INTERNATIONAL INTERNATIONAL GENERAL CERTIFICATE (2011 specification)
Candidate’s observation
sheet
IGC3 – THE HEALTH AND SAFETY PRACTICAL APPLICATION Sheet number
Student name
xxxxxxxxxxxxxxxxxxxxxxxxxxxxxx
Place inspected
xxxxxxxxxxxxxxxx
Company __________
Observations Observat ions
Hazards and consequences
Student number Date of inspection
Control measures
1
of __4___
xxxxxxxxxxx
/ xx /xxxx
xx
Timescale Timesc ale
Immediate and longer term actions
PLANT Raw material conveyor has no prior moving alarm. Risk of contact with moving parts. Lead to entanglement and injury of human body or part of it.
-Stop conveyor being used. -Apply prior moving alarm due to standard. -Tool box talk on perception of risk and guarding to operators.
Immediate 48 hours
Hydraulic steel sheet cutter in tins moulding unit has no guard on blades. Risk of contact with moving parts lead to finger amputation.
-Stop machine being used. -Set a fix guard to cover exposed blades. -Tool box talk on safe operation of hydraulic cutter. -Competent supervisor to ensure guard is used correctly.
Immediate 3 days 1 week
-Contact fire fighting company to replace it. -Carry out pressure testing to all hose reel and replace the damage ones. -To add portable fire extinguishers to use in case of damage of hose.
Immediate
Poor electrical connection in electrical panel of absorption unit. Risk of overheated, lead to fire and explosion.
-Isolate electrical panel. -Proper connection by competent person. -Tool box talk on electricity safety to all staff.
Immediate 24 hours 1 week
Emergency stop on grinding machine were difficult to access because clutter. Hazard of not stop machine as quickly as possible, lead to increase severity of injury.
-Remove clutter from emergency stop. -Tool box talk on emergency control system. -Reposition emergency stop location.
Immediate 1 week
Boiler unit is too hot. Risk of exposure to excessive heat, lead to heat stroke and stress to workers.
-Isolate and shield the hot surfaces. -Frequent breaks and job rotations. -Provide appropriate ventilation fans and coolers.
3 days Ongoing 2 weeks
Fire fighting hose reel nozzle close to western gate is damage. Risk of inability to control fire; lead to spread fire then increase damage or injury.
1 week
2 weeks
1 month 1 week
1 month
INTERNATIONAL GENERAL CERTIFICATE (2011 specification)
Candidate’s observation
sheet
IGC3 – THE HEALTH AND SAFETY PRACTICAL APPLICATION
Observations
Hazards and consequences Control
room’s
seats are hard flat surface and unadjustable. Risk of back injury and haemorrhoids.
Control measures
Timescale
Immediate and longer term actions
-Replace seat with proper and adjustable seat. -Provide Training and instructions in correct seat adjustment. -Carry out DSE assessment for all users.
Immediate
-Ear plugs must be provided. -Carry out noise survey to ascertain how over all level can be reduced. - Job rotation to reduced time of exposure.
Immediate 1 month
High dust level of hazardous substances in packing area. Risk of inhalation hazardous chemical lead to respiratory diseases.
-Provide respiratory mask. -Provide appropriate LEV. -Frequent breaks and job rotation.
Immediate 1 month On going
Sanitary, resting and eating facilities are applied in well standard.
-Good practise. -continue to provide and maintain.
On going
An electrical socket is close to wash basin in centrifugal unit. Risk of socket damped lead to electrical shock to workers.
-Stop wash basin being used. -Isolate socket. -Reposition socket to safer location.
Immediate Immediate 3 days
Noise levels were excessively high in crushing unit. Risk of hearing damage and confusion in an emergency case.
Packing operator were not wearing hand gloves. Risk of contact with hazardous substances lead to skin dermatitis.
1 week 1 month
1 week
-Instruct operator to wear gloves. Immediate -Ensure suitable gloves are available 24 hours close to job. -Provide training and instructions in hand 1 week gloves importance and usage to workers. -Maintain pipe leakage by competent 24 hours Water pipe leakage on floor close too -Cleaning person. surface floor. Immediate cooling tower entrance. Risk of slip -Maintain -Conductpipe inspection leakage to check by competent leakage. 241hours month Lead to serious injury. plumber.
INTERNATIONAL GENERAL CERTIFICATE (2011 specification)
Candidate’s observation sheet
IGC3 – THE HEALTH AND SAFETY PRACTICAL APPLICATION
Observations
Control measures
Timescale
Hazards and consequences
Immediate and longer term actions
The cable of mixing motor had been exposed. Hazard of contact with worker lead to electrical shock and death.
-Stop machine being used. -Replace cable and re-route cable to keep it away from been damage. -Ensure all machines and apparatuses are earthed.
immediate 24 hours
-Remove all flammable substances a way from oven. -Training and instructions in safe use and store of flammable substances to all staff.
Immediate
Chemical substances in lab have been stored in unresisting fire cabinet and poor singed. Risk of spread fire. Lead to increase severity of injury and damage.
-Stop using this cabinet. -Provide a proper fire resisting cabinet with lockable door and clearly signed. -Training and instructions in safe use and store of chemical substances to all staff.
Immediate 5 days
All fire extinguishers had been tested and were in date.
-Good practise. -Continue to provide and maintain.
On going
Lab analyst using chemical agent without catch spill tray. Risk of spill contamination which lead to emission toxic vapour to atmosphere and inhalation.
-Stop using chemical agent. -Provide a proper tray to catch spill. -Provide training and instructions chemical hazards to lab operators.
Immediate 3 days 3 weeks
STORE Fire exit door in product ’s store completely blocked by stock and bulk of products. Risk of worker being trapped in the event of fire then suffering burn or death.
- Ensure that all escape routes are clear, provision of adequate light and emergency signs. -The store area must be racked to take excess materials. - Provide Training and instructions to all staff in emergency procedures and how to evacuate in emergency case
Laboratory The analyst Using flammable substances close to dryer oven. Risk of catch fire lead to human burn and explosion.
in
2 weeks
3 weeks
3 weeks
3 days 3 weeks 1 month
INTERNATIONAL GENERAL CERTIFICATE (2011 specification)
Candidate’s observation
sheet
IGC3 – THE HEALTH AND SAFETY PRACTICAL APPLICATION
Observations
Hazards and consequences
Control measures
Timescale
Immediate and longer term actions
Storage of acetylene and oxygen cylinders in same store without any barrier. Risk of catching fire from any sources around lead explosion and property damage.
-The cylinder must be separated. -provide well ventilated and secure store.
Immediate 1 month
Storage of raw chemical material in unmarked container. Risk of using incorrect material. May lead to loss material and human poisoning.
-Clearly mark and sign container. -Provide proper container. -Training staff on how to storage chemical materials.
24 hours 3 days 3 weeks
Large heavy and awkward boxes were being manually handled by store workers using poor techniques. Risk of back disorder and shoulder injury.
-Handling of boxes by two persons. -Tool box talk in safe handling technique -Provide trolley to make handling safer.
Immediate 2 weeks 1 month
Forklift truck had no sign of daily check being carried out. Risk of loss control which lead to accident.
-Daily check list must be drawn up. -Training in how to complete checklist for driver. -Develop checklist to be fitted for future reference.
Immediate 1 week
Poor lighting at store entrance. Risk of forklift collision with pedestrian or racks which could fall on workers lead to serious injury or death.
-Provide adequate lighting and wearing high visible clothing. -Protect racks with guard rail. -Reposition entrance location so that forklift cannot collision.
3 days
Rack near walkway had length of wood protruding into walkway at head height. Risk of worker struck against protrudes wood lead to head and eye injury.
-Rack maintained to be in safe condition. -Clear route must be marked.
Immediate 1 week
1 month
1 week 3 months
INTERNATIONAL GENERAL CERTIFICATE (2011 specification)
Candidate report template
Report on an inspection of the petrochemical plant, QC laboratory and store. Introduction The inspection was carried out at (Vona Petrochemical Company) it has about 70 employees in three main sections (Plant, QC Lab and Warehouse). The company produce several materials such as construction detergents and solvent by reaction raw petroleum products. The QC Lab testing raw materials and final products, the warehouse divided in to two sections one for raw materials and another for final products. th The inspection was carried out on 02 of Sep 2014 at 10:00 AM to identify hazards, assess risk and set suitable control measure to eliminate or reduce risks, which lead to maintain health, safety, quality and productivity.
Executive Summary The inspection demonstrates there are significant weaknesses in some serious hazards such as:
Fire safety The fire risk rising from improper storage and using of flammable substances. Should be controlled through separated flammable substances from ignition sources and develop safe system of work.
Health of workers The health risk arising from exposure to high dust level of hazardous chemical. Should be control through improving ventilation.
Machinery guards and safety devices The risk of injury from the hydraulic sheet cutter. Should be controlled by removing machine from use immediately and not using until the guard is fixed.
Electricity safety Electrical risk increase by poor connection in electrical panel. Should be controlled through correct electrical connections.
Working practices There were evidences of lack of safety awareness of the staff. Should be controlled through provide appropriate and adequate training and instructions. These corrective actions will reduce the risk of accident and ill-health in plant. This will have the effect of improving efficiency and productivity then increase profits. And will help to reduce cost of investigation and insurance premiums. Failure to take these actions will lead to decrease productivity, increase accident, sickness rate, staff turnover and risk of prosecution which it could mean fines, compensation and loss of goodwill costumers and damage of company reputation. More detailed coverage is provided in the main body of this report, which includes timescales and approximate cost.
Main findings of the inspection Fire safety There were many fire hazards in the plant, flammable substances were close to source of ignition in QC lab, acetylene and oxygen stored in the same store, without barrier which could cause fire and explosion and lead to burning, death and damage in property. Chemical substances stored in unresisting fire cabinet and poor signed, this increase severity of fire by spread fire. Fire exit door completely blocked by stock and bulk of product which could prevent an emergency evacuation These risks breach of INTERNATIONAL LABOUR ORGANISATION Occupational safety and health, as state in Article 10(A, B, C), Article 3(M) of R164 Recommendation and Article 16(1) and article 18 of C155 Convention. The management should: - Ensure that flammable substances are separated from ignition sources. - Ensure that fire spread is reduced by provide a proper fire resisting cabinet with lockable door and clearly signed. - Ensure that all escape routes are clear, adequately lit and emergency signs. - Train all staff in emergency procedures and how to evacuate during emergency case. The estimated cost of these measures is 5000$
Health of workers The most reasons of ill-health, sickness and stress are exposure to excessive dust and noise, the noise levels were excessively high that lead to increase stress and depressed then decrease staff morale. High dust level of hazardous chemical that increase respiratory diseases then increase absenteeism rate which effect directly on production rate These risks breach of INTERNATIONAL LABOUR ORGANISATION Occupational safety and health, as state in Article 3 (B, E, F, and P), Article 3(E, J) of R164 Recommendation and Article 5 (B), Article 4 of C155 Convention. The management should: - Carry out noise survey to ascertain how over all level can be reduced. - Provide local exhaust Ventilation system. - Reduced the exposure time by organised job rotations. - Conduct training to the workers on how to deal with this kind of hazard. The estimated cost of these measures is 10000$.
Machinery guard and safety devices A poor standard of guarding around fixed machinery is significant issue, for example there is no guard around hydraulic steel sheet cutter and this increase likelihood of finger amputation which lead to absenteeism, cost of first aid treatment and compensation. Emergency stop on grinding machine were difficult to access and this decrease ability of dealing while something gone wrong. These risks breach of INTERNATIONAL LABOUR ORGANISATION Occupational safety and health, as state in Article 3(A,D) of R164 Recommendation and Article 5(A), Article 16(1,2) of C15 Convention. The management should: - Set a fix guard to cover exposed blades and adjusting the work place lay out around machine to adequate space and easy access to control of machine. - Tool box talk on safe operation and competent supervisor to ensure guard is used correctly. The estimated cost of these measures is 500$
Electricity safety Sufficient evidence was seen during the inspection to demonstrate the risk of an electrical incident causing serious injury, death or property damage and that increase direct and indirect cost. There was evidence of poor connection in electrical panel which cause overheated. There was electrical socket close to wash basin, that increase likelihood of electrical shock, as we know any accident decrease staff morale which lead to poor quality and productivity. These risks breach of INTERNATIONAL LABOUR ORGANISATION Occupational safety and health, as state in Article 10(A, C) of R164 Recommendation and Article 16(1) and Article 5(A) of C155 Convention. The management should: - Ensure that the correct electrical connections are applied. - Reposition socket and plugs to safer location. - Ensure all machines and apparatuses are earthed. - Conduct awareness session on electrical hazard for all employees. The estimated cost of these measures is 400$
Working practices The inspection demonstrates lack of safety awareness by staff in this plant which will cause ill-health and increase severity of injury, damage and loss. There were number of unsafe practises, including Using flammable substances close to dryer oven, packing operator were not wearing hand gloves, Manual handling using poor techniques, Storage of raw chemical material in unmarked container. These risks breach of INTERNATIONAL LABOUR ORGANISATION Occupational safety and health, as state in Article 4(D), Article 10(A, B, C) of R164 Recommendation and Article 5(C, E), Article 13 and Article 16(2, 3) of C155 Convention. The management should: - Remove all flammable substances a way from ignition sources. - Instruct operator to wear PPE - Provide handling aids to make handling safer. - Training and instructions in safe use and store of chemical substances to all staff. The estimated cost of these measures is 5000$
Conclusions The main objective of this report is to identify and explain exactly the weaknesses points at the health and safety management system of Vona Company and how can be improved. Such problems had been appeared through this report, like poor storage procedure of flammable and chemical substance, and the high level of dust of hazardous chemicals, in addition to the poor electrical connection and lack of safety guard of machineries and there is evidence that the safety awareness of the staff is low. The improvement of storage procedures of the flammable and chemical substance through segregation and aggregation from any source of ignition and to put clear warning signs, and as well the good ventilation by using local exhaust fan to reduce the level of the hazardous dust. All Electrical cables should be connected properly as per standard procedures, Safety guards to be fixed at the hazardous machineries and to conduct adequate training and safety awareness session for all employees of Vona Company. The Commitment of Vona Company management towards the health and safety principles like the compliance with the legislations, law and standard to provide a safe place of work, safe plant and equipments, safe system of work, adequate training and supervision and to hire competent employees. Also the economic factors should be consider by Vona management, since it has been related to the accident and ill-health and both of them costed money, because when the accident occurs there will be direct and indirect costs associated with the events, these costs affected on the production performance, reputation, compensation and to the total profit of the Vona company. The importance of the moral obligation and duty of Vona company management towards their employees,
through taking care of their health and safety, to avoid injury, sick and death of the workers and to ensure that they are safe in their work Through out of this report I would like to draw attention of Vona top Management Company to the benefits of the good health and safety practices and it is direct effects on increasing the level of complaisance to the law and standards, and reducing the number of accident and ill-health in the company which may lead to improve the efficiency and productivity then increase profits. Also will help in reducing the cost of incident investigations and insurance premiums, increase the moral, cultures and motivations of the employees of Vona company, and of course this will reducing the damage of equipments, staff complains & turnover. As a hall value it increases the company reputation and encourages good customers.
Recommendations Recommendation
Likely resource implications
Priorit y
Target date
No external cost it may take half an hour of maintenance time
High
Immediatel y
Ensure that fire spread is reduced by provide a proper three fire resisting cabinet with lockable door and clearly signed.
The estimated cost 2000$
High
1 month
Ensure that all escape routes are clear, adequately light and emergency signs are available.
The estimated cost 300$
High
3 days
No external cost it cost of internal trainer and employee time.
Mediu m
1 month
No external cost it cost of
Low
1 month
High
1 month
Low
1 week
High
3 days
Mediu m
3 weeks
High
5 days
High
2 weeks
Fire safety Ensure that flammable substances are separated from ignition sources.
Train all staff in emergency procedures and how to evacuate in emergency case
Health of workers Carry out noise survey to ascertain how over all level can be reduced.
internal engineer’s time
Provide two local exhaust Ventilation system. Train all staff on the chemical hazards and it is effect on their health.
The estimated cost 10000$ No external cost it cost of internal trainer and employee time.
Machinery guard and safety devices
The estimated cost 500$
Set a fix guard to cover exposed blades Tool box talk on safe operation and Competent supervisor to ensure guard is used correctly
Electricity safety
No external cost it cost of internal supervisor ’s time
The estimated cost 100$
Reposition socket and plugs to safer location. Ensure all machines and apparatuses are earthed
No external cost it may take half an hour of maintenance time
Working practices Provide handling aids to make handling safer.
The estimated cost 5000$
Mediu m
1 month
Training and instructions on safe handling and store of chemical substances to all staff
No external cost it cost of internal trainer and employee time.
Low
3 weeks
Signed ________________________
Date _________________________
