1.

0 Introduction

In this assignment, we are assigned to conduct HIRARC for one of the mechanical
engineering department laboratories or workshops. Our main objective is to assist in
identifying potential hazard as well as provide a suitable method to keep the risk within
the laboratory or workshop under control. In that way, HIRARC is carried out with the
purpose of providing a systematic and neutral approach to identifying hazards and their
relevant risks. There are literally three processes of HIRARC being conducted which
include hazard identification, risk assessment and risk control.

Before proceeding to the following section, it is essential to distinguish between hazard

and risk. Hazard is a source or state with a possibility to cause harm in phrase of human
injury, disease, health, property damage, environment destruction or in combination of
these harmful consequences. In contrast, risk is defined as the possibility or probability of
the hazard resulting in harm or destruction to the people, property or the environment. It
is the combination of likelihood and severity of a unique hazardous event happening. In
the form of mathematical equation, risk can be tabulated by the equation: [Risk =
Likelihood × Severity] where likelihood is the possibility of an event to happen within a
certain period of time or in specified conditions, whereas; severity is the result or
consequence from an event in term of their severity.

2.0 Planning and Conducting of HIRARC

2.1 Purpose of HIRARC

The purposes of HIRARC are listed in the following:-

a) To determine all the relevant factors which may result in damage to workers and
others (hazards);
b) To take into account of what the likelihood is of that danger actually be facing
anyone in the situation of a particular event and the potential severity which could
be caused from it (risks); and
c) To allow employers to plan, initiate and control preventive actions to make sure
that the risks are sufficiently managed at all times.
2.2 Planning of HIRARC Activities

In general, HIRARC processes shall be planned and carried out:-

a) Under circumstance:-
1. Where hazard is apparent to create significant danger;
2. Where there is uncertainty in the adequacy of existing controls; and/or
3. Before applying corrective or preventive actions.
b) By company or organization planning to enhance OSH Management System in a
continuous manner.

2.3 Process of HIRARC

Basically, there are 4 simple procedures required for the process of HIRARC:-
a) Arrange and categorize work activities;
b) Determine or identify hazard;
c) Carry out risk assessment (examine and predict risk from each identified hazard),
this can be done through calculation or prediction of:-
1. Likelihood of specified event, and
2. Severity of hazard;
d) Make judgment for the risk whether it is endurable and implement control
measures (if needed).

Flowchart of HIRARC Process

Classification of work activities

Hazard Identification

Risk Assessment

Risk Control Action Plan (If needed)

Implement
2.3.1 Classification of work activities

Arrange and categorize work activities according to their same properties like:-
1. Specified task such as packing, loading, fixing the door;
2. Production stages/ service process;
3. Relatively big such as building a vehicle;
4. Relatively small such as fixing a screw; or
5. Physical areas within/outside buildings.

3.0 Hazard Identification (HI)

Purpose of Hazard Identification

The purpose of hazard identification is to pinpoint the critical working functions of duties
in which those duties showing notable risks towards safety and health of workers together
with several hazards involving certain apparatus as resulted from energy sources, labor
states or activities conducted. In literal, hazards can be separated into three main
categories including health hazards and safety hazards.

3.1 Health Hazards

The health hazard is any factor which can result in sickness or discomfort to an individual.
A health hazard may affect either all or part of a person’s body and result in either short-
term immediate effects or long-term problems. It is usually uneasy to identify the signs
and symptoms of health disease right away. As an example, the affected person with
hearing loss due to high exposure under high noise levels is difficult to detect at first until
the illness becomes well advanced. Health hazards are further categorized into different
groups which include chemical hazard, physical hazards and work design (ergonomic)
hazards.

While conducting hazard identification in materials laboratory in UCTS, there are several
health hazards being discovered in different categories. These health hazards are grouped
respectively according to their attributes. The categories of health hazards in this case
include the chemical, physical and work design hazards. In the following, these health
hazards corresponding to their work activities are listed in table format associated with
the relevant pictures as their evidences.

Health Hazard – Chemical

No. Work Activity Chemical Hazard Which can cause/Effect

Changing or refilling Ultra
Grade 19 mechanical Prolonged exposure Respiratory and Skin
1
vacuum pump oil in air to oil vapor or mist Irritation
ballast

Figures 1&2: Ultra Grade 19 Oil in Material Laboratory

Explanation (Prolonged Exposure to Oil Vapor or Mist): The Ultra Grade 19 oil is
specially produced to an exclusive specification for the use in air ballast pumps with the
purpose to provide the best possible vacuum performance. While utilizing this product,
there could be a possibility that the container is not closed or there are some leakages on
the container itself. In that way, the oil inside the container might be vaporized and
escapes into the surrounding air. Eventually, this may result in high concentration of the
oil vapor inside the material laboratory after certain time duration under enclosed
condition. As for that, an individual who enters the laboratory might feel irritated on
either respiratory organ or skin after prolonged period. Hence, skin or lungs discomfort
can be resulted as a long-term effect of exposure to oil vapor or mist.

Health Hazards – Physical

No. Work Activity Physical Hazard Which can cause/Effect

Conducting tensile strength High noise level of Change in hearing or
2
test on metals metal fracture sound ringing in ears (tinnitus)

Figure 3: Metal Tensile Strength Testing Machine in Material Laboratory

Explanation (High noise level of metal fracture sound): In our prior knowledge,
hearing loss can be resulted due to long-term exposure to high levels of noise. However,
short-term high noise exposure can also lead to a sudden change in hearing in which
one’s ears may feel filled up or ringing in the ears which is known as tinnitus. Even
though these short-term issues are reversible after escaping the noise for a certain period
of time, the repeated exposures to high noise level can result in irreversible tinnitus
and/or hearing loss.

Health Hazard – Work Design (Ergonomic)

No. Work Activity Work Design Hazard Which can cause/Effect

Manual handling of Wrong positioning of
3 Falling/Tripping
machine machine

Figure 4: Machine Being Positioned on Ground in Material Laboratory

Explanation (Wrong positioning of machine): A work design hazard is considered as a

physical factor in the surrounding which damages the musculoskeletal system. The term
‘ergonomics’ is taken as the study of how a workplace and equipment utilized as well as
the working condition can best be developed in the flavor of comfort, efficiency, safety
and productivity (Comcare, 2014). In this case, a machine has been wrongly positioned
on ground which might cause discomfort while handling the machine manually. Besides,
it is also unsafe to be positioned on ground somewhere in the middle of the laboratory as
it might cause an individual being tripped and fall without notice.

3.2 Safety Hazards

In general, a safety hazard is any form of energy or force which is adequately strong to
result in injury or property destruction. It is usually noticeable for an injury resulted from
a safety hazard. This is due to that negative effects or harm caused by the safety hazard
are direct and immediate. As an example, a person may be seriously cut by sharp
equipment if not handled with care. It can be deduced that safety hazards can cause
damage when safety controls and measures within a workplace are not sufficient. In
material laboratory, there are several hazards being identified and classified as safety
hazards as shown in the following.

No. Work Activity Hazard Which can cause/Effect

Material Composition Compressed Gas Frostbite, injury or damage by

4
Testing (Argon) freezing & Explosion

Moving or walking
5 Floor failure Slipping/Tripping
inside the laboratory

Moving parts of
Operating the Shearing/Entanglement/Friction
6 machinery, tools
mechanical equipments or Abrasion
and equipment
 Stored or placed on Release of potential energy at
Storing on-going
7 high place like any hitting point after falling
process testing metals
table off from high place

Figure 5: Tanks

Containing Compressed Argon Gas in Material Laboratory

Explanation (Compressed argon gas): If compressed argon is suddenly released from a

tank straight into the eyes or onto the skin, it may eventually lead to frostbite, injury or
damage by freezing in which it can proceed from initial redness, being itchy and finally
localized destruction of body tissue if there is no proper treatment applied (Caldwell,
2017). This is due to that any compressed gases may have flammable, oxidizing,
hazardously reactive, corrosive or toxic features. Hence, unsuccessful managed release of
compressed gas in a particular laboratory can rupture reaction containers resulting in
leakage of equipment or causing fugitive chemical reactions. In other perspective, there is
also a possibility that sudden explosion of compressed argon gas can occur if a heat
source is brought near to the pressurized argon tanks without careful precautions taken.
As a consequence, this can lead to sudden increase in both pressure and temperature of
the compressed argon gas inside the tank and eventually sudden explosion happens when
critical explosive point of the compressed argon gas is reached. Thus, it is very dangerous
and hazardous to bring in any heat source into the material laboratory due to the presence
of compressed argon gas inside the laboratory.

Figure 6: Floor Failure in Material Laboratory

Explanation (Floor failure): It can be observed inside the picture shown that there is a
floor failure in the material laboratory. This can definitely become one of the safety
hazards in such a way that it can cause a particular person to be tripped if without notice.
As the person being tripped, he or she may suffer in pain where the collision happens
between the floor and some body parts. In severe situation, that particular person may
accidentally or unintentionally be knocked out by hitting his or her head at the edge of a
table as a chain consequence from tripping.

Figure 7: Mini Lathe Machine with Moving Parts in Material Laboratory

Explanation (Moving parts of machinery, tools and equipment):Inside the material
laboratory, there are quite a number of machines with their respective functions.
Examples of these machines include the universal testing machine, impact testing
machine, mini lathe machine and others. There are also other tools and equipments
provided to assist in material testing and measurements. However, there are some
machines which contain moving parts which may result in unintended effects threatening
the user’s safety if not handled with precautions. In example, a mini lathe machine
(Figure 5) is found to have its moving parts unshielded. Hence, this may cause several
hazards including sharing, entanglement, or friction or abrasion hazards.

Figure 8: On-going Process Metals Being Placed on a Table

Explanation (Metals stored/placed on high place): There is no wrong in storing or
placing the on-going process testing metals on a table which is considerably high.
However, there will always be a possibility for these metals to cause harm to an
individual if they fell off from the table due to unintended actions and hit his or her foot.
In detail explanation, potential energy stored in a particular metal starts to be released and
transformed into kinetic energy as it fells down until the kinetic energy reaches its
maximum at a critical point close to the ground. So this can result in a considerably large
impact force being generated and applied onto an individual’s foot. Therefore, the person
who does not wear safety shoes inside the material laboratory may suffer pain if these
testing metals are not stored safely and properly.
4.0 Risk Assessment (RA)
5.0 Risk Control (RC)

Risk control is the actions taken to inactivate or eliminate health and safety hazards as far
as reasonably practicable which the hazards do not pose a risk to the workers who need to
access the working place and operate the equipment in a frequent manner. However, most
of the time we will find it difficult to eliminate the hazards present in the working
environment because we cannot eliminate the source of hazards. Therefore, we ought to
minimize the risk of hazards as much as possible by developing and implementing
control measures corresponding to the hazards.

5.1 Selection of Appropriate Risk Control Measures

In previous sections of HI and RA, we have known that there are several types of safety
and health hazards which carries a variety of severity. Therefore in RC, we need to
identify and choose the most suitable control measures to minimize the risk of hazards as
far as we can go. In other words, it is advisable that the level of control methods matches
with the level of severity of the hazards. For example, the hazard with the highest
severity should be dealt with excellent control measures.

The rules of thumb in determining and selecting a suitable risk control method involves:
i. Evaluate the severity of the hazards and discerning short and long terms controls;
ii. Select and implement short-term control when instant protection of the workers
are urgent. Normally, short-term control is more simple and easier to be carried
out but it is just temporary. It will remain until the long-term or permanent control
is available and applicable.
iii. Select and implement long-term control if the method is reasonably applicable
and the workers are able to adapt to the changes.

5.2 Hierarchy of Control

The control hierarchy lists out several types of control methods differed in effective level.
Basically there are three effective level, namely most effective, fairly effective and least
effective. Generally, the closer a control method is to the source of hazards, the more
effective it is.
5.2.1 Most Effective Control Method

The most effective control method is applied at the source of the hazards, where the
problems are created. In this context, elimination method performs the best which it
removes the source of hazard directly and therefore it is considered as the most effective
control method. Elimination involves the getting rid of dangerous job, tool, process,
equipment, substance or chemical. However, it is the most difficult one to be carried out
because most of the time all of the sources of hazards are needed to carry out specific
experiment or testing.

In our case, only one of the safety hazard identified in the material lab can be eliminated,
which is the floor failure. The source of the hazard is cracks on the surface of floor which
can be eliminated directly by simply repairing and maintaining the floor surface. For
other hazards, we need to attempt other control measures to minimize the risk of hazards.

5.2.2 Fairly Effective Control Method

Fairly effective control method involves substitution and engineering control methods.
Substitution method is replacing the hazardous substance with another alternative which
is less or non-hazardous. Normally it is done to the hazardous chemicals which can be
replaced with another chemicals with lower hazardous level. However in our case, the
only chemical found in the material lab is Ultra Grade 19 mechanical vacuum pump oil
used in air ballast. It is just irritant, which is the lowest hazardous level of chemicals.
Therefore, it is difficult to find non-hazardous alternative which can perform the similar
function. Thus, substitution method is not appropriate in our case.

There are 6 methods categorized under engineering control measure, namely redesign,
isolation, automation, barriers, absorption and dilution. For our case, redesign
(rework jobs and processes) and dilution (dilute or dissipate hazards such as toxic gas
through ventilation system) methods are not applicable. The other 4 control methods are
feasible as follow:
a) Isolation
Isolation is normally used when a hazard cannot be eliminated or replaced. The hazards
are isolated, contained and kept away from the workers so that the workers can avoid
from continuously exposed to or contacting the hazards. In our case, isolation is taken for
two physical hazards identified in the material lab, which are the wrong positioning of
Charpy test machine and improper placing of heavy on-going process testing materials on
a high place like table.

The Charpy test machine should be relocated to a wider and safer zone away from the
walking path instead of at the middle so that the risk of knocking into it or tripping and
falling over it can be minimized. Those heavy on-going process testing materials on the
table should be stored in a cupboard or a container so that the workers’ feet will not have
the risk to get hurt by the falling impact of the heavy stuffs. By these, the two hazards are
said to be successfully isolated from the workers.

b) Automation
Automation is replacing the dangerous manual operating method with automatic or
mechanizing operating method. For example, the release of the controlling valve of the
compressed argon gas should be computer-controlled instead of manual handling. If the
valves can be opened or closed via software on the computer, the risk of getting injured
by the gas impulse released from high pressure can be greatly reduced since the operator
is of a safe distance away from the compressed gas.

c) Barriers
Barriers are used as obstacles to block the hazards from reaching the workers. Taking the
mini lathe machine as example, the sharp parts of mechanism and also the rotating shaft
with high speed should be enclosed by a transparent protective cover to avoid
entanglement and piercing injuries in case the workers accidentally touch the moving
mechanism during operation. The protective cover serve as a barrier to avoid the workers
from contacting the dangerous mechanism during operation.
d) Absorption
Absorption is reducing the risk of a hazard in its energy content, such as noise. For
example, baffles can be installed on the inner walls of universal tensile test machine to
absorb the sound energy and thus reduce the noise level of metal fracture transmitted
outside.

5.2.3 Least Effective Method

Least effective method involves administrative control and personal protective

equipment (PPE) which always serve as backup plan and also additional protection to
other control measures. Although they are the comparatively the least effective, their
importance and function cannot be neglected and exempted in supplement to the most
effective and fairly effective control methods.

There are 5 elements in administrative controls namely safe work procedures,

supervision and training, job rotations, housekeeping, repair and maintenance
programs and hygiene. All these are applicable in the material lab as supplement control
measures.

a) Safe Work Procedures

Safe work procedures are standardized practices and correct operating steps of equipment
in the workplace. For example in the material lab, safe work procedures of every
equipment especially the one with high risk of hazards like the mini lathe machine needs
to be attached to serve as guidelines and alert to the workers.

b) Supervision and Training

Before workers operate any equipment in the workplace, regardless whether he/she is
experienced or not, they should undergo supervision and training initially to acknowledge
or refresh themselves about the correct operating procedures and ways to minimize the
risk of hazards. In our case, this should be done prior to any person who needs to access
the material lab for assignment or experiment. Appropriate supervision should be
provided to them to assist them in identifying potential hazards and evaluating work
procedures.
c) Job Rotations
Job rotations require workers to take turn or schedule the work time well to reduce the
exposure period to a hazard. For example, workers can take turn to operate the universal
tensile test machine which tends to produce large noise during the fracturing of metal
specimen. Meanwhile, the tensile test should be scheduled at a time when others are not
in the material lab.

d) Housekeeping, Repair and Maintenance Programs

Housekeeping includes cleaning, waste disposal and spill cleanup. Machine and
equipment need regular maintenance to ensure their optimum performance. All of the
equipment, tools and apparatus in the material lab need to be maintained and checked
regularly to reduce the likelihood to cause hazards to the operators. For example, the
cracked floor surface should be repaired and maintained in good condition to avoid
falling or tripping of the workers.

e) Hygiene
Hygiene practices are essential to reduce the risk of self-exposure to chemicals especially
the toxic chemicals or substances and also the chance of carrying the chemicals back to
the families at home. For example, after a worker changes or refills Ultra Grade 19
mechanical vacuum pump oil, he/she should take a shower or change the contaminated
clothes with a clean one before leaving the material lab. Work clothing and casual
clothing should be stored in separated lockers.

PPE and clothing are normally the last resort whereby other control measures are not
applicable. Sometimes they do serve as additional protection to the workers when needed.
For example when dealing with the irritant Ultra Grade 19 mechanical vacuum pump oil,
the worker should put on mask and hand gloves to avoid from breathing in the chemical
vapor and also skin contact with the chemical. Besides, safety boots need to be put on to
avoid from the injuries resulted from falling heavy substances onto the feet, like the
hazard of heavy on-going process materials which are placed on the table.
5.3 Monitoring Controls

Monitoring controls are the last step in RC which the effectiveness of every control
measure needs to be checked regularly. Evaluation and monitoring on the hazards control
methods should be conducted frequently during inspections, routine maintenance and
other activities. In order to track the effectiveness of the control measures implemented,
documentation should be done on each control activities and the report should consider 6
questions:

1. Have the hazards been under control by the measures taken?

2. Will the controls pose any risk to the workers?
3. Is there any new hazard to be identified?
4. If yes, is the new hazard significant to be controlled and what are its appropriate
controls?
5. Is there any accident report which has not been analyzed?
6. Is there any other control measures required?

Whenever it is necessary, the hazards need to be reevaluated and new control measures
should be implemented as well.

6.0 Conclusion

HIRARC is essential in every workplace to ensure the safety of workers and also visitors
from outside. Without proper HIRARC to be conducted, workers are often unaware of
hidden hazards and not knowing the risk of exposure to those hazards. Some might cause
detrimental effects like disabilities and even death. Luckily, so far we don’t discover any
hazard with very high risks and severity which can cause death in the material lab. After
conducting HIRARC in the material lab, we find that in overall the risk level and number
of hazards identified in the material lab is still controllable as long as the operators follow
risk controls method properly and the dos and don’ts in the lab. Last but not least, we
suggest that a fire extinguisher and a first-aid kit need to be prepared in the material lab
in case of any emergency happens, though we don’t find any source of fire hazard. The
HIRARC conducted in the material lab is summarized in the following table:
 HIRARC Summarization Form:

3. Risk Control
1. Hazard Identification (HI) 2. Risk Assessment (RA)
(RC)
Work Which can Existing Risk Recommended
No. Hazard Likelihood Severity Risk
Activity cause/effect Control (if any) Control Measures
Put on mask and
Changing or
hand gloves to
refilling Ultra
Prolonged avoid from
Grade 19
exposure to Respiratory and Skin breathing in the
1 mechanical Nil
oil vapor or Irritation chemical vapor
vacuum
mist and also skin
pump oil in
contact with the
air ballast
chemical.
1.Baffles can be
High noise installed to absorb
Conducting
level of Change in hearing or Hearing the sound energy
tensile
2 metal ringing in ears Protection and thus reduce
strength test
fracture (tinnitus) Devices (PPE) the noise level of
on metals
sound metal fracture
transmitted out.
 2.Job rotation policy
to reduce the
exposure duration.
Relocate the
Manual Wrong
machine to a wider
handling of positioning
3 Falling/Tripping Nil and safer zone
machine of machine
away from the
walking path.
1.Automatic valve
Material Compressed Frostbite, injury or control via
Manual Safety
4 Composition Gas damage by freezing computer.
Valve
Testing (Argon) & Explosion 2.Establish safety
work procedures.
Repair and
maintain the
Moving or
cracked floor
walking Floor
5 Slipping/Tripping Nil surface to
inside the failure
eliminate the
laboratory
hazard.
 1.Fully enclose the
Operating the Moving
dangerous
mechanical parts of Shearing/Entangleme
Partial Protective mechanism with
6 equipment machinery, nt/Friction or
Cover transparent cover
like mini tools and Abrasion
2.Establish safety
lathe machine equipment
work procedures.
Stored or Release of potential
Storing on- Stored in a
placed on energy at any hitting Safety boots
7 going process cupboard or a
high place point after falling off (PPE)
testing metals container.
like table from high place
References