Transcript Accident and Loss Statistics Chemical Process Safety ChE 258

Accident and Loss Statistics
Chemical Process Safety
ChE 258
Overview






Accidents
Models
Engineering Ethics
Loss Statistics
Perceptions
Example
Definition

Accident –

is an undesired event that resulted in
unwanted deterioration of
 health of a living organism
 value of an organization
 quality of the environment
Safety, Hazard, and Risk

Safety or loss prevention is the
prevention of accidents by the use of
appropriate technologies to identify the
hazards of a chemical plant and to
eliminate them before an accident
occurs.
Safety, Hazard, and Risk


A hazard is anything with potential for
producing an accident
Risk is the probability of a hazard
resulting in an accident.
Types of Personnel Accidents






Struck by
Contact by
Caught in
Caught between
Foot-level Fall
Exposure





Struck against
Contact with
Caught out
Overexertion
Fall to below
Accident Causation Theory



“Acts of God”
“Pilot Error” – beginning of industrial
revolution
“Mismanagement” – current legal
leanings
Heinrich Domino Theory
Predictable chronological sequence of
causal factors lead to accidents
 Fault of person
 Unsafe practices
 Unsafe conditions
 Accident, and
 Loss

Developed by H.W. Heinrich in 1920’s
Marcum’s 7 Domino Sequence
of “Misactsidents”
Supposes that all accidents can be avoided and that the
liability resides with management
 Inadequate preparation
 Substandard performance
 Miscompensated risks
 Harmful contact incident
 Adverse reaction
 Sustained losses, and
 Incurred costs
System-Induced Error
An accident occurs if a triggering event
occurs at a time when the innate error
tendencies of humans as determined by
performance influencing factor lead to an
error in an unforgiving environment
Developed during the 1980’s
System-Induced Error

Innate error tendencies of humans



Fallible memory
Reliance on rules
Information processing limitations
System-Induced Error

Performance influencing factors

Physiological and Psychological state



Low motivation
Overloaded
Inadequate training
System-Induced Errors

Unforgiving Environment


Absence of barriers (physical) to making
errors
No support for recovery
System-Induced Error
An accident occurs if a triggering event
occurs at a time when the innate error
tendencies of humans as determined by
performance influencing factor lead to an
error in an unforgiving environment
Chemical Engineering Ethics
American Institute of Chemical Engineers
Fundamental Principles
Engineers shall uphold and advance the
integrity, honor and dignity of the engineering
profession by
1 using their knowledge and skill for the
enhancement of human welfare;
2 being honest and impartial and serving with
fidelity the public, their employers, and
clients;
3 striving to increase the competence and
prestige of the engineering profession
Chemical Engineering Ethics
American Institute of Chemical Engineers
Fundamental Canons
1 Engineers shall hold paramount the safety, health, and
welfare of the public in performance of their professional
duties.
2 Engineers shall perform services only in areas of their
competence.
3 Engineers shall issue public statements only in an objective
and truthful manner.
4 Engineers shall act in professional matters for each
employer or client as faithful agents or trustees, and shall
avoid conflicts of interest.
Chemical Engineering Ethics
American Institute of Chemical Engineers
Fundamental Canons
5 Engineers shall build their professional reputations on the
merits of their services.
6 Engineers shall act in such a manner as to uphold and
enhance the honor, integrity, and dignity of the
engineering profession.
7 Engineers shall continue their professional development
throughout their careers and shall provide opportunities
for the professional development of those engineers under
their supervision.
OSHA



Occupational Safety and Health
Administration
Established by Congress in 1970 in the
“Occupational Safety and Health Act of 1970”
OHSAct
OSHA has defined terms related to work
related losses
OSHA Definitions

Occupational Injury is any injury such
as a cut, fracture, sprain, amputation,
etc. which results from an exposure
involving a single incident in the work
environment.
From Table 1.2 in text
OSHA Definitions

Occupational Illness of an employee is
any abnormal condition or disorder,
other than one resulting from an
occupational injury caused by exposure
to environmental factors associated
with employment. It includes acute and
chronic illnesses or diseases which may
be caused by inhalation, absorption,
ingestion, or direct contact.
OSHA Definitions

Lost Workdays are those days which the
employee would have worked but could
not because of occupational injury or
illness. Also need to account for
diminished long term performance.
OSHA Definitions

Recordable Cases are those involving an
occupational injury or occupational
illness, including deaths. Not
recordable are first aid cases which
involve onetime treatment and
subsequent observation of minor
scratches, cuts, burns, splinters, etc.,
which do not ordinarily require medical
care.
OSHA Definitions

Nonfatal cases without lost workdays are
cases of occupational injury or illness which
did not involve fatalities or lost workdays but
did result in (1) transfer to another job or
termination of employment, or (2) medical
treatment other than first aid, or (3)
diagnosis of occupational illness, or (4) loss of
consciousness, or (5) restriction of work or
motion.
OSHA Definitions


There are tables of
“lost work days” that
are assigned to
losses of various
members of the
body
Fatality is equivalent
to 24 worker years
OSHA Definitions

These “lost work
days” are not only
based on how long
it will take to
recover but also on
the individuals
diminished ability to
carry out the job
function
Injury and Loss Statistics

There are several different statistics
that have been defined and collected by
government and industrial agencies
OSHA Injury & Illness Rate
OSHA Injury&Illness Rate =
(# of Injuries&Illness*200,000)/(Total hrs all employees)
Based on 100 worker-years
 40hrs   50wk 
WorkYear  
 2000 hr


yr
 wk   yr 
OSHA Lost Workdays Incidence Rate

Same bases, but use lost workdays
Lost Workdays Incidence Rate =
(# lost workdays * 200,000)/(Total hrs worked)
Other Loss Statistics
FAR is the Fatal Accident Rate
FAR=(# of Fatalitiesx108)/(Total hrs all employees)
Based on 1000 workers’ career
 40hr   50wk   50 yr 
5 hr
WCareer  

10




career
 wk   yr   career 
Table 1.3 & 1.4 lists several FARs
Other Loss Statistics

Fatality Rate


# Fatalities / yr
FatalityRate  

Total
#
PeopleExposed


Causes of Accidental Death in US
Major causes of death in US
Accident Pyramid


Typically there are
numerous property
losses and minor
injuries for every
fatality
“An accident is
usually visible the
day before it
happens”
Risk




Risk is the product of the probability of the
occurrence of an accident and the severity of
the accident
The Chemical Processing Industry has the
possibility for severe accidents due to
operating conditions and materials
Engineers try to reduce the probability of
occurrence to reduce the risk
In the real world we have to accept some
risks
Public Perceptions


Public Opinion Poll “Would
you say chemicals do
more good than harm,
more harm than good, or
about the same amount
of each”
The Chemical
Manufacturers Association
(CMA) recently (2000)
changed its name to
American Chemists
Council (ACC) to avoid the
word “chemical”
Risk to Human Life Survey


You will rank which
causes the greatest
number of deaths
each year
Each question is the
same, only
decreasing rank

Causes of death










Handguns
Smoking
Motor Vehicles
Private Aviation
Commercial Aviation
Alcoholic Beverages
Nuclear Power
Food Preservatives
Pesticides
Skiing
Risk to Human Life Survey






Start Internet Explorer
http://classes.che.umr.edu
LIBRIX Front Page
Give username and password
If first time, username is AFS Email
name and password is Student number
“Risk to Human Life” survey
LIBRIX



Go to “My Profile”
Change password to your choice so that
you can remember
Will use LIBRIX some more during the
semester.
In Class Assignment
The FAR for travel by car is reported as 57 while
that for travel by air is 240
1)
2)
If the average speed of travel is 50 mph by
car and 250 mph by air, determine the
deaths per million miles travel by car or air.
If you are required to make a round trip
from St. Louis to Los Angeles, which is the
safer mode of transportation as indicated by
the statistics?
Solution
1) Calculations
6


57
deaths
1
hr
10



deaths
Car   

0.0114




8
MillionMiles
 10 hr  50miles   MillionMiles 

106
 240deaths  1hr  
Air   
 0.0096 deaths



8
MillionMiles
 10 hr  250miles   MillionMiles 
2) For a fixed distance, air travel is the safest mode