Health and Safety Measures

Pamantasan ng Lungsod ng MaynilaUniversity of the City of Manila

College of Engineering and TechnologyChemical Engineering Department

Health and Safety Measures

Safety Verification

Yearly, JGCI Chemical Corporation received a visit from Occupational Safety and Health Centre under the Department of Labor and Employment to perform a safety check. During a safety Check, the experts explain the meaning of the safety check and the agenda of the day. Annual visit is organized to each section of the plant, involving safety representatives, heads of sections and security chiefs to check the facilities, the adequacy of existing security rules, situations or parts of the installation that are subject to accidents and any other potentially dangerous situations.

Safety and Training

Foremen and Assistant Foremen are required to be trained in Accident Investigation Procedures by the Safety Director.All employees who work with, or are exposed to, hazardous chemicals are to be trained in Hazard Communication, in accordance with Philippine regulation

Machine operators and maintenance personnel are to be trained in Lockout/Tagout procedures. Individual locks/keys will be assigned to those individuals participating in the LOTO program.

All employees who use Personal Protective Equipment (PPE) will be trained in the proper use of such equipment

First-aid training will be conducted by Philippine Red Cross



Personal Protective Equipment

Personal Protective Equipment (PPE) should provide adequate protection against the risk from the hazardous chemicals to which the wearer is exposed, for the duration of the exposure, taking into account the type of work being carried out. Employee that will use PPE should be trained on how to use it effectively and how to keep it in good condition. JGCI Chemical Corporation provided and maintained all personal protective equipment that is necessary to protect our employees from workplace hazards that can cause them injury.

1. Eye and Face Protection

In our company employees can be exposed to a number of hazards that can put their eyes and face in danger. OSHA requires employers to ensure that employees have appropriate eye or face protection if they are exposed to eye or face hazards from flying particles, molten metal, liquid chemicals, acids or caustic liquids, chemical gases or vapors, potentially infected material or potentially harmful light radiation. Our company makes sure that our employees wear appropriate eye and face protection and that the selected form of protection is appropriate to the work being performed.

According to OSHA, in selecting the most suitable eye and face protection for employees should take into consideration the following elements:

Figure_ : image of eye and face protection



Ability to protect against specific workplace hazards.

Should fit properly and be reasonably comfortable to wear.

Should provide unrestricted vision and movement.

Should be durable and cleanable.

Should allow unrestricted functioning of any other required PPE

Common types of eye and face protection

SAFETY SPECTACLES . These protective eyeglasses have safety frames constructed of metal or plastic and impact-resistant lenses. Side shields are available on some models.

GOGGLES . These are tight-fitting eye protection that completely cover the eyes, eye sockets and the facial area immediately surrounding the eyes and provide protection from impact, dust and splashes. Some goggles will fit over corrective lenses.

FACE SHIELDS . These transparent sheets of plastic extend from the eyebrows to below the chin and across the entire width of the employee's head. Some are polarized for glare protection. Face shields protect against nuisance dusts and potential splashes or sprays of hazardous liquids but will not provide adequate protection against impact hazards. Face shields used in combination with goggles or safety spectacles will provide additional protection against impact hazards.

LASER SAFETY GOGGLES . These specialty goggles protect against intense concentrations of light produced by lasers.

WELDING SHIELDS. Constructed of vulcanized fiber or fiberglass and fitted with a filtered lens, welding shields protect eyes from burns caused by infrared or intense radiant light; they also protect both the eyes and face from flying sparks, metal spatter and slag chips produced during welding, brazing, soldering and cutting operations



2. Head Protection

JGCI Chemical Corporation ensures that each affected employee wears a protective helmet when working in areas where there is a potential for injury to the head from falling objects. Protecting employees from potential head injuries is a key element of any safety program. A head injury can impair an employee for life or it can be fatal. Hard hats can protect employees from impact and penetration hazards as well as from electrical shock and burn hazards.

JGCI Chemical Corporation ensures that its employees wear head protection if any of the following apply:

Objects might fall from above and strike them on the head

They might bump their heads against fixed objects, such as exposed pipes or beams

There is a possibility of accidental head contact with electrical hazards

Types of hard hats

Class A hard hats provide impact and penetration resistance along with limited voltage protection (up to 2,200 volts).

Class B hard hats provide the highest level of protection against electrical hazards, with high-voltage shock and burn protection (up to 20,000 volts). They also provide protection from impact and penetration hazards by flying/falling objects.

Class C hard hats provide lightweight comfort and impact protection but offer no protection from electrical hazards.

BUMP HAT designed for use in areas with low head clearance. They are recommended for areas where protection is needed from head bumps and lacerations.



3. Foot and Leg Protection

JGCI Chemical Corporation ensures that each affected employee wears a protective footwear when working in areas where possible foot or leg injuries from falling or rolling objects or from crushing or penetrating materials. Also, employees whose work involves exposure to hot substances or corrosive or poisonous materials must have protective gear to cover exposed body parts, including legs and feet.

Foot and leg protection choices include the following:

LEGGINGS protect the lower legs and feet from heat hazards such as molten metal or welding spark. Safety snaps allow leggings to be removed quickly.

TOE GUARDS fit over the toes of regular shoes to protect the toes from impact and compression hazards.

METATARSAL GUARDS protect the instep area from impact and compression. Made of aluminum, steel, fiber or plastic, these guards may be strapped to the outside of shoes.

SAFETY SHOES have impact-resistant toes and heat-resistant soles that protect the feet against hot work surfaces common in roofing, paving and hot metal industries. Safety shoes may also be designed to be electrically conductive to prevent the buildup of static electricity in areas with the potential for explosive atmospheres or nonconductive to protect workers from workplace electrical hazards

4. Hand and Arm Protection

JGCI Chemical Corporation ensures that each affected employee wears a protective gloves when working in areas where potential hazards include skin absorption of harmful substances, chemical or thermal burns, electrical dangers, bruises, abrasions, cuts, punctures, fractures and amputations that cannot be eliminated through engineering and work practice controls. Protective equipment includes gloves, finger guards and arm coverings or elbow-length gloves.



For JGCI Chemical Corporation employee, natural (latex) rubber gloves are used due to it is comfortable to wear. Its feature outstanding tensile strength, elasticity and temperature resistance. In addition to resisting abrasions caused by grinding and polishing, these gloves protect workers' hands from most water solutions of acids, alkalis, salts and ketones.

5. Body Protection

JGCI Chemical Corporation ensures that each affected employee wears a body protection like laboratory coats, coveralls, vests, jackets, aprons, surgical gowns and full body suits when working in areas where potential hazards like Temperature extremes; Hot splashes from molten metal and other hot liquids; Potential impacts from tools, machinery and materials and Hazardous chemicals

Protective clothing comes in a variety of materials, each effective against particular hazards, such as:

PAPER-LIKE FIBER used for disposable suits provide protection against dust and splashes.

TREATED WOOL AND COTTON adapts well to changing temperatures, is comfortable, and fire-resistant and protects against dust, abrasions and rough and irritating surfaces.

DUCK is a closely woven cotton fabric that protects against cuts and bruises when handling heavy, sharp or rough materials.

LEATHER is often used to protect against dry heat and flames.

RUBBER, RUBBERIZED FABRICS, NEOPRENE AND PLASTICS protect against certain chemicals and physical hazards.

6. Hearing Protection



JGCI Chemical Corporation ensures that each affected employee wears a hearing protection when working in areas having excessive noise. Some types of hearing protection include:

SINGLE-USE EARPLUGS are made of waxed cotton, foam, silicone rubber or fiberglass wool. They are self-forming and, when properly inserted, they work as well as most molded earplugs.

PRE-FORMED OR MOLDED EARPLUGS must be individually fitted by a professional and can be disposable or reusable.

EARMUFFS require a perfect seal around the ear.

7. Respirators

Respirators serve to protect the user from breathing in contaminants in the air, thus preserving the health of one's respiratory tract. There are two main types of respirators. One type of respirator functions by filtering out chemicals and gases or airborne particles from the air breathed by the user. Gas masks and particulate respirators are examples of this type of respirator. A second type of respirator protects users by providing clean, respirable air from another source. This type includes airline respirators and self-contained breathing apparatus.

Guarding of hazardous machinery

JGCI Chemical Corporation installed machine guarding in order to protects the operators’ fingers from being caught in the unprotected position by reducing the opening to a size so that it cannot be passed with body parts such as hands and fingers. Beside this hazardous equipment, exposed walkways, access-ways and working platforms also have a guarding.

Lockout Tagout Tryout

JGCI Chemical Corporation used lockout tagout tryout as safety measure (as seen in figure__), to ensure that dangerous machines and installations are properly shut off and not started up again prior to the completion of maintenance or servicing work.



It works with physical locks and tags, which ensure that energy sources can only be unblocked and released by the employee who is working in the machine. In our company the plant manager is responsible for safety at its facility. The decision to implement a plant-wide procedure such as “Lockout Tagout Tryout” can only be made with the full support of the management team. During implementation, the key responsibility is with the maintenance group which needs to apply the procedure for its own safety. The “Lockout Tagout Tryout” is a straightforward procedure that clearly shows whether it is being followed by the operators involved or not. Implementation of the practice requires tailor-made solutions and instructions and above all full commitment by management.

Anti-Fall Cord System

The Anti-Fall Cord system was installed in the JGCI Chemical Corporation plant (as seen in figure __) at the request of risk prevention delegates to prevent accidents caused by falls in operations requiring access to some pieces of equipment. To protect workers from falling, Anti-Fall Cords, with automatic brake-arrest, were installed in the roof above tanks and chests where access to the interior is required from above. The Anti-Fall Cord protects the worker from falling even if he loses control. By the installation of Anti-Fall Cords accidents are avoided in maintenance operations which require access to elevated area or equipment.

Figure_ : lockout tagout tryout



Safe Access to Confined Spaces

It is a good practice to reduce the risk of major injury or death whilst carrying the maintenance operations in the plant. The good practice describes measures needed to access confined spaces, and modifies one specific procedure in particular.

For some maintenance activities in JGCI Chemical Corporation plant (as seen in figure __), workers are required to enter confined spaces, characterized by limited access openings and poor, or absence of, natural ventilation. In these confined spaces, and in the presence of hazardous chemicals and gases, a serious accident can occur, which can result in serious injury or death. If any task has to be carried out within the confined space, then once the preliminary cleaning operation has been completed, any residue removed and the forced ventilation is turned off, the operators will check the gas density with a portable instrument. Supervisors are responsible for implementing the good practice since they will instruct their workers to enter confined spaces for some operations. The benefits of the good practice are to reduce the risks that workers are exposed to when entering confined spaces thereby making their work safer.

Figure_ : anti fall cord system



Health and Safety Team

In order to detect and resolve some technical and safety problem, JGCI Chemical Corporation establish a health and safety pillar wherein the Human Resources, Production, Occupational Safety and Paramedics have regular meeting where problems are being picked up and opportunities for improvement are being found.

The decision to implement a plant-wide procedure can only be made with the full support of the management team. When the team is set into action the members of the departments involved in it are responsible for its work and also its results.

Emergency Action Plan

The Emergency Action Plan is used to ensure employee safety from fire and other emergency. At the time of an emergency, all employees should know what type of evacuation is necessary and what their role is in carrying out the plan. When a fire is detected it is necessary that the fire alarm pull station be activated as soon as

Figure_ : safe access to confined space



possible. The fire alarm will notify the emergency response team who will perform assigned duties. The activation of the alarm will also notify the local fire department.In the event of fire, bomb threat, or toxic chemical release; employees are to proceed to the nearest available and safe exit and leave the building as soon as possible. Floor plans (maps) and exits have been posted in each department.

Occupational Safety Observation

Occupational Safety Observations is acquired in JGCI Chemical Corporation in able to help to sensitize our workers to Health and Safety and everyone assumes more responsibility for Health and Safety issues. This practice aims to involve each employee in considering their colleagues’ workplaces with regards to aspects of

safety. For the observation, workers visit totally different areas of the plant to watch the behavior of their colleagues with their own eyes. Findings and impressions are discussed by the observer with his colleagues who he has observed. Proposals to improve health and safety are tested and, wherever applicable, implemented

Safe Ideas Award

Figure_ : occupational safety observation



The Safe Ideas Award was implemented at JGCI Chemical Corporation in order to maximize commitment at all levels within the organization. The aim is to work as a team towards the achievement of this shared objective. It works by promoting ideas, proposals and suggestions to improve health and safety, regarding organization, management, behavior and technical improvements. The more concrete and up-to- date, the better they are. A jury of health and safety experts selects the best ideas.

Figure_ : safe ideas award



Plant location

The geographical location of the final plant can have strong influence on the success of the industrial venture. Considerable care must be exercised in selecting the plant site, and many different factors must be considered. Primarily the plant must be located where the minimum cost of production and distribution can be obtained but, other factors such as room for expansion and safe living conditions for plant operation as well as the surrounding community are also important. The location of the plant can also have a crucial effect on the profitability of a project.

Selection of a Plant Location

The various principal factors that must be considered while selecting a suitable plant site, are briefly below.

1. Raw Materials Availability

The source of raw materials is one of the most important factors influencing the selection of a plant site. Attention should be given to the purchased price of the raw materials, distance from the source of supply, freight and transportation expenses, availability and reliability of supply, purity of raw materials and storage requirements.

2. Location

The location of markets or intermediate distribution centers affects the cost of product distribution and time required for shipping. Proximity to the major markets is an important consideration in the selection of the plant site, because the buyer usually finds advantageous to purchase from near-by sources.

3. Availability of Suitable Land



The topography of the tract of land structure must be considered, since either or both may have a pronounced effect on the construction costs. The cost of the land is important, as well as local building costs and living conditions. Future changes may make it desirable or necessary to expand the plant facilities. The land should be ideally flat, well drained and have load-bearing characteristics. A full site evaluation should be made to determine the need for piling or other special foundations.

4. Transport

The transport of materials and products to and from plant will be an overriding consideration in site selection. If practicable, a site should be selected so that it is close to some major forms of transport: road, waterway or a seaport. Road transport is being increasingly used, and is suitable for local distribution from a central warehouse. If possible the plant site should have access to all types of transportation. It is necessary to have an effective transportation facilities for the plant personnel.

5. Availability of Labors

Labors will be needed for construction of the plant and its operation. Skilled construction workers will usually be brought in from outside the site, but there should be an adequate pool of unskilled labors available locally and labors suitable for training to operate the plant. Skilled tradesmen will be needed for plant maintenance. Local trade union customs and restrictive practices will have to be considered when assessing the availability and suitability of the labors for recruitment and training.

6. Availability of Utilities

The word “utilities” is generally used for the ancillary services needed in the operation of any production process. These services will normally be supplied from a central facility and includes water and electricity which are briefly described as follows.



a. Water

The water is required for large industrial as well as general purposes, starting with water for cooling, washing, and steam generation. The plant therefore must be located where a dependable water supply is available namely rivers or seas. The temperature, mineral content, slit and sand content, bacteriological content, and cost for supply and purification treatment must also be considered when choosing a water supply.

b. Electricity

Power and steam requirements are high in most industrial plants and fuel is ordinarily required to supply these utilities. Power, fuel and steam are required for running the various equipment like generators, motors, turbines, plant lightings and general use and thus be considered as one major factor is choice of plant site.

7. Environmental Impact and Effluent Disposal

Facilities must be provided for the effective disposal of the effluent without any public nuisance. In choosing a plant site, the permissible tolerance levels for various effluents should be considered and attention should be given to potential requirements for additional waste treatment facilities. As all industrial processes produce waste products, full consideration must be given to the difficulties and coat of their disposal. The disposal of toxic and harmful effluents will be covered by local regulations, and the appropriate authorities must be consulted during the initial site survey to determine the standards that must be met.

8. Local Community Considerations

The proposed plant must fit in with and be acceptable to the local community. Full consideration must be given to the safe location of the plant so that it does not impose a significant additional risk to the community.

9. Climate



Adverse climatic conditions at site will increase costs. Extremes of low temperatures will require the provision of additional insulation and special heating for equipment and piping. Similarly, excessive humidity and hot temperatures pose serious problems and must be considered for selecting a site for the plant. Stronger structures will be needed at locations subject to high wind loads or earthquakes.

10. Taxation and Legal Restrictions

State and local tax rates on property income, unemployment insurance, and similar items vary from one location to another. Similarly, local regulations on zoning, building codes, nuisance aspects and others facilities can have a major influence on the final choice of the plant site.

Alternative Plant Locations

1. Alternative Plant Location 1

Place: BULACAN

Bulacan is a first class province of the Republic of the Philippines located in the Central Luzon Region (Region 3) in the island of Luzon, north of Manila and part of the Metro Luzon Urban Beltway Super Region.

It has 569 barangays from 21 municipalities and 3 component cities (Malolos, the capital city; Meycauayan; and San Jose del Monte). Bordering Bulacan are the provinces of Pampanga to the west, Nueva Ecija to the north, Aurora and Quezon to the east, and Metro Manila and Rizal to the south. Bulacan also lies on the north-eastern shore of Manila Bay. In the 2010 census, Bulacan had a population

Figure 1: Bulacan Province



of 3,124,433 people, the highest population in Region 3 and second-most populous province in the whole Philippines (after Cavite).

Nowadays, Bulacan is among the most progressive provinces in the Philippines. Its people—the Bulaqueños (or Bulakenyo in Filipino) are regarded as highly educated, enterprising and industrious.

Geography

Bulacan is bounded by Nueva Ecija on the north, Aurora (Dingalan) on the northeast, Quezon (General Nakar) on the east, Rizal (Rodriguez) on the southeast, Metro Manila (Valenzuela City, Malabon City, Navotas City, Caloocan City and Quezon City) on the south, Manila Bay on the southwest, and Pampanga on the west.

Several rivers irrigate the province of Bulacan; the largest one is that of Angat. Angat River passes through the towns of Norzagaray, Angat, Bustos, San Rafael, Baliuag, Plaridel (Quingua), and Calumpit. It flow thence into the Pampanga River, goes out again, washes Hagonoy and loses itself in the mangroves. The banks of these rivers are very fertile and are covered with trees.

Terrain

Bulacan lies in the southern portion of the fertile plains of Central Luzon. The area is drained by the Angat and Pampanga rivers. The Sierra Madre mountain range forms the highlands of Bulacan in the east. Angat Lake, which was formed by the Angat Dam is located in that area. The highest point in the province at 1,206 meters is Mount Oriod, part of the Sierra Madre.

Climate

November to April is generally dry while wet for the rest of the year. The northeast monsoon (amihan) prevails from October to January bringing in moderated and light rains. From February to April, the east trade winds predominate but the Sierra Madre (Philippines) mountain range to the east disrupts the winds resulting to a dry period. From May to September, the southwest



monsoon (habagat). The hottest month is May having an average temperature of 29.7 °C (85.5°F) while the coldest is February with an average temperature of 25.1 °C (77.2°F).

Transportation

Bulacan is dubbed as "The Gateway to the Northern Philippines". The province is linked with Metro Manila primarily through the North Luzon Expressway and Manila North Road (better known as the MacArthur Highway) which crosses the province into Pampanga and western part of Northern Luzon (western Central Luzon, Ilocos and Cordillera Administrative Region). While taking the Cagayan Valley Road in Guiguinto, the road leads to Nueva Ecija and to the eastern part of Northern Luzon (eastern Central Luzon and Cagayan Valley Region). Bulacan will be accessed by the future C-6 Road connecting the provinces of Rizal and Cavite and the cities of Taguig, Parañaque and Muntinlupa in Metro Manila.


Place: LAGUNA

Laguna, officially known as the Province of Laguna is a province of the Philippines found in the CALABARZON region in Luzon. Its capital is Santa Cruz and the province is located southeast of Metro Manila, south of the province of Rizal, west of Quezon, north of Batangas and east of Cavite. Laguna hugs the southern shores of Laguna de Bay, the largest lake in the country. The city with the highest population (based on 2010 census) is Calamba, while the least populated is the Municipality of Famy. Province of Laguna is the second ISO 9001:2008 certified province in the Philippines.

Geography

Laguna lies on the southern shores of Laguna de Bay, the largest lake in the country. On the southern border of the



province are Mt. Makiling and Mt. Banáhaw, both are long dormant volcanoes, but still sources of geothermal energy. Mt. Makiling is popular for the numerous hot spring resorts that are found on its slopes. Pagsanjan Falls, is a popular waterfall that tumbles down a deep gorge in the hills. The eastern portion of Laguna straddles the southernmost portions of the Sierra Madre mountain range.

Climate

The province is relatively dry from November to April and wet during the rest of the year for a small portion near the southern boundary. The other parts, west of Santa Cruz municipality, experience a dry season from November to April and rainy season during the rest of the year. The eastern and southern most portions do not have distinct season, with rainfall more evenly distributed throughout the year.

Transportation

The South Luzon Expressway (SLEx) passes through Laguna. A public-private partnership initiative of the national government include plans to build a circumferential road along Laguna de Bay shoreline, the Laguna de Bay Flood Control Dike Expressway (or C-6 Extension), from San Pedro to Siniloan. Some of the proposed road networks is the Calamba-Los Baños Expressway and the Cavite–Laguna Expressway that will connect the provinces of Cavite and Laguna.


Place: CAVITE

Cavite is a province in the Philippines located on the southern shores of Manila Bay in the CALABARZON region on Luzon Island. It is one of the most industrialized and one of the fastest growing provinces in the country because of its close proximity to Metro Manila, located just 14 kilometers (8.7 mi) south of the capital. The province is known as the Historical Capital of the Philippines.

Geography



Cavite is surrounded by Laguna province to the east, Metro Manila to the northeast, and Batangas province to the south. To the west lies the West Philippine Sea. It is located within the Greater Manila Area, not to be confused with adjacent Metro Manila, the defined capital region. The urban influence of the metropolis together with easy accessibility, adequate infrastructure and comparatively fresh natural setting makes the picturesque province an ideal refuge.

Climate

Cavite belongs to Type 1 climate based on the Climate Map of the Philippines by the Philippine Atmospheric, Geophysical

and Astronomical Services Administration (PAGASA). Being a Type 1, Cavite has two pronounced seasons – the dry season, which usually begins in November and ends in April, and the rainy season, which starts in May and ends in October.

Transportation

There are three main highways traversing the province: Aguinaldo Highway runs in a general north-south direction; the Governor's Drive runs in a general east-west direction and the A. Soriano Highway runs within the coastal towns on the west. The existing road length computed in terms of road density with respect to population at the standard of 2.4 kilometers per 1,000 population has a deficit of 3,532.71 kilometers.

In 2011, the Cavite Expressway (CAVITEX) was opened, which lessened the heavy volume of vehicles on Aguinaldo Highway in Bacoor. This project decreased the traffic congestion in Aguinaldo Highway in Bacoor, so travel time from Imus to Baclaran/Pasay is lessened to only one hour.

Last July 1, 2013, the Kaybiang Tunnel, the country's longest underground highway tunnel at 300 meters was opened along the Ternate-Nasugbu Road piercing through Mt. Pico De Loro's north ridge that shortens the travel time from Manila to the western coves of Cavite and Nasugbu, Batangas.

Figure 3: Province of Cavite



Comparison Analysis of Plant Location

The table shown below was used to select the suitable plant location for JCGI Corporation. The important factors were considered and graded to their importance on the whole production. The grade varies on their respective importance and stated in the table. The number beside the factors was the highest grade possible and 0 as the lowest.

Table 1: Comparison in Choosing the Best Plant Location

FACTORS GRADE RANGE BULACAN LAGUNA CAVITESources of Raw

Material 15 5 5 10Water and Electricity Resources

15 13 13 13

Transportation and

Communication

15 13 13 13

Labor Force 15 11 12 13Proximity to Metro Manila 15 12 10 14Topographical

Features 10 8 7 9

Body of Water 10 8 8 9

Climate Type 5 4 4 4

TOTAL 100 74 72 85

As shown in the table above, the Province of Cavite succeed over the two provinces based on the grade range given by the proponents. Its proximity to Metro Manila and the source of raw materials favored its success. Also, it gained an easy access to various transportation and receiving body of water. The main plant will be situated in Tanza, Cavite where it is approximately 40 km south of Manila and the nearest possible place from the source of the major raw material located at Rosario, Pasig City. Hence, the proponents considered the Province of Cavite as a suitable plant location for the JCGI Corporation.

The JCGI Corporation manufacturing plant will be situated at the 10-hectare land in Tanza, Cavite and the nearby receiving body of water is the Cañas River.



Plant Location in Tanza, Cavite

The proponents have found an advertisement in OLX.com regarding a selling of land in Tanza, Cavite. A 10-hectare lot sells at a price of 400 pesos per 400 square meters.

Figure 4: Advertisement of a 10-hectare lot in Tanza, Cavite

Health and Safety Measures

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