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INTERNATIONAL GENERALCERTIFICATE Candidate’s observation(2011 specification) sheet

IGC3 – THE HEALTH ANDSAFETY PRACTICAL APPLICATIONSheet number 1 of __4___

Student name xxxxxxxxxxxxxxxxxxxxxxxxxxxxxx Student number xxxxxxxxxxx

Place inspected xxxxxxxxxxxxxxxxCompany __________ Date of inspection xx / xx /xxxx

Observations Control measures Timescale

Hazards and consequences Immediate and longer term actions

PLANT

Raw material conveyor has no priormoving alarm. Risk of contact withmoving parts. Lead to entanglementand injury of human body or part of it.

-Stop conveyor being used.-Apply prior moving alarm due tostandard.-Tool box talk on perception of risk andguarding to operators.

Immediate48 hours

1 week

Hydraulic steel sheet cutter in tinsmoulding unit has no guard on blades.Risk of contact with moving parts leadto finger amputation.

-Stop machine being used.-Set a fix guard to cover exposed blades.-Tool box talk on safe operation ofhydraulic cutter.-Competent supervisor to ensure guard isused correctly.

Immediate3 days1 week

2 weeks

Fire fighting hose reel nozzle close towestern gate is damage. Risk ofinability to control fire; lead to spreadfire then increase damage or injury.

-Contact fire fighting company to replaceit.-Carry out pressure testing to all hosereel and replace the damage ones.-To add portable fire extinguishers to usein case of damage of hose.

Immediate

1 month

1 week

Poor electrical connection in electricalpanel of absorption unit. Risk ofoverheated, lead to fire and explosion.

-Isolate electrical panel.-Proper connection by competent person.-Tool box talk on electricity safety to allstaff.

Immediate24 hours1 week

Emergency stop on grinding machinewere difficult to access because clutter.Hazard of not stop machine as quicklyas possible, lead to increase severity ofinjury.

-Remove clutter from emergency stop.-Tool box talk on emergency controlsystem.-Reposition emergency stop location.

Immediate1 week

1 month

Boiler unit is too hot. Risk of exposureto excessive heat, lead to heat strokeand stress to workers.

-Isolate and shield the hot surfaces.-Frequent breaks and job rotations.-Provide appropriate ventilation fans andcoolers.

3 daysOngoing2 weeks


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INTERNATIONAL GENERALCERTIFICATE Candidate’s observation

(2011 specification) sheet

IGC3 – THE HEALTH ANDSAFETY PRACTICAL APPLICATION



Control room’s seats are hard flatsurface and unadjustable. Risk of backinjury and haemorrhoids.

-Replace seat with proper and adjustableseat.-Provide Training and instructions incorrect seat adjustment.-Carry out DSE assessment for all users.

Immediate

1 week

1 month

Noise levels were excessively high incrushing unit. Risk of hearing damageand confusion in an emergency case.

-Ear plugs must be provided.-Carry out noise survey to ascertain howover all level can be reduced.- Job rotation to reduced time ofexposure.

Immediate1 month

1 week

High dust level of hazardoussubstances in packing area. Risk ofinhalation hazardous chemical lead torespiratory diseases.

-Provide respiratory mask.-Provide appropriate LEV.-Frequent breaks and job rotation.

Immediate1 monthOn going

Sanitary, resting and eating facilities areapplied in well standard.

-Good practise.-continue to provide and maintain.

On going

An electrical socket is close to washbasin in centrifugal unit. Risk of socketdamped lead to electrical shock toworkers.

-Stop wash basin being used.-Isolate socket.-Reposition socket to safer location.

ImmediateImmediate3 days

Packing operator were not wearinghand gloves. Risk of contact withhazardous substances lead to skindermatitis.

Water pipe leakage on floor close toocooling tower entrance. Risk of slipLead to serious injury.

-Maintain pipe leakage by competentperson.-Conduct inspection to check leakage.

24 hours

1 month

-Instruct operator to wear gloves.-Ensure suitable gloves are availableclose to job.-Provide training and instructions in handgloves importance and usage to workers.

Immediate24 hours

1 week

-Cleaning surface floor.-Maintain pipe leakage by competentplumber.

Immediate24 hours


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The cable of mixing motor had beenexposed. Hazard of contact with workerlead to electrical shock and death.

-Stop machine being used.-Replace cable and re-route cable tokeep it away from been damage.-Ensure all machines and apparatusesare earthed.

immediate24 hours

2 weeks

Laboratory

The analyst Using flammablesubstances close to dryer oven. Risk ofcatch fire lead to human burn andexplosion.

-Remove all flammable substances a wayfrom oven.-Training and instructions in safe use andstore of flammable substances to all staff.

Immediate

3 weeks

Chemical substances in lab have been

stored in unresisting fire cabinet andpoor singed. Risk of spread fire. Lead toincrease severity of injury and damage.

-Stop using this cabinet.

-Provide a proper fire resisting cabinetwith lockable door and clearly signed.-Training and instructions in safe use andstore of chemical substances to all staff.

Immediate

5 days

3 weeks

All fire extinguishers had been testedand were in date.

-Good practise.-Continue to provide and maintain.

On going

Lab analyst using chemical agentwithout catch spill tray. Risk of spillcontamination which lead to emissiontoxic vapour to atmosphere andinhalation.

-Stop using chemical agent.-Provide a proper tray to catch spill.-Provide training and instructions inchemical hazards to lab operators.

Immediate3 days3 weeks

STOREFire exit door in product’s storecompletely blocked by stock and bulk ofproducts. Risk of worker being trappedin the event of fire then suffering burn ordeath.

- Ensure that all escape routes are clear,provision of adequate light andemergency signs.-The store area must be racked to takeexcess materials.- Provide Training and instructions to allstaff in emergency procedures and howto evacuate in emergency case

3 days

3 weeks

1 month


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Storage of acetylene and oxygen

cylinders in same store without anybarrier. Risk of catching fire from anysources around lead explosion andproperty damage.

-The cylinder must be separated.

-provide well ventilated and secure store.

Immediate

1 month

Storage of raw chemical material inunmarked container. Risk of usingincorrect material. May lead to lossmaterial and human poisoning.

-Clearly mark and sign container.-Provide proper container.-Training staff on how to storagechemical materials.

24 hours3 days3 weeks

Large heavy and awkward boxes werebeing manually handled by store

workers using poor techniques. Risk ofback disorder and shoulder injury.

-Handling of boxes by two persons.-Tool box talk in safe handling technique

-Provide trolley to make handling safer.

Immediate2 weeks

1 month

Forklift truck had no sign of daily checkbeing carried out. Risk of loss controlwhich lead to accident.

-Daily check list must be drawn up.-Training in how to complete checklist fordriver.-Develop checklist to be fitted for futurereference.

Immediate1 week

1 month

Poor lighting at store entrance. Risk offorklift collision with pedestrian or rackswhich could fall on workers lead to

serious injury or death.

-Provide adequate lighting and wearinghigh visible clothing.-Protect racks with guard rail.

-Reposition entrance location so thatforklift cannot collision.

3 days

1 week

3 months

Rack near walkway had length of woodprotruding into walkway at head height.Risk of worker struck against protrudeswood lead to head and eye injury.

-Rack maintained to be in safe condition.-Clear route must be marked.

Immediate1 week


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INTERNATIONAL GENERALCERTIFICATE Candidate report template(2011 specification)

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 threemain sections (Plant, QC Lab and Warehouse). The company produce several materials such asconstruction detergents and solvent by reaction raw petroleum products. The QC Lab testing rawmaterials and final products, the warehouse divided in to two sections one for raw materials andanother for final products.The inspection was carried out on 02

th 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, qualityand productivity.

Executive SummaryThe inspection demonstrates there are significant weaknesses in some serious hazards such as:Fire safetyThe fire risk rising from improper storage and using of flammable substances. Should be controlledthrough separated flammable substances from ignition sources and develop safe system of work.

Health of workersThe health risk arising from exposure to high dust level of hazardous chemical. Should be controlthrough improving ventilation.

Machinery guards and safety devicesThe risk of injury from the hydraulic sheet cutter. Should be controlled by removing machine from useimmediately and not using until the guard is fixed.

Electricity safetyElectrical risk increase by poor connection in electrical panel. Should be controlled through correct

electrical connections.

Working practicesThere were evidences of lack of safety awareness of the staff. Should be controlled through provideappropriate and adequate training and instructions.

These corrective actions will reduce the risk of accident and ill-health in plant. This will have the effectof improving efficiency and productivity then increase profits. And will help to reduce cost ofinvestigation 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 andapproximate cost.


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Main findings of the inspection

Fire safetyThere were many fire hazards in the plant, flammable substances were close to source of ignition inQC lab, acetylene and oxygen stored in the same store, without barrier which could cause fire andexplosion and lead to burning, death and damage in property.Chemical substances stored in unresisting fire cabinet and poor signed, this increase severity of fireby spread fire. Fire exit door completely blocked by stock and bulk of product which could prevent anemergency 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 18of 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 workersThe most reasons of ill-health, sickness and stress are exposure to excessive dust and noise, thenoise levels were excessively high that lead to increase stress and depressed then decrease staffmorale.High dust level of hazardous chemical that increase respiratory diseases then increase absenteeismrate 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), Article4 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 toabsenteeism, cost of first aid treatment and compensation. Emergency stop on grinding machine weredifficult 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 C15Convention.

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.



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Electricity safetySufficient evidence was seen during the inspection to demonstrate the risk of an electrical incidentcausing serious injury, death or property damage and that increase direct and indirect cost. There wasevidence of poor connection in electrical panel which cause overheated.There was electrical socket close to wash basin, that increase likelihood of electrical shock, as weknow 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 C155Convention.

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.


Working practicesThe inspection demonstrates lack of safety awareness by staff in this plant which will cause ill-healthand increase severity of injury, damage and loss. There were number of unsafe practises, includingUsing 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 13and 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.


ConclusionsThe main objective of this report is to identify and explain exactly the weaknesses points at the healthand safety management system of Vona Company and how can be improved. Such problems hadbeen 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 andlack 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 throughsegregation and aggregation from any source of ignition and to put clear warning signs, and as wellthe good ventilation by using local exhaust fan to reduce the level of the hazardous dust. All Electricalcables should be connected properly as per standard procedures, Safety guards to be fixed at thehazardous machineries and to conduct adequate training and safety awareness session for allemployees of Vona Company.

The Commitment of Vona Company management towards the health and safety principles like thecompliance with the legislations, law and standard to provide a safe place of work, safe plant andequipments, safe system of work, adequate training and supervision and to hire competentemployees. Also the economic factors should be consider by Vona management, since it has beenrelated to the accident and ill-health and both of them costed money, because when the accidentoccurs 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. Theimportance of the moral obligation and duty of Vona company management towards their employees,


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through taking care of their health and safety, to avoid injury, sick and death of the workers and toensure that they are safe in their work

Through out of this report I would like to draw attention of Vona top Management Company to thebenefits of the good health and safety practices and it is direct effects on increasing the level ofcomplaisance 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 willhelp 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 thedamage of equipments, staff complains & turnover. As a hall value it increases the companyreputation and encourages good customers.

Recommendations

Recommendation Likely resourceimplications

Priority

Targetdate

Fire safety

Ensure that flammable substances are separatedfrom ignition sources.

No external cost it may takehalf an hour ofmaintenance time

High Immediatel

y

Ensure that fire spread is reduced by provide aproper three fire resisting cabinet with lockabledoor and clearly signed.

The estimated cost 2000$ High 1 month

Ensure that all escape routes are clear, adequatelylight and emergency signs are available.

The estimated cost 300$ High 3 days

Train all staff in emergency procedures and how toevacuate in emergency case

No external cost it cost ofinternal trainer andemployee time.

Medium 1 month

Health of workers

Carry out noise survey to ascertain how over alllevel can be reduced.

No external cost it cost ofinternal engineer’s time

Low 1 month

Provide two local exhaust Ventilation system. The estimated cost 10000$ High 1 monthTrain all staff on the chemical hazards and it iseffect on their health.


Low 1 week

Machinery guard and safety devices

Set a fix guard to cover exposed bladesThe estimated cost 500$

High 3 days

Tool box talk on safe operation and Competentsupervisor to ensure guard is used correctly

No external cost it cost ofinternal supervisor ’s time

Medium

3 weeks

Electricity safety

Reposition socket and plugs to safer location.

The estimated cost 100$ High 5 days

Ensure all machines and apparatuses are earthed No external cost it may takehalf an hour of

maintenance time

High 2 weeks


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Working practices

Provide handling aids to make handling safer. The estimated cost 5000$ Medium

1 month

Training and instructions on safe handling and storeof chemical substances to all staff


Low 3 weeks

Signed ________________________ Date _________________________

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