HIRA Relevant Statutes and Standards

Statute Section Provision

The Factories Act, Sec. 7-A : Provide and ensure risk free
1948 Duties of the environment to the workers at
Occupier workplace.
“ HAZARDOUS PROCESS ” The Factories Act 1948 Section 2 (cb)

Any Process or Activity referred in The First Schedule where

unless special care is taken Raw Materials or Intermediates or
Finished Products, By Products, Waste or Effluents may
- Cause material impairment to the health of persons engaged
in or connected therewith
- Result in the Pollution of the general environment.
The Factories Act,1948 - Schedules
• The First Schedule : It has a list of 29 types of
industries involving hazardous processes.
• The Second Schedule : It has a table showing
permissible level of certain chemical substances in
Work Environment expressed in Time-Weighted
Average (TWA) Concentration for 8 hrs. as well as in
Short Term Exposure Limit (STEL) (for 15 mts.). The
permissible levels are expressed both in parts per
million (ppm) and milligramme per cub. metre
(mg/m3).
• The Third Schedule : It has a list of 29 types of
Notifiable Diseases
First Schedule : List of Industries involving Hazardous Processes

1. Ferrous Metallurgical Industries

2. Non-ferrous Metallurgical Industries
3. Foundries (ferrous and non-ferrous)
4. Coal (including coke) industries
5. Power generating industries
6. Pulp and paper (including paper products) industries
7. Fertilizer industry
8. Cement industries
9. Petroleum industries
10. Petrochemical industries
11. Drugs and pharmaceutical industries
12. Fermentation Industries (Distilleries and Breweries)
13. Rubber (Synthetic) industries
14. Paints and pigment industries
15. Leather tanning industries
First Schedule : List of Industries involving Hazardous Processes

16. Electro – plating industries

17. Chemical industries
18. Insecticides, fungicides, herbicides and other pesticides industries
19. Synthetic resin and plastics
20. Man-made fiber (cellulosic and non-cellulosic) industry
21. Manufacture and repair of electrical accumulators
22. Glass and ceramics
23. Grinding or glazing of metals
24. Manufacture, handling and processing of asbestos and its products
25. Extraction of oils and fats from vegetable and animal source
26. Manufacture, handling and use of benzene and substances containing benzene
27. Manufacturing processes and operations involving carbon disulphide
28. Dyes and dyestuff including their intermediates
29. Highly flammable liquids and gases
 Schedule II : Permissible Levels of Certain Chemical Substances in
Work Environment [The Factories Act, 1948, Section 41F]

Permissible limits of exposure

S. No Substance Time-weighted
Short-term exposure
average Concentration
limit (15min)*
(8hrs)

ppm mg/m3** ppm mg/m3**

1. Acetaldehyde 100 180 150 270
2. Acetic acid 10 25 15 37
3. Acetone 750 1780 1000 2375
8. Ammonia 25 18 35 27
27. Carbon monoxide 50 55 400 440
30. Chlorine 1 3 3 9
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Statute Rule Provision
The Manufacture, Rule 10 – Safety Safety report to be prepared (new and
Storage and Reports and existing industrial activity) --content -
Import of Safety Audit Schedule 8 - submit to the authority.
Schedule 8 - Items 5 and 7 under
Hazardous Reports
the schedule related to hazard analysis
Chemical Rules, and assessment.
1989
(Amendment
2000)
 MSIHC 1989 / CIMAH Rules - SCHEDULE II & III
Sr Chemicals Threshold Quantities Threshold Quantities
(tonnes) rules 4,5,7 to 9 & (tonnes)
13 to 15 rule 10 to 12
1 Chlorine 10 t 25 t
2 Hydrogen 2t 50 t

3 Ammonia 50 t 500 t

• prepare on site emergency plan • Fresh Safety Audit- Every

Year
• mock drill once in 6 months
• Preparation of Safety
Report
 Statutory Requirement
Statute Rule Provision

Model Rule. Rule 7 (e) – Discussing reports on safety,

under the Safety Committee environmental and occupational health
Factories Act – Prescribed surveys, safety audits, risk
1948 under Section 41 assessment and disaster management
and 41 G of The plans and implementation of the
Factories Act, recommendations made in the reports.
1948.
Rule 82A (11.2) Enclose a copy of the report on Risk
– Site Appraisal Assessment study.
Committee

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 Statutory Requirement
Statute Rule Provision

Model Rule. under the Rule 82B (5) – concerning Relevant techniques and methods, such as
Factories Act 1948 Health and Safety Policy – risk assessment for periodical assessment of
Prescribed under Section 7A(3), the status on health, safety and environment
and taking all the remedial measures.
41B(2) and 112 of The Factories
Act, 1948

Rule 82G (a) : concerning A report on status relating to risk

Disclosure of Information to assessment and environmental impact
District Emergency Authority: assessment and the measures taken for
prevention of accidents.

The Building and Other Rule 39 - Health and Safety policy Techniques and methods for assessment of
Construction Workers risk to safety, health and environmental and
(Regulation of Employment and remedial measures there for;
Conditions of Service) Central
Rules, 1998

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 Statutory Requirement
Statute Rule Provision
Environment Schedule II of the
Protection Rules Environment Impact ‘Risk of accidents during
Assessment construction or operation of
1986
Notification for the project, which could
environmental affect human health & the
clearance for new environment’.
projects /
modifications.
Relevant Standards
IS/ISO 45001 (2018) : Occupational Health and Safety Management
Systems Requirements with guidance for use
Clause 6.1.2 Hazard Identification and Assessment of Risk
6.1.2.1 Hazard identification
• The organization shall establish, implement and maintain a process(es) for hazard
identification that is ongoing and proactive. The process(es) shall take into account but
not be limited to:
-how work is organized, social factors (including workload, work hours, victimization,
harassment and bullying), leadership and the culture in the organization;
-routine and non-routine activities and situations, including hazards arising from
infrastructure, equipment, materials, substances and the physical conditions of the
workplace;
-product and service design, research, development, testing, production, assembly,
construction, service delivery, maintenance and disposal,
-human factors;
- how the work is performed;
6.1.2.1 Hazard identification

-past relevant incidents, internal or external to the organization, including

emergencies, and their causes;
-potential emergency situations;
- people, including consideration of:
1) those with access to the workplace and their activities, including workers,
contractors, visitors and other persons;
2) those in the vicinity of the workplace who can be affected by the activities of
the organization;
3) workers at a location not under the direct control of the organization
6.1.2.1 Hazard identification
-other issues, including consideration of:
• 1) the design of work areas, processes, installations, machinery/equipment,
operating procedures and work organization, including their adaptation to the
needs and capabilities of the workers involved;
• 2) situations occurring in the vicinity of the workplace caused by work-related
activities under the control of the organization;
• 3) situations not controlled by the organization and occurring in the vicinity of
the workplace that can cause injury and ill health to persons in the workplace;
• -actual or proposed changes in organization, operations, processes, activities,
and the OH& S management system
• Changes in knowledge of and information about hazards
 Review and Revision
The following are examples of when a HAZID revision should occur

Organizational
changes

New
projects
Process or
HAZID condition
Revision monitoring
changes
Incident
investigation
results

Abnormal conditions
through design
envelope changes

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Hazard Identification and Assessment of Risk

• Hazard Identification process must be ongoing to ensure existing hazards are

known, and
• New hazards recognised before they are introduced:
- Prior to modification of facility
- Prior to change in SMS or workforce
- Before and during abnormal operations, troubleshooting
- Plant condition monitoring, early warning signals
- Employee feedback from routine participation in work
- After an incident
Hazard Identification and Assessment of Risk

• A systematic, transparent and comprehensive HAZID process should be used

based on a comprehensive and accurate description of the facility
• Major accidents and the underlying hazards should not be disregarded simply
because:
- They appear to be very unlikely
- They have not happened previously
- They are considered to be adequately controlled by existing measures
Hazard Identification and Assessment of Risk

The Hazard Identification approach is required to:

• Be team-based
• Use a a process that is systematic
• Be pro-active in searching for hazards
• Assess all hazards
• Analyse existing controls and barriers - preventative and
mitigative
• Consider size and complexity in selecting approach to use
Hazard Identification and Assessment of Risk

Hazard Identification Team Selection

• The team selection for the area or plant is critical to the whole
hazard identification process
• Personnel with suitable skills and experience should be available to
cover all issues for discussion within the HAZID process
• A well managed, formalised approach with appropriate
documentation is required
• Team selection and training in methodology used is to be provided
Hazard Identification and Assessment of Risk

HAZID Study Team

The typical study team would comprise:

• Study facilitator
• Technical secretary
• Operations management
• HSR/Operations representative
• Project engineer or project design engineer for new projects
• Process engineer
• Maintenance representative
• Instrument electrical representative

Note: the above team make up is indicative only

Hazard Identification and Assessment of Risk

HAZID Planning

The following steps are required:

• Planning and preparation

• Defining the boundaries and provide system description
• Divide plant into logical groups
• Review P&IDs and process schematics to ensure accuracy
• Optimise HAZID process by means of preplanning work involving relevant
stakeholders (operations, maintenance, technical and safety personnel)
Hazard Identification and Assessment of Risk

Issues for consideration

• Equipment can be off-line

• Safety devices can be disabled or fail to operate
• Several tasks may be concurrent
• Procedures are not always followed
• People are not always available
• How we act is not always how we plan to act
• Things can take twice as long as planned
• Abnormal conditions can cross section limits
• Power failure
IS 15656 (2006): Hazard identification and
risk analysis Code of practice
This code describes specific techniques to prevent human and property
losses in the operation and management of process plant.
The overall methodology presented in this code allows systematic
identification of hazards as well as quantification of the risks associated
with the operation of process plants. Applied with due expertise and
rigour the prescribed methodology can help the user understand the
relative levels of hazards and risk potential in an installation.
This aids the selection and prioritization of necessary strategies for
accident prevention and limiting their consequences. Therefore, the
Code can be used for improving plant safety performance as well as to
reduce human and property losses.
 IS 15656 (2006): Hazard identification and
risk analysis Code of practice
Risk analysis is a process that consists of a number of sequential steps as
follows:
a) Hazard Identification - Identifying sources of process accidents
involving release of hazardous material in the atmosphere and the various
ways (that is scenarios) they could occur.
b) Consequence Assessment – Estimating the probable zone of impact of
accidents as well as the scale and/or probabiJity of damages with respect to
human beings and plant equipment and other structures.
c) Accident Frequency Assessment - Computation of the average likelihood
of accidents.
d) Risk Estimation - Combining accident consequence and frequency
to obtain risk distribution within and beyond process plant
Hazard Identification Methods

Comparative methods:
Checklist-Compliance with standard
Audit-Operation match with design intent
Indices-Relative ranking of units
PHA – Early hazard identification

Fundamental methods:
What if – Accident event sequence
HAZOP – Identifies process hazards
FMEA–Equipment failure mode & outcome

Logic diagramed methods

FTA – Estimation of incident frequency
ETA – Model of sequence of events
CCA – Outcome arising from event combination
HRA – A person successfully
NSC performing a task. 31
 Hazard Identification and Risk Assessment techniques

Hazard Identification Methods:

1. Checklist – for quick identification

2. Safety Audit – To ensure the procedures match
with design intent
3. Hazard Indices – for identifying relative hazards
for ranking of plant process units based on
degree of risk
4. PHA – Preliminary Hazard Analysis – at design
phase to provide guidance for final design
5. What if Analysis – To identify possible
(accident) event sequences related to hazards
during modification, development or pre start-
up stage.

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 Hazard Identification and Risk Assessment techniques

Hazard Identification Methods:

6. FMEA - Failure Mode and Effect Analysis – To

identify equipment failure and effect on plant
operation
7. HAZOP - Hazard and Operability Study
Guidewords : No,
Less,
More,
Part of,
As well as,
Reverse,
Other than

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 Hazard Identification and Risk Assessment techniques

Hazard Analysis Methods:

1. FTA – Fault Tree Analysis: Deductive approach

for identifying how basic events lead to an
accident event by using AND, OR gates.
2. ETA – Even Tree Analysis: For identifying the
event sequences from initiating event to
accident scenario.

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 Hazard Identification and Risk Assessment techniques

Risk Analysis Methods:

1. HIRA : Hazard Identification & Risk Assessment

/ Qualitative Risk Assessment
2. QRA : Quantitative Risk Assessment /
Consequence Modeling
a. Source Model
b. Fire and Explosions Model
c. Effect Model

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 Steps in Consequence Analysis

1. Characterising source of release of material

or energy associated with hazard analysed.

2. Estimating transport of material and/or

energy in environment to target of interest.

3. Identifying the effects of the propagation of

the energy or material on the target of interest.
4. Quantifying the health, safety, environmental
or economic impacts on the target of interest.
November 19, 2009 NSC 36
 Hazard Identification and Risk Assessment techniques

Hazard Identification and Risk Assessment (HIRA)

(Qualitative Risk Assessment)
Sample Format:

Activity Hazard Risk Existing Initial Risk Level Prog. Residual Risk Level

Proposed control
Acceptable (Y/N)
Ref.
SN control
No
Measures

Legal (Y/N)

Measures
Severity

Severity

(13x14)
(If any)
Likely

Likely
Level

Level
hood

hood
(7x8)
Risk

Risk
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
1

*Hierarchy of control: (1) Elimination, (2) Substitution, (3) Engineering

Controls, (4) Signage/ warning and/or administrative control, 5) Personal
Protective Equipment
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Importance of Hazard Identification

Trevor Kletz

“What has not been identified can neither be assessed nor

mitigated...”
 THANK YOU
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