections; ii. task safety analysis or job hazard analysis; iii. preliminary investigations; iv. potential accident factors; v. failure analysis; vi. accident and incident investigations. It is in your interest to adopt your own process and your own identification techniques so that they match oner management procedures and the size of business. In fact, the identification method may vary depending on the size of the work place. 4.3.3 Analyze and estimate risk Risk is the determination of likelihood and severity of the credible accident/event sequences in order to determine magnitude and to priorities identified hazards. It can be done by qualitative, quantitative or semi quantitative method. D e p ar tment of O c c up ati ona l S afe ty and He a lt h 9  HIRARC Guidelines for Hazard Identification, Risk Assessment and Risk Control A qualitative analysis uses words to describe the magnitude of potential severity and the likelihood that those severity will occur. These scales can be adapted or adjusted to suit the circumstances and different descriptions may be used for different risks. This method uses expert knowledge and experience to determine likelihood and severity category. In semi-quantitative analysis, qualitative scales such as those described above are given values. The objective is to produce a more expanded ranking scale than is usually achieved in qualitative analysis, not to suggest realistic values for risk such as is attempted in quantitative analysis. Quantitative analysis uses numerical values (rather than the descriptive scales used in qualitative and semi-quantitative analysis) for both severity and likelihood using data from a variety of sources such as past accident experience and from scientific research. Severity may be determined by modeling the outcomes of an event or set of events, or by extrapolation from experimental studies or past data. Severity may be expressed in terms of monetary, technical or human impact criteria, or any of the other criteria. The way in which severity and likelihood are expressed and the ways in which they are combined to provide a level of risk will vary according to the type of risk and the purpose for which the risk assessment output is to be used. In this guidelines qualitative and semi quantitative method uses as an example. 4.3.3.1 Likelihood of an occurrence This value is based on the likelihood of an event occurring. You may ask the question “How many times has this event happened in the past?” Assessing likelihood is based worker experience, analysis or measurement. Likelihood levels range from “most likely” to “inconceivable.” For example, a small spill of bleach from a container when filling a spray bottle is most likely to occur during every shift. Alternatively, a leak of diesel fuel from a secure holding tank may be less probable. Table A indicates likelihood using the following values - LIKELIHOOD (L) EX A M PL E RATING Most likely The most likely result of the hazard / event being realized 5 Possible Has a good chance of occurring and is not unusual 4 Conceivable Might be occur at sometime in future 3 Remote Has not been known to occur after many years 2 Inconceivable Is practically impossible and has never occurred 1 Table A 10 D e p ar tment of O c c up ati on a l S afe ty an d He a lt h HIRARC 4.3.3.2 Severity of hazard Guidelines for Hazard Identification, Risk Assessment and Risk Control 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: SEVERITY (S) EX A M PL E RATING Catastrophic Numerous fatalities, irrecoverable property damage 5 and productivity Fatal Approximately one single fatality major property damage 4 if hazard is realized Serious Non-fatal injury, permanent disability 3 Minor Disabling but not permanent injury 2 Negligible Minor abrasions, bruises, cuts, first aid type injury 1 Table B 4.3.3.3 Risk assessment Risk can be presented in variety of ways to communicate the results of analysis to make decision on risk control. For risk analysis that uses likelihood and severity in qualitative method, presenting result in a risk matrix is a very effective way of communicating the distribution of the risk throughout a plant and area in a workplace. Risk can be calculated using the following formula: L x S = Relative Risk             L = Likelihood S = Severity D e p ar tment of O c c up ati ona l S afe ty and He a lt h 11  HIRARC Guidelines for Hazard Identification, Risk Assessment and Risk Control An example of risk matrix (Table C) is shown below: Severity (S) Likelihood (L) 1 2 3 4 5 5 5 10 15 20 25 4 4 8 12 16 20 3 3 6 9 12 15 2 2 4 6 8 10 1 1 2 3 4 5 Table C High Medium Low 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: RISK DESCRIPTION ACTION 15 - 25 HIGH A HIGH risk requires immediate action to control the hazard as detailed in the hierarchy of control. Actions taken must be documented on the risk assessment form including date for completion. A MEDIUM risk requires a planned approach to 5 - 12 MEDIUM controlling the hazard and applies temporary measure if required. Actions taken must be documented on the risk assessment form including date for completion. 1-4 LOW A risk identified as LOW may be considered as acceptable and further reduction may not be necessary. However, if the risk can be resolved quickly and efficiently, control measures should be implemented and recorded. Table D 12 D e p ar tment of O c c up ati on a l S afe ty an d He a lt h HIRARC Guidelines for Hazard Identification, Risk Assessment and Risk Control Hazards assessed, as “High Risk” must have immediate actions, to resolve risk to life safety and or the environment. Individuals responsible for required action, including follow up must be clearly identified. A further detail risk assessment method may require such as quantitative risk assessment as means of determine suitable controls measures. 5.0 Control Definition: Control is the elimination or inactivation of a hazard in a manner such that the hazard does not pose a risk to workers who have to enter into an area or work on equipment in the course of scheduled work. Hazards should be controlled at their source (where the problem is created). The closer a control to the source of the hazard is the better. This method is often referred to as applying engineering controls. If this does not work, hazards can often be controlled along the path to the worker, between the source and the worker. This method can be referred to as applying administrative controls.   If this is not possible, hazards must be controlled at the level of the worker through the use of personal protective equipment (PPE), although this is the least desirable control. 5.1 Selecting a suitable control Selecting a control often involves – a. evaluating and selecting short and long term controls; b. implementing short-term measures to protect workers until permanent controls can be put in place; and c. implementing long term controls when reasonably practicable. For example, suppose a noise hazard is identified. Short-term controls might require workers to use hearing protection. Long term, permanent controls might remove or isolate the noise source. 5.2 Types of Control 5.2.1 At the source of the hazard a. 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. b. 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. D e p ar tment of O c c up ati ona l S afe ty and He a lt h 13  HIRARC Guidelines for Hazard Identification, Risk Assessment and Risk Control 5.2.2 Engineering control a. Redesign - Jobs and processes can be reworked to make them safer. For example, containers can be made easier to hold and lift. b. Isolation - If a hazard cannot be eliminated or replaced, it can some times 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. c. 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. d. 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 tacting moving parts. 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. f. Dilution - Some hazards can be diluted or dissipated. For example, ventilation systems can dilute toxic gasses before they reach operators. 5.2.3 Administrative controls a. 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. b. 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. c. 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. d. 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. e. 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. 14 D e p ar tment of O c c up ati on a l S afe ty an d He a lt h HIRARC Guidelines for Hazard Identification, Risk Assessment and Risk Control 5.2.4 Personal protective equipment Personal protective equipment (PPE) and clothing is used when other controls measures are not feasible and where additional protection is needed. Workers must be trained to use and maintain equipment properly. The employer and workers must understand the limitations of the personal protective equipment. The employer is expected to require workers to use their equipment whenever it is needed. Care must be taken to ensure that equipment is working properly. Otherwise, PPE may endanger a workers health by providing an illusion of protection. 5.3 Monitoring controls The effectiveness of controls must be checked regularly. Evaluate and monitor hazard controls during inspections, routine maintenance, and other activities. Ask the following questions – a. have the controls solved the problem? b. is any risk to workers posed by the controls contained? c. are all new hazards being identified? d. are significant, new hazards appropriately controlled? e. are accident reports being analyzed? f. are any other measures required? Document control activities to track their effectiveness, if necessary re-evaluate hazards and implement new control measures. 5.4 Safe work procedures Through the completion of a Job Hazard Analysis, sometimes hazards are identified and cannot be eliminated or engineered out of a particular task. Safe Work Procedures are step by step instructions that allow workers to conduct their work safety when hazards are present. A Safe Work Procedure identifies the materials and equipment needed, and how and when to use them safety.   Safe Work Procedures are generally prepared for - a. critical high risk jobs where accidents have or could result in severe injuries; b. hazardous work where accidents occur frequently; c. new or altered tasks have been introduced; d. new equipment has been added to a process; e. a job that requires many detailed tasks; D e p ar tment of O c c up ati ona l S afe ty and He a lt h 15  HIRARC Guidelines for Hazard Identification, Risk Assessment and Risk Control f. where two or more workers required for a job, and each must perform specific tasks simultaneously; and g. specific tasks are done infrequently. Safe Work Procedures must include: a. regulatory requirements; b. necessary personal protective equipment; c. required training; d. worker responsibilities; e. specific sequence of steps to follow to complete the work safely; f. required permits; and g. emergency procedures. An example of a task that requires the development of a safe work procedure is confined space entry. Individuals who must work within confined spaces must ensure that safe work procedures are developed and followed to maximize life safety. 5.5 Personal protective equipment (PPE) Personal protective equipment means any equipment which is intended to be worn or held by a person at work and which protects him against one or more risks to his health or safety and any additional accessory designed to meet that objective; PPE is usually chosen to provide protection appropriate to each of type of hazard present. There are specifications for the types of PPE used for protecting an individual’s head, eyes, footwear, limb and body, fire retardant clothing, respiratory, hearing, and personal flotation devices. It may also include required apparel for example when traffic hazards are present high visible and distinguishable “vests must be worn” 6.0 Documenting HIRARC 6.1 Responsibility and accountability Proper management of hazards sporadically identified in the workplace can be done through effective process. Ultimately, the individual or team who identified the hazard must ensure proper communication of the hazard to the appropriate workplace authority (manager, department head, or designated person). Each HIRARC must be fully documented. The HIRARC form must be completed by the HIRARC team and signed 16 D e p ar tment of O c c up ati on a l S afe ty an d He a lt h HIRARC Guidelines for Hazard Identification, Risk Assessment and Risk Control by the in charge personnel of the area. Departments responsible for the hazards and their control are required to maintain all records of assessments for at least 3 years. (In some cases, legislative requirements will determine the minimum time to retain records). The appropriate authority is responsible for ensuring that effective and timely controls are applied to the hazard and communicating the results back to the originator.   Management or employer must endorse and approve the HIRARC results. Employer must communicate all HIRARC to employees, monitor the follow up action and keep the records. The HIRARC Form (see APPENDIX C) is an example to document the HIRARC process.             6.2 Documenting process Instructions to team leader and persons conducting HIRARC - a. complete HIRARC Form. It is recommended to use a single form for each work process; b. record the names and designation of HIRAC team members; c. outline the process workflow and indicate in the form under ‘process/ location column; e. list all activities ( routine and non-routine) for each work process under the “Work Activity” column; f. identify the hazards associated with each activity and record in “Hazard” column; g. determine the effect of each hazard identified and record in “Effect” column; h. record any existing hazard control measures; i. 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); j. by using Risk Matrix ( Table C and D ) assign one risk and record in “Risk” column; k. based on the risk assigned, recommend appropriate risk control measures ( see Table D); l. assign a suitable person to implement the recommended risk control and indicate the follow up action date and status; m. repeat the HIRARC for other activities and process; n. conduct another round of HIRARC after control measures have been implemented; and o. review HIRARC for every three years or whenever there are changes in process or activities. D e p ar tment of O c c up ati ona l S afe ty and He a lt h 17  HIRARC Guidelines for Hazard Identification, Risk Assessment and Risk Control 7.0 Consultation If practicable, there must be consultation with the relevant health and safety representative(s) when identifying, assessing and controlling risks. Consulting directly with employees and drawing on their experience and knowledge is more effective in reducing risk. 8.0 Training Information, instruction and training provide employees with the skills and knowledge to perform their work in a manner that is safe and without risks to health. It enables them to - a. follow health and safety procedures; b. use risk controls set in place for their protection; and c. have an appreciation of the nature of the hazard; the risks associated with their use; and the reason why risk controls are used. Managers, Supervisors Health and Safety Representatives and others who may be required to perform risk assessments by agreement with management shall be trained in hazard identification risk assessment and control methods. They must be trained in the risk assessment process and be familiar with - i. the regulations associated with the hazard; ii. have a practical understanding of the work hazards; and iii. consult with the Health and Safety Representative. 18 D e p ar tment of O c c up ati on a l S afe ty an d He a lt h HIRARC Guidelines for Hazard Identification, Risk Assessment and Risk Control APPENDIX A Examples of Workplace Hazards The Hazard Identification listed is to assist in the identification of hazards in the work place. This table provides some additional explanation of the meaning of the hazard classifications. WORK ENVIRONMENT Adequate Access Refers to adequate access to, from and within the workplace Air Conditioning Refers to uncontaminated air in the work space Confined Spaces Means enclosed work space where people do not normally work (defined in standards) Temperature Extremes: a) Heat This includes contact with hot objects, hyperthermia, fire (Not explosions) b) Cold This includes contact with cold objects and hypothermia Lighting Refers to adequate illumination for the particular work being done Mental Stress Includes bullying, workplace violence, shift work, excessive work loads Dehydration Adequate water supply for the individuals while working ENERGY Electrical Includes contact with exposed wires and contact with high voltage Gravity Includes falls, trips and slips of persons as well as objects falling, working at heights Kinetic Energy: a) The body hitting objects Hitting objects with part of the body b) Hit by moving objects Being hit by moving objects but excluding falling objects c) Explosion An explosion may also include heat as a hazard d) Penetrating objects This includes all objects that can penetrate including needles Vibration Includes vibration to parts or to the whole body Acoustic/Noise Includes exposure to single, sudden sound or long term exposure Pressure Pressure in hydraulic and pneumatic systems MECHANICAL Vehicles Being caught between, struck by or against vehicles (includes fork lifts) Mobile and Fixed Plant Being caught between, struck by or against plant (defined in legislation) D e p ar tment of O c c up ati ona l S afe ty and He a lt h 19  HIRARC Guidelines for Hazard Identification, Risk Assessment and Risk Control Powered Equipment Includes electrical or fuel powered equipment, tools and appliances Non-Powered Equipment Includes non-powered hand tools, appliances and equipment MANUAL HANDLING Muscular Stress a) Lifting, carrying Refers to muscular stress while lifting, carrying, or putting down objects b) Other handling Refers to muscular stress while handling objects other than above c) Without handling Refers to muscular stress with no objects being handled d) Repetitive movement Refers to repetitive movement and low muscular loading Ergonomics Includes fatigue, stress or errors due to workplace design ANIMAL / INSECT Bites/ Stings Includes bites and stings from animals and/or insects BIOLOGICAL Biological /Microbiological Includes bacterial, fungal, viral, parasitic or human/animal tissue/fluids blood products CHEMICAL Refers to single or long term contact with chemicals Flammable Refers to chemicals which burn Corrosive Refers to chemicals which will corrode tissue or metals Toxic Refers to chemicals which will poison a worker Oxidizers Refers to chemicals which will provide oxygen to a fire, or react readily Compressed Gases Refers to gases which under high pressure IONIZING RADIATION Refers to radioactive substances and radiation producing equipment like X-rays OTHER RADIATION Laser Refers to coherent low divergent electromagnetic radiation. the Helium-Neon lasers used in the undergraduate Physics labs, or the laser pointers Ultraviolet Refers to electromagnetic radiation from 180 nm to 400 nm Infrared Refers to electromagnetic radiation from 700 nm to 1 mm Radiofrequency Refers to electromagnetic radiation from 100 kHz to 300 MHz 20 D e p ar tment of O c c up ati on a l S afe ty an d He a lt h HIRARC Guidelines for Hazard Identification, Risk Assessment and Risk Control Microwave Refers to electromagnetic radiation from 0.3GHz to 300 GHz Electromagnetic Field Includes static magnetic fields and low frequencies from 0 to 100kHz. The NMR magnets used in research laboratories. ELF magnetic fields induce electric fields in the body which result in current flows and heating in biological tissue. ENVIRONMENTAL Release Atmosphere, sanitary sewer, storm sewer Contamination Ground water, fresh water, soil MAJOR EVENT/ACTIVITY OTHER EVENT/ACTIVITY Includes events such as sporting or public events on or off campus NATURAL EVENT/ ACTIVITY Rain/Storm/Lightning/ Preparation is the key to being able to address these issues Flooding OTHER EVENT/ACTIVITY Working Alone Loss of personal security, unable to communicate with emergency services PROPERTY EVENT/ACTIVITY Structure Collapse Loss of building Structure Damage Wall crumbling System Component Loss of monitoring system or suppression system Water Damage Plumbing leak, Utility Disruption Loss of essential services - gas, electricity, water D e p ar tment of O c c up ati ona l S afe ty and He a lt h 21  HIRARC Guidelines for Hazard Identification, Risk Assessment and Risk Control APPENDIX B Checklist for Workplace Hazard Examples EXAMPLES OF POTENTIALLY DAMAGING HAZARDS WORK ENVIRONMENT MANUAL HANDLING IONIZING RADIATION Adequate Access Muscular Stress Radioactive Materials Air Conditioning Lifting, carrying Confined Spaces Other handling OTHER TYPES OF Temperature Extremes Without handling RADIATION (including skin contact) Repetitive movement Laser Heat (inc. fire, flames) Ergonomics Ultraviolet Cold Infrared Lighting CHEMICAL Radiofrequency Mental Stress Flammable Microwave Dehydration Toxic Electromagnetic Field Falls, trips, slips etc. Corrosive Falling objects Oxidizer MAJOR EVENT Working at Heights Compressed Gases Student activities function Kinetic Energy Public event The body hitting objects BIOLOGICAL Violence Hit by moving objects Hold up Explosion Microbiological Intoxicated students Penetrating objects Animal tissue/fluids Firearms / Weapons Vibration Human tissue Food Poisoning Pressure – pneumatic, Human Blood and fluids hydraulic Pathogenic NATURAL Acoustic/Noise Zoonotic Lightning ENERGY ENVIRONMENTAL Rain Storm Electrical Air Release Flooding Gravity Sewer Release Sun Release to Property Wind MECHANICAL PROPERTY Vehicles ANIMAL / INSECT Mobile and Fixed Plant Structural Collapse Bites/ Stings Powered Equipment Structural Damage Research Animals Non-Powered Equipment Utility Failure Utility Disruption OTHER Water Damage Working Alone Remote location 22 D e p ar tment of O c c up ati on a l S afe ty an d He a lt h  APPENDI X C HIRARC Form H I R A RC F OR M Company: Conducted by: Process / Location: (Name, designation) Approved by: Date: (from... to...) (Name, designation) Date: Review Date: Next Review Date: 1. Ha z ard Id enti f i c ati on 2. R i sk An a l ysis 3. R isk C ontrol Work Existing Risk Recommended PIC No. Aktivity Hazard Which can cause/effect Control Likelihood Severity Risk Control (Due date/ HIRARC (if any) Measures status) 1 2 3 4 5 Guidelines for Hazard Identification, Risk Assessment and Risk Control D e p ar tment of O c c up ati ona l S afe ty and He a lt h 23 24 APPENDI X D Worked example Scenario 1: Wood panel cutting process A team of two workers operates a cross-cut saw machine. Their work includes loading wood panel onto the machine, cutting the wood and unloading the cut wood. They also need to repair and maintain the machine regularly as well as to change the blades of the machine. (Caution: This example may not be applicable to similar work in your workplace). H I R A RC F OR M Company: 2F Furniture Entp Conducted by: Mr. S (Supervisor), Miss M & Mr. L (Operator) Process / Location: Wood cutting/Panel Sect. (Name, designation) 24 Jun 2007 to 28 July 2007 Approved by: Mr. K Date: (from... to...) (Name, designation) (Manager) D e p ar tment of O c c up ati on a l S afe ty an d He a lt h Date: 25 Julai 2007 Review Date: 1. 2. 1. Ha z ard Id enti f i c ati on 2. R i sk An a l ysis 3. R isk C ontrol HIRARC Guidelines for Hazard Identification, Risk Assessment and Risk Control Work Existing Risk Recommended PIC No. Aktivity Hazard Which can cause/effect Control Likelihood Severity Risk Control (Due date/ (if any) Measures status) Loading the Cutting Cuts / first aid type injury Safe work practice 4 Use leather hand glove Andy (26 July 2007) 1 4 1 (Low) machine with wood blades / completed Operating the Unguarded Hand get caught into rotating parts / Safe work practice, daily To Fix L-guard Chia (26 Ogos 2007) machine machine amputation pre-use check and regular 12 2 4 3 (Medium) / In progress maintenance Flying Serious cuts & eye injuries by flying Warning signs; Training, 12 Use stronger blades; Mutu (26 Ogos 2007) 4 3 (Medium) To Fix L-guard / completed fragments fragments of blades that break during cutting Safety goggles Install Unloading cut wood Heavy load Muscular strain / back pain Manual lifting procedure 3 1 3 Use mechanical lifter 3 (Low) Ali (20 Ogos 2007) / KIV Repair and Unguarde Serious cuts from blade & getting cought Cover ‘on button’ Safe work 4 4 16 To make delay start Ahmad (18 Ogos 2007) 4 maintenance of the machine; in rotating parts if machine is practice (High) button / completed machine unsafe work accidentally started practise  Worked example Scenario 2: Wall exterior plastering work A group of three workers was instructed to do plastering work at exterior wall at first floor of the building. Their work includes erecting working platform, wall plastering with concrete and do clearing work. (Caution: This example may not be applicable to similar work in your workplace). H I R A RC F OR M Company: 3D Construction Eng. Entp. Conducted by: Mr. B (Supervisor), Mr. S & Mr. R (Plasterer) Process / Location: Plastering Work/Exterior Wall. (Name, designation) 24 Jun 2007 to 30 July 2007 Approved by: Mr. J Date: (from... to...) (Name, designation) (Site Manager) Date: 25 Julai 2007 Review Date: 1. 2. 1. Haz ard Id enti f i c ati on 2. R i sk An a l ysis 3. R isk C ontrol HIRARC Work Aktivity Existing Risk Recommended PIC No. Hazard Which can cause/effect Control Likelihood Severity Risk Control (Due date/ (if any) Measures status) Erect working Unguarded Head injury / fatal Safety helmet, 4 5 20 1) Fence upper floor 1) Muthu/ 1 platform floor housekeeping (High) exposed edges 20 Ogos 07 completed 2) Establish Safe Work 2) Ravi/ Procedure use JSA 2 Sept 07 completed Loading concrete Uneven Fall of person / broken leg Housekeeping, 4 3 12 Put plank on floor, anti Muthu/ onto platform floor safety shoes (medium) slip mat 26 July 07 completed 2 Heavy load Muscular strain / Back pain Manual lifting procedure 3 1 3 (low) Use small container Muthu/26 July 07 completed Plastering Defective Fall from height / fatal Safety belt 4 5 20 1) Install handrail Muthu/26 July 07 completed platform (High) 2) Use new plank as 3 platform Hot weather Dehydrate Nil 3 1 3 (low) Provide drinking facilities Ahmad to purchase/ Guidelines for Hazard Identification, Risk Assessment and Risk Control Clearing unused material Sharp object Finger cut Nil 3 1 3 (low) Use leather glove, use tool 26 July 07 in progress 4 D e p ar tment of O c c up ati ona l S afe ty and He a lt h 25  HIRARC Guidelines for Hazard Identification, Risk Assessment and Risk Control APPENDIX E Example of Hazard Identification Technique A. Job Hazard Analysis Definition Job Hazard Analysis (JHA) breaks a job or task into specific steps, analyzes each step for specific hazards, develops safe work procedures to eliminate or reduce those hazards, and integrates safe work procedures into safety and health programs. JHAs must be developed for each job or task. Supervisors and workers must complete the JHA together. Procedure Basic Steps - Job Hazard Analysis is broken down into 6 major steps: a. Select the job task to be analyzed. Prioritize which job tasks to analyze. Those job tasks where accidents and injuries are occurring should be analyzed first. Look at job tasks where there is a potential for serious injury. Look at new job tasks, these are important if a new process requires the development of new procedures and job tasks b. Identify the major sequence of steps for each step (Specific job step Description). Once a job task has been chosen, it must be broken down into logical steps. Limit the number of steps in a JHA to a manageable number. Most jobs can be described in ten or less steps. The job steps must be kept in their proper sequence to ensure a proper analysis. The opportunity to make recommendations will come later in the analysis. c. Identify the potential hazards for each step (Hazard Identification) Once the job steps have been chosen, the potential hazards for each step can be identified. Whatever can go wrong may go wrong! What are the potential hazards as a result of each task step? Is the worker exposed to hazardous chemicals? Is the worker subject to poor workstation design? There may only be one, or there may be a large number for each job step. d. Determine preventative measures to protect against the hazards (Required Precautions) i. The most important aspect of the job hazard analysis is to determine preventive measures to control or eliminate the identified hazards. What actions must be taken to control or eliminate the hazard? 26 D e p ar tment of O c c up ati on a l S afe ty an d He a lt h HIRARC Guidelines for Hazard Identification, Risk Assessment and Risk Control ii. Eliminate the Hazard - Substitute with less hazardous substance/ material iii. Contain/Enclose the Hazard - Use a fume hood or proper shielding iv. Revise Safe Work Procedures - Adding additional steps v. Reduce Worker Exposure - This is the least effective option in most cases, but may have to be used when permanent work process change is impossible or impracticable. Examples of this option include job rotation, where worker exposure is reduced, and the provision of personal protective equipment (PPE) to workers. e. Develop a worker-training program Reformat the job hazard analysis into a training program to help the employee eliminate or reduce hazards. f. Re-evaluation Re-evaluate the job descriptions and modify the job hazard analysis’ accordingly B. Example - Job Hazard Analysis a. Selecting Jobs for Analysis A job hazard analysis can be performed for all jobs in the workplace, whether the job task is “special” (non-routine) or routine. Even one-step jobs—such as those in which only a button is pressed—can and perhaps should be analyzed by evaluating surrounding work conditions. To determine which jobs should be analyzed first, review your job injury and illness reports. Obviously, a job hazard analysis should be conducted first for jobs with the highest rates of disabling injuries and illnesses. Also, jobs where “close calls” or “near misses” have occurred should be given priority. Analyses of new jobs and jobs where changes have been made in processes and procedures should follow. Eventually, a job hazard analysis should be conducted and made available to employees for all jobs in the workplace. b. Involve the Employee Once you have selected a job for analysis, discuss the procedure with the employee performing the job and explain its purpose. Point out that you are studying the job itself, not checking on the employee’s job performance. Involve the employee in all phases of the analysis—from reviewing the job steps and procedures to discussing potential hazards and recommended solutions. You also should talk to other workers who have performed the same job. D e p ar tment of O c c up ati ona l S afe ty and He a lt h 27  HIRARC Guidelines for Hazard Identification, Risk Assessment and Risk Control c. Conducting the Job Hazard Analysis Before actually beginning the job hazard analysis, take a look at the general conditions under which the job is performed and develop a checklist. Below are some sample questions you might ask - i. Are there materials on the floor that could trip a worker? ii. Is lighting adequate? iii. Are there any live electrical hazards at the jobsite? iv. Are there any chemical, physical, biological, or radiation hazards associ ated with the job or likely to develop? v. Are tools—including hand tools, machines, and equipment - in need of repair? vi. Is there excessive noise in the work area, hindering worker communication or causing hearing loss? vii. Are job procedures known and are they followed or modified? viii. Are emergency exits clearly marked? ix. Are trucks or motorized vehicles properly equipped with brakes, overhead guards, backup signals, horns, steering gear, and identification, as necessary? x. Are all employees operating vehicles and equipment properly trained and authorized? xi. Are employees wearing proper personal protective equipment for the jobs they are performing? xii. Have any employees complained of headaches, breathing problems, dizziness, or strong odors? xiii. Is ventilation adequate, especially in confined or enclosed spaces? xiv. Have tests been made for oxygen deficiency and toxic fumes in confined spaces before entry? xv. Are work stations and tools designed to prevent back and wrist injuries? xvi. Are employees trained in the event of a fire, explosion, or toxic gas release? 28 D e p ar tment of O c c up ati on a l S afe ty an d He a lt h HIRARC Guidelines for Hazard Identification, Risk Assessment and Risk Control Naturally this list is by no means complete as each worksite has its own requirements and environmental conditions. You should add your own questions to the list. Photographs, if appropriate, may be used in creating a more detailed analysis of the work environment. d. Breaking the Job Down Nearly every job can be broken down into job tasks or steps. In the first part of the job hazard analysis, list each step of the job in order of occurrence as you watch the employee performing the job. Be sure to record enough information to describe each job action, but do not make the breakdown too detailed. Later, go over the job steps with the employee. e. Identifying Hazards After you have recorded the job steps, next examine each step to determine the hazards that exist or that might occur. Ask yourself these kinds of questions: i. Is the worker wearing personal protective clothing and equipment, including safety harnesses that are appropriate for the job? ii. Are work positions, machinery, pits or holes, and hazardous operations adequately guarded? iii. Are lockout procedures used for machinery deactivation during mainte nance procedures? iv. Is the worker wearing clothing or jewelry that could get caught in the machinery or otherwise cause a hazard? v. Are there fixed objects that may cause injury, such as sharp machine edges? vi. Is the flow of work improperly organized (e.g., Is the worker required to make movements that are too rapid)? vii. Can the worker get caught in or between machine parts? viii. Can the worker be injured by reaching over moving machinery parts or materials? ix. Is the worker at any time in an off-balance position? x. Is the worker positioned to the machine in a way that is potentially dangerous? xi. Is the worker required to make movements that could lead to or cause hand or foot injuries, or strain from lifting— the hazards of repetitive motions? D e p ar tment of O c c up ati ona l S afe ty and He a lt h 29  HIRARC Guidelines for Hazard Identification, Risk Assessment and Risk Control xii. Can the worker be struck by an object or lean against or strike a machine part or object? xiii. Can the worker fall from one level to another? xiv. Can the worker be injured from lifting or pulling objects, or from carrying heavy objects? xv. Do environmental hazards—dust, chemicals, radiation, welding rays, heat, or excessive noise—result from the performance of the job? Repeat the job observation as often as necessary until all hazards have been identified. 30 D e p ar tment of O c c up ati on a l S afe ty an d He a lt h HIRARC Guidelines for Hazard Identification, Risk Assessment and Risk Control C. Worked example Job Hazard Analysis Cleaning Inside Surface of Chemical Tank - Top Manhole Entry STEP HA Z A RD R E QU I R E M E N T S 1. Determine Improper oxygen level Establish confined space entry procedures (Code of what is in the Chemical exposure - Practice for confine space). tank, what Gas, dust, vapor - Obtain work permit signed by safety, maintenance, process is irritant, toxic and supervisors. going on in Liquid - irritant, toxic, Test air by qualified person. the tank, and corrosive, heated Ventilate to 19.5% -23.5% oxygen and less than 10% what hazards Solid - irritant, LEL of any flammable gas. Steaming inside of tank, this can pose. corrosive flushing and draining, then ventilating, as previously Moving blades/ described, may be required. equipment Provide appropriate respiratory equipment - SCBA or air line respirator. Provide protective clothing for head, eyes, body, and feet. Provide harness and lifeline. (Reference:......). Tanks should be cleaned from outside, if possible. 2. Select Operator with Examination by industrial physician for suitability to and train respiratory or heart work. operators. problem; other physical Train operators. limitation. Untrained Dry run. (Reference:......). operator - failure to perform task 3. Set up Hoses, cord, equipment Arrange hoses, cords, lines, and equipment in orderly equipment - tripping hazards. fashion, with room to manoeuvre safely. Electrical - voltage Use ground-fault circuit interrupter. too high, exposed Lockout and tag mixing motor, if present. conductors. Motors not locked out and tagged. 4. Install ladder Ladder slipping. Secure to manhole top or rigid structure. in tank. 5. Prepare to Gas or liquid in tank. Empty tank through existing piping. enter tank. Review emergency procedures. Open tank. Check of jobsite by industrial hygienist or safety professional. Install blanks in flanges in piping to tank (isolate tank). Test atmosphere in tank by qualified person (long probe). D e p ar tment of O c c up ati ona l S afe ty and He a lt h 31  HIRARC Guidelines for Hazard Identification, Risk Assessment and Risk Control STEP HA Z A RD R E QU I R E M E N T S 6. Place Trip or fall. Use mechanical-handling equipment. equipment Provide guardrails around work positions at tank top. at tank-entry   Provide personal protective equipment for conditions position. found. (Reference:......). 7. Enter tank. Provide outside helper to watch, instruct, and guide operator entering tank, with capability to lift operator from tank in emergency. 8. Cleaning Reaction to chemicals, Provide protective clothing and equipment for all tank. causing mist or operators and helpers. expulsion of air Provide lighting for tank (Class I, Div. 1). contaminant. Provide exhaust ventilation. Provide air supply to interior of tank. Frequent monitoring of air in tank. Replace operator or provide rest periods. Provide means of communication to get help, if needed. Provide tow-man standby for any emergency. 9. Cleaning up. Handling of equipment, Dry run. causing injury. Use material-handling equipment. 32 D e p ar tment of O c c up ati on a l S afe ty an d He a lt h HIRARC Guidelines for Hazard Identification, Risk Assessment and Risk Control Department of Occupational Safety and Health Ministry of Human Resources Level 2,3 & 4, Block D3, Complex D, Federal Government Administrative Centre 62530 W.P. Putrajaya. D e p ar tment of O c c up ati ona l S afe ty and He a lt h