Introduction
In chemical, pharmaceutical, and petrochemical industries, work involves hazardous chemicals, high-pressure systems, complex processes, and heavy equipment, which create inherent safety risks.
Understanding hazards, risks, incidents, accidents, unsafe acts, unsafe conditions, and near misses is essential to prevent injuries, fires, explosions, environmental damage, and production loss.
Effective identification, reporting, investigation, and control of these safety elements help organizations recognize early warning signs, take timely corrective and preventive actions, comply with legal requirements, and build a strong safety culture.
Proper incident and accident management focuses on fact finding, root cause elimination, and prevention of recurrence, ensuring protection of people, assets, processes, and the environment.
Index
- Hazard
- Risk
- HIRA
- Introduction to Incident
- Causes of Incidents
- Types of Incidents
- Accident
- Difference Between Incident and Accident
- Unsafe Act
- Reasons/Factors Contributing to Unsafe Acts
- Prevention of Unsafe Acts
- Unsafe Condition
- Types of Unsafe Conditions
- Prevention of Unsafe Conditions
- Near Miss
- Incident Reporting
- Corrective and Preventive Actions
- Learning from Incidents
- Heinrich's Accident Triangle & Key Concepts
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1. Hazard
A hazard is anything that has the potential to cause harm, such as injury, illness, fire, explosion, environmental damage, or property loss.
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Common Types of Hazards:
- Chemical: Toxic, flammable, corrosive, reactive substances
- Physical: Heat, pressure, noise, radiation, moving machinery
- Fire and Explosion: Flammable vapors, dust clouds, ignition sources
- Mechanical: Rotating equipment, conveyors, lifting operations
- Electrical: Live parts, short circuits, static electricity
- Process: High pressure/temperature, runaway reactions, overfilling
2. Risk
Risk is the chance or likelihood that a hazard will cause harm, combined with the severity of the consequence.
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Risk Components:
- Likelihood: How likely an incident can happen
- Severity: How serious the injury, damage, or loss can be
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Examples:
- Flammable solvent present → fire risk
- Toxic gas handling → health risk
- High-pressure reactor → explosion risk
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Key Point:
Risk is reduced by controlling hazards through engineering controls, safe procedures, and proper supervision.
3. HIRA – Hazard Identification and Risk Assessment
- Systematic process to identify hazards
- Assess risk level
- Decide control measures
- Prevent injury, fire, explosion, and environmental damage
Hazard Identification:
- Identify hazards in routine, non-routine, and emergency activities
Common Hazards in Chemical, Pharmaceutical & Petrochemical Industries:
- Chemical: Toxic, flammable, corrosive, reactive chemicals, gases
- Process: High pressure, high temperature, runaway reactions, leaks
- Fire & Explosion: Flammable vapors, dust clouds, static electricity
- Mechanical: Rotating equipment, pumps, compressors, lifting jobs
- Electrical: Live panels, poor earthing, static charge
- Physical: Heat, noise, vibration, radiation
- Biological (Pharma): Microorganisms, contamination
- Ergonomic: Manual handling, repetitive work
Risk Assessment:
- Evaluate likelihood of occurrence
- Evaluate severity of consequences
Risk Factors Considered:
- Type and quantity of chemicals
- Pressure and temperature conditions
- Exposure frequency
- Past incidents and near misses
- Existing safety controls
Risk Level:
- Risk = Likelihood × Severity
- Classified as Low, Medium, or High
Risk Control Measures (Hierarchy of Control):
- Elimination: Remove hazardous chemical or activity
- Substitution: Use less hazardous material
- Engineering Controls:
- Closed systems
- Interlocks and alarms
- Ventilation and gas detection
- Pressure relief devices
- Administrative Controls:
- SOPs and work permits
- Training and supervision
- Inspection and maintenance
- PPE:
- Gloves
- Goggles
- Respirators
- Flame-resistant clothing
Documentation:
- HIRA register for each activity
- Risk rating recorded
- Control measures documented
- Responsibility and review date defined
Review and Update:
- After incidents or near misses
- After process, chemical, or equipment changes
- Periodic review
Importance of HIRA:
- Prevents accidents and major incidents
- Ensures statutory compliance
- Protects manpower, plant, and environment
4. Introduction to Incident
An incident is any unplanned and unwanted event that causes or has the potential to cause injury, illness, fire, explosion, chemical release, equipment damage, environmental harm, or production loss.
Importance of Incident Management in Industries:
- Identifies early warning signs before major accidents occur
- Prevents fires, explosions, and toxic exposures
- Protects workers, plant assets, and the environment
- Helps in root cause identification and corrective action
- Ensures legal and regulatory compliance
- Reduces repetition of accidents and downtime
- Strengthens overall safety culture
An incident is any unplanned and unwanted event that causes or has the potential to cause injury, illness, fire, explosion, chemical release, equipment damage, environmental harm, or production loss.
Importance of Incident Management in Industries:
- Identifies early warning signs before major accidents occur
- Prevents fires, explosions, and toxic exposures
- Protects workers, plant assets, and the environment
- Helps in root cause identification and corrective action
- Ensures legal and regulatory compliance
- Reduces repetition of accidents and downtime
- Strengthens overall safety culture
4.1 Causes of Incidents
Unsafe Acts:
Ignoring SOPs, non-use of PPE, shortcuts, improper operation of equipment.
Unsafe Conditions:
Chemical leaks, poor maintenance, faulty equipment, inadequate ventilation.
Human Factors:
Lack of training, fatigue, stress, overconfidence, poor communication.
Process Failures:
Abnormal pressure or temperature, blocked lines, failed interlocks, wrong chemical charging.
Equipment Failure:
Mechanical breakdown, corrosion, worn-out parts, improper repair.
Management Factors:
Weak safety culture, poor supervision, production pressure, inadequate risk assessment.
Environmental Factors:
Heat, humidity, poor lighting, noise, weather impact on outdoor installations.
Poor Planning:
Inadequate job planning, missing permits, improper sequencing of work.
Emergency Control Failure:
Non-functional alarms, detectors, or fire protection systems.
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Unsafe Acts:
Ignoring SOPs, non-use of PPE, shortcuts, improper operation of equipment.Unsafe Conditions:
Chemical leaks, poor maintenance, faulty equipment, inadequate ventilation.Human Factors:
Lack of training, fatigue, stress, overconfidence, poor communication.Process Failures:
Abnormal pressure or temperature, blocked lines, failed interlocks, wrong chemical charging.Equipment Failure:
Mechanical breakdown, corrosion, worn-out parts, improper repair.Management Factors:
Weak safety culture, poor supervision, production pressure, inadequate risk assessment.Environmental Factors:
Heat, humidity, poor lighting, noise, weather impact on outdoor installations.Poor Planning:
Inadequate job planning, missing permits, improper sequencing of work.Emergency Control Failure:
Non-functional alarms, detectors, or fire protection systems.
4.2 Types of Incidents
Accident
An unplanned event that results in injury, occupational illness, property damage, fire, explosion, or environmental impact.-
Near Miss
An unplanned event that did not cause injury or damage but had the potential to do so under slightly different conditions. -
Unsafe Act
Any action by a person that deviates from approved safety procedures or safe work practices, increasing the risk of an incident. -
Unsafe Condition
A hazardous physical or operational condition such as defective equipment, poor housekeeping, leakage, or inadequate safeguards. -
Property Damage Incident
An event that causes damage to machinery, equipment, buildings, or materials without causing personal injury. -
Environmental Incident
An uncontrolled release or discharge of substances that negatively affects air, water, soil, or surrounding ecosystems. -
Fire Incident
Uncontrolled ignition and burning of combustible materials that may cause injury, damage, or process disruption. -
Explosion Incident
A sudden and violent release of energy due to pressure build-up, chemical reaction, or ignition of flammable materials. -
Chemical Exposure Incident
Unintended exposure of personnel to hazardous chemicals through inhalation, skin contact, or ingestion. -
Electrical Incident
An event involving electrical energy such as electric shock, arc flash, short circuit, or electrical fire. -
Mechanical Incident
Injury or damage caused by moving parts, rotating equipment, lifting operations, or mechanical failure. -
Medical Incident
A sudden illness or health-related emergency occurring at the workplace, whether work-related or not. -
Security Incident
Events involving theft, sabotage, violence, or unauthorized access that threaten people, assets, or operations. -
Traffic / Vehicle Incident
Collisions, overturning, or near-miss events involving industrial vehicles or road transport within or outside the site. -
Process Safety Incident
Failures in process containment or control, such as leaks, overpressure, runaway reactions, or safety system failures. -
First Aid Case
Minor injury requiring simple on-site treatment without medical leave or work restriction. -
Lost Time Injury (LTI)
A work-related injury or illness that results in the employee being unable to perform normal work duties for at least one shift. -
Fatal Incident
An incident that results in the death of an employee, contractor, or other affected person.
5. Accident
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An accident is an unplanned and unexpected event that results in injury, illness, fire, explosion, chemical release, environmental damage, property damage, or production loss.
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Common Causes:
- Unsafe acts and unsafe conditions
- Equipment or process failure
- Lack of training or SOP violation
- Poor maintenance and supervision
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Impact:
- Injury or fatality to workers
- Fire, explosion, or toxic exposure
- Damage to plant and environment
- Production shutdown and legal issues
An accident is an unplanned and unexpected event that results in injury, illness, fire, explosion, chemical release, environmental damage, property damage, or production loss.
Common Causes:
- Unsafe acts and unsafe conditions
- Equipment or process failure
- Lack of training or SOP violation
- Poor maintenance and supervision
Impact:
- Injury or fatality to workers
- Fire, explosion, or toxic exposure
- Damage to plant and environment
- Production shutdown and legal issues
6. Difference Between Incident and Accident
Incident:
An unplanned event that may or may not cause harm. It includes near misses and unsafe events where damage or injury did not occur.
Accident:
An unplanned event that results in actual harm, such as injury, illness, damage, fire, explosion, or loss.
In simple words:
- Incident: Potential harm
- Accident: Actual harm
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6. Difference Between Incident and Accident
Incident:
An unplanned event that may or may not cause harm. It includes near misses and unsafe events where damage or injury did not occur.Accident:
An unplanned event that results in actual harm, such as injury, illness, damage, fire, explosion, or loss.
In simple words:
- Incident: Potential harm
- Accident: Actual harm
7. Unsafe act
Any action by a person that violates safety rules/ practices, creating risk of accident.
Examples
- Not wearing required PPE
- Failure to Lock Out Tag Out (LOTO)
- Bypass or Removal of Safety Inteelock/ Devices
- Using defective Equipment
- Use of Tools for other than their intended purpose
- Operating a machine which is found to be faulty
- Operating a machine without competence & Training
- Lack of Awareness on Safety Practices
- Operating equipment without authorization or training
- Improper handling of chemicals and hazardous materials
- Smoking, hot work, or mobile use in restricted / hazardous areas
- Working at height without fall protection
- Smoking, hot work, or mobile use in restricted / hazardous areas
7.1 Reasons / Factors Contributing to Unsafe Acts
- Lack of safety awareness and training
- Inadequate understanding or non-compliance with SOPs
- Overconfidence due to past accident-free experience
- Careless from routine and repetitive work
- Time pressure and production targets
- High workload and insufficient manpower
- Fatigue, stress, and long working hours
- Poor planning of work activities
- Weak safety culture
- Poor supervision, monitoring, and control
- Pressure from management for production
- Taking shortcuts to save time or effort
- Poor behavioral attitude toward safety
- Non-use, non-availability, or discomfort of PPE
- Poor communication and unclear instructions
- Improperly repaired or poorly maintained equipment
- Failure to identify and control potential hazards
- Risk-taking behavior and unsafe decision-making
7.2 Prevention of Unsafe Acts
-
Clear SOPs and Policies:
Simple, written procedures for all activities; easily available at work areas; mandatory compliance. -
Training:
Regular safety, job-specific, and refresher training on hazards, SOPs, PPE, and emergency response. -
Engineering Controls:
Use of safety interlocks, guards, automation, gas detectors, ventilation, and alarm systems to reduce human error. -
Reporting Encouragement:
Promote reporting of unsafe acts, unsafe conditions, and near misses without fear of punishment. -
Rules and Policy Enforcement:
Strict implementation of safety rules, permit-to-work systems, and disciplinary action for repeated violations. -
Empowerment:
Authority to stop unsafe work; encourage workers to speak up and intervene when unsafe acts are observed. -
Monitoring:
Continuous supervision, safety rounds, audits, CCTV, and behavior-based safety observations to ensure compliance.
8. Unsafe condition
8.1 Types of Unsafe Conditions
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Mechanical Conditions:
Damaged equipment, missing guards, worn-out parts, leaking valves, faulty tools. -
Chemical Conditions:
Chemical leaks, spills, toxic vapors, incompatible chemical storage, corrosive exposure. -
Electrical Conditions:
Exposed wiring, loose connections, overloaded panels, improper earthing. -
Physical Conditions:
Slippery floors, uneven surfaces, poor lighting, excessive noise, extreme heat or cold. -
Process Conditions:
High pressure or temperature, abnormal process parameters, blocked vents, failed interlocks. -
Environmental Conditions:
Poor ventilation, accumulation of flammable or toxic gases, dust clouds. -
Fire and Explosion Conditions:
Accumulation of flammable materials, ignition sources near hazardous areas, faulty fire protection systems. -
Housekeeping Conditions:
Spills, cluttered walkways, improper waste storage, blocked exits. -
Structural Conditions:
Corroded structures, weakened platforms, damaged ladders, unsafe scaffolding.
8.2 Prevention of Unsafe Conditions
-
Hazard Identification:
Regular inspections to identify leaks, defects, and abnormal conditions. -
Preventive Maintenance:
Timely repair and maintenance of equipment, pipelines, valves, and safety devices. -
Engineering Controls:
Proper guards, interlocks, ventilation, gas detectors, pressure relief systems. -
Good Housekeeping:
Immediate cleaning of spills, clear walkways, proper waste and chemical storage. -
Safe Design and Layout:
Adequate spacing, proper drainage, fire-resistant construction, clear emergency exits. -
Process Monitoring:
Continuous monitoring of pressure, temperature, and flow to avoid deviations. -
Proper Storage:
Segregation and labeling of chemicals; compliant storage of flammable and toxic materials. -
Electrical Safety:
Proper earthing, insulated wiring, regular testing of electrical systems. -
Fire Protection Systems:
Functional alarms, sprinklers, hydrants, and extinguishers. -
Reporting and Correction:
Immediate reporting and rectification of unsafe conditions before work continues.
9. Near Miss
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An unplanned event that did not cause injury, damage, or loss, but had the potential to cause a serious accident.
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Examples:
- Small chemical leak stopped before exposure
- Gas alarm activated but no ignition occurred
- Object falling near a worker without injury
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Importance:
- Acts as an early warning sign
- Helps prevent major accidents
- Improves process and workplace safety
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Key Point:
Near misses must be reported and investigated with the same seriousness as accidents.
10. Incident Reporting
Why Incident Reporting Is Important
- Prevents repeat accidents by finding real causes
- Protects people, plant, environment, and assets
- Ensures legal and statutory compliance
- Improves safety culture and work discipline
- Reduces downtime, losses, and operational disruptions
What Should Be Reported
- Accidents causing injury, illness, fire, explosion, or damage
- Near misses with serious potential risk
- Unsafe acts such as wrong operation or bypassing safety systems
- Unsafe conditions like leaks, corrosion, faulty equipment, poor housekeeping
- Chemical spills, gas leaks, exposure incidents
- Safety-critical equipment failures (valves, pumps, instruments, interlocks)
- Environmental incidents like effluent overflow or emission exceedance
When and How to Report
- Report immediately after any incident or near miss
- Do not delay reporting of major injuries, fires, leaks, or releases
- Inform supervisor or shift in-charge first
- Make the area safe and stop unsafe activity
- Provide first aid or emergency response if required
- Record details in the incident report system with time, place, people involved, chemicals, equipment, and photos
Roles and Responsibilities
- Employee / Contractor: Report incidents and near misses immediately, share true facts
- Supervisor / Shift In-Charge: Ensure safety, start reporting, and preliminary investigation
- Safety / EHS Team: Do root cause analysis, define corrective and preventive actions, handle statutory reporting
- Management: Provide resources, review incidents, close actions, and support a non-blame reporting culture
11. Corrective and Preventive Actions
Corrective Actions (Immediate Control):
- Actions taken after an incident to control the situation and stop further harm
- Examples: isolating equipment, stopping work, repairing leaks, cleaning spills, replacing damaged parts
- Focused on immediate risk removal
Preventive Actions (Long-Term Control):
- Actions taken to eliminate root causes and prevent recurrence
- Examples: revising SOPs, engineering modifications, improved maintenance plans, additional training, better supervision
- Focused on system and process improvement
Tracking and Closure:
- Assign responsibility and target dates for actions
- Monitor progress until completion
- Verify effectiveness of actions
- Close actions only after risk is fully controlled
12. Learning from Incidents
Incident Trends and Analysis:
- Study incident data to identify repeating issues and high-risk areas
- Analyze trends related to process units, equipment, chemicals, and activities
- Helps in prioritizing safety controls and resource allocation
Lessons Learned:
- Identify what went wrong and why
- Share learnings across departments to avoid similar incidents
- Improve procedures, training, and awareness
Preventing Recurrence:
- Implement effective corrective and preventive actions
- Strengthen engineering controls and SOPs
- Improve training, supervision, and safety culture
- Monitor effectiveness to ensure incidents do not repeat
Ratio:
300 : 29 : 1
- 300 Near Misses
- 29 Minor Injuries
- 1 Major Injury / Serious Accident
Meaning:
For every 1 major accident, there are many warning signs in the form of near misses and minor incidents.
Importance:
- Controlling near misses and unsafe acts reduces major accidents
- Focus on early reporting and correction prevents fires, explosions, and serious injuries
Interview Questions
What is accident investigation?
Accident investigation means to carried out immediately the occurrence of accident to find out real facts to avoid the future accident.
What is accident prevention?
Accident prevention may be defined as an integrated programme and directed to control un safe mechanical or physical condition.
Write causes of accidents?
Direct cause: Unsafe act and unsafe condition.
Indirect Cause: 1. Lack of knowledge or skill 2. Improper attitude 3. Physical or mental deficiency