A STUDY AND ANALYSIS ON OCCUPATIONAL HEALTH RISK IN ABC LIMITED RASLAFFAN INDUSTRIAL CITY DOHA, QATAR
Unit 2 Assignment report submitted to British Safety Council in partial fulfillments of the requirements for award of International Diploma in Occupational Safety & Health By STUDENT NAME Register No:
Verified By Mr.R.XXXXXXX Project Manager, ABC Limited, Doha, Qatar
1
LIST OF CONTENTS
S.NO
DETAILS
PAGE. NO
1
Executive Summery
4
2
Description of workplace & activity
5-8
3
Identification of Occupational health hazards
9 - 10
4
Background Research
11
5
Assessment of Risks
12
6
Proposed control Measures
13 - 15
7
Conclusion
16
8
Bibliography
17
2
LIST OF APPENDICES
S.NO
TITLE
NO
1
Foam Glass Insulation MSDS
1
2
PIR insulation - MSDS
2
3
COSHH Risk Assessment
3
4
Job Freeze Audit document
4
5
Tool Box Talk document
5
6
Verification Certificate
6
3
Part - 1 Executive Summery The study on Occupational health risk carried out at ABC Limited workshop and warehouse facility located at Raslaffan Industrial City, Doha, Qatar. ABC limited one of the largest insulation, painting, scaffolding, fire proofing, civil contracting organization with excess of 25 years of experience in Oil & Gas, Power generation sectors in the Gulf region. The organization has got excellent Safety Management system and supports for every genuine safety recommendations to prevent ill health of employees. The Occupational health risk assessment carried out with a team members at foam fabrication shop . During the foam fabrication activity using various machineries, the particulate matter and a mild odor of acidic gas observed. Even with operational engineering controls in place, (exhaust ventilation system and dust collector) it is less effective at the point of actual fabrication. The necessary recommendations made to replace the dust mask with NIOSH approved respiratory cartridges to protect from the mild acidic odor and particulate matter and safety goggle with a mono goggle with side protection to protect the eyes. Trial carried out for a month and found to be comfortable and satisfactory from employees. Organization procured the same for use and implemented in work location.
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Part – 2 Description of Workplace and Activity
ABC Limited of Qatar associated with XYZ group, one of the largest insulation, painting, scaffolding, fire proofing, refractory and c ivil contracting organization has access to the full financial and technical expertise of the group. ABC limited has in excess of twenty five years of experience and reputation serving clients in the Oil & Gas, Power generation and Commercial sectors in the Gulf. The study was undertaken in the ABC workshop and warehouse facility situated in Grid locator # AB / 32 at west support services area of Raslaffan Industrial city, Doha, Qatar. This work area comprises of the following: 1. Office and Administration building 2. Warehouse Building 3. Maintenance Workshop 4. Sheet metal workshop 5. Foam insulation cutting & fabrication shop 6. Grit blasting and coating area 7. Power Room 8. Utility Room 9. Guard House.
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The study was undertaken in the foam glass and PIR prefabrication workshop. Scope of work For thermal insulation of utility systems, Cora foam or PIR rigid foam is used. The rigid expanded polyurethane modified polyisocyanurate foam is being manufactured and supplied by Duna – USA Inc in the size of 18cm x 45cm x 60 cm blocks. The foam blocks are cut, fabricated to the required / relevant size & shape and fabricated in the workshop to suit the shape and position of the pipeline / equipment(s) needs to be insulated.
FOAM GLASS / PIR FOAM
SHAPED FABRICATED FOAM
BLOCK
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EQUIPMENTS HANDLED: The following machineries are being used to fabricate foam in the workshop. 1. Computerized profile cutting equipment 2. Horizontal and vertical band saw 3. Horizontal block splitter 4. Table saw 5. Routing machine 6. Multipurpose Shiplap Machine 7. Large Bend cutting machine 8. Small bend cutting machine WORK ACTIVITY 1. As per the requirements of the size & shape, the solid rigid foam block will be cut by CNC machine for automatic operation. 2. The same cutting operation normally done by using horizontal and vertical band saw machine. 3. On cutting into required piece, it will be shaped to the requirement with help of growing machine as well as using horizontal band saw to attain required curvature for the cylindrical sub strates. 4. All the above said work activities are performed after a thorough risk assessment carried out by a team of members, after the risk brought to As Low As reasonably practicable level ( ALARP) by suitable & sufficient control measures and suitable & adequate personal protective equipments ( PPEs)usage with supervision.
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FOAM FABRICATION ACTIVITY USING HORIZONTAL / VERTICAL BAND SAW MACHINES
FOAM GLASS / PIR FOAM BLOCK
VERTICAL BAND SAW
18 CM X 45 CM X 60 CM SIZE
MACHINE
HORIZONTAL BAND
SHAPED FABRICATED
SAW MACHINE
FOAM
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Part – 3 Identification of Occupational Health Hazard
A thorough risk assessment carried out in the foam glass / PIR workshop forming a team. The team members were: 1. Mr.Karunaharan
-
Project Manager
2. Mr. Nagabooshanam
-
HSE Officer
3. Mr.Cheriyl Mathai babu
-
Fabrication shop In charge
4. Mr. Ananta Prasty
-
CNC machine operator
5. Mr.Manian Gopi
-
Worker Representative
6. Unnikrishnan Jhodiger
-
Worker Representative
The list of hazards identified at workplace during operation is: 1. Slip, trip and fall 2. Thermal and fire hazard 3. Contact with moving parts/machinery 4. Contact with stationary objects 5. Manual Handling 6. Handling chemical / harmful substances 7. Dust 8. Electrical hazards 9. Environmental hazards
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All the above hazards are adequately controlled and the risks are brought below As Low As Reasonably Practicable (ALARP) level and activities are monitored under continuous supervision. In addition to routine risk assessment, the organization carries out Monthly COSHH inspection, Weekly job freeze audit and daily tool box talks to ensure employees safety and prevention of occupational ill health. SELECTION OF HAZARD FOR STUDY The company management suggested having study on the hazards related to foam glass / PIR fabrication operation as recently they observed a quarry from an employee regarding the PPE they were using during fabrication activity. As in the rest of the activities the risk is within controlled level, as suggested by the management, foam glass / PIR fabrication work activity is taken to do a detailed risk assessment specific to respiratory and eye protection.
10
Part – 4 Background Research Two types of insulation materials are being used for thermal insulation purposes. One is foam glass (Glass Oxide chemicals) and the other one is polyurethane modified polyisocyanurate foam that is called PIR foam ( MSDS as appendices 1 & 2 ). During fabrication activity, generally particulate respirator (dust mask – N95) and safety goggle (spectacle meets ANSI Z-87.1-2010 and CE EN 166 – 2201) were being used in addition to hand protection, head protection, general body protection and foot protection. HAZARDS IDENTIFIED During the process of foam fabrication, it releases quantities of particulate matter 10 from foam glass and PIR foam blocks. In addition to particulate release, a suspected negligible odor of acidic gas found to be present which was the concern for the employee exposed to the said activity. It is further observed that the safety goggle used is not giving any side protection for employee. (COSHH assessment as appendices – 3) Even though engineering controls like exhaust ventilation, dust collector is available and in use, still the effectiveness at the point of foam fabrication, it is less effective.
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Part – 5 Assessment of Risks Activity: Foam fabrication in foam glass / PIR workshop Hazard
Who might be harmed
Existing
Further
Identified
& How
control
necessary action
measures Release of
Employee involved in the Exhaust
Identify adequate
particulate
activity by breathing
Ventilation.
respiratory
Dust Collector.
protection
matter
Use of dust mask ( N 95 ) ( 3M 9010) Release of
Employee involved in the Exhaust
Identify adequate
negligible
activity by breathing
Ventilation
respiratory
quantity of
Use of dust
protection
acidic
mask ( N 95 )
fumes
( 3M 9010)
Particulate
Employee involved in the Safety goggle
Identify adequate
matter
activity. Particulate may
eye protection
(Dust) enter enter through sides of eyes /
without side protection
the goggle
eyebrow
MSDS of both foam material – appendices 1 & 2 COSHH assessment – appendices 3
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Part – 6 Proposed Control Measures Case 1 & 2 :
Release of particulate matter and odor of acidic gas during fabrication of foam
Existing control measures Disadvantages
: Use of dust mask (N95, 3M 9010) : Does not protect against any particulate matter fully and cannot filter acidic fumes
Consequences
: Prolonged exposure to particulate matter and acidic gas may cause respiratory problem ( Chronic effect)
Key control measures
: Instead of dust mask, use of respirator with filter cartridge (3M – 6000 series & NIOSH approved) to filter the acidic / organic vapor and the particulate matter
Projected cost
: Present cost of dust mask - Qr 01 /piece Respirator with cartridge - Qr 135 / piece
Expected benefits
: Protection of employees from ill health Employee satisfaction High morale due Mgt commitment Increased production Reduction in sickness / absenteeism.
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Proposed Control Measures Case – 3 : Particulate matter enter eyes during fabrication work
Existing control measure : Use of safety goggle without side protection Consequence
: The particulate matter may enter through sides of the goggle and create irritation to eyes and eye problems
Key projected control measure: Instead of safety goggle, use of goggle with side protection ( BS EN 166 – 2001) Mono goggle / Splash proof goggle is recommended for use Projected cost
: Safety goggle – Qr 16 / piece Goggle with side protection – Qr 60
Benefits
: Protection of employee’s eyes Reduced sickness / absenteeism Reduced visit to first aid centre Improved morale / satisfaction
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IMPROVEMENTS POST RISK ASSESSMENT AT FABRICATION SHOP
DUST MASK WITH
RESPIRATORY MASK WITH
SAFETY GOGGLE
SIDE PROTECTED SAFETY
(PRIOR TO ASSESSMENT)
GOGGLE (POST ASSESSMENT)
EXISTING ENGINEERING CONTROLS
DUST COLLECTOR
EXHAUST VENTILATION
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Conclusion
ABC Limited Management, Qatar decided to adhere the said recommendations and procured few pieces of said personal protective equipments as a trial basis to check the result from activity area. Post one month use of recommended respiratory mask instead of dust mask and side protected mono goggles instead of normal safety goggles, the employees feel comfortable while using recommended personal protective equipments. The effective use of the same is being monitored and recorded.
16
Part – 7 Bibliography
1. www.3M.com / PPE safety – June 2015
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