Nebosh IGC-3 Observation Sheet (00218445) Final

(1)

INTERNATIONAL GENERAL Candidate’s observation sheet CERTIFICATE

(2014 specification) IGC3 – THE HEALTH AND

SAFETY PRACTICAL APPLICATION

Student Name: Muahammad Kaiser Faheem Student Number: 00218445 Place Inspected: Ittehad Chemical Ltd. Lahore Date of Inspection: 02 / 02 / 2014.

Item

Observation

Hazards and Consequences

Control Measures Immediate/longer term action

Time Scale

01

Observation:

Worker was working in the hazardous Chemical area.

Hazard & Consequences:

Chemicals hazard, i.e, Calcium Carbonate, Hydro-Chloric Acid, Calcium Chloride, coal and Flocculent.

Calcium Chloride is irritant to skin and eyes. Hydro-Chloric Acid is corrosive to the eyes, skin, and mucous membranes. Lung and skin problems such as black lung disease, is caused by inhaling coal dust.

Immediate action:

Provide PPE to the workers

Short term:

Health surveillance

Long Term:

Exposure limit to chemical will decrease by job rotation. Immediate 3 Month Regularly

03

02

Observation

House-keeping was not good in the ware house of the Calcium Chloride and in bagging section. As calcium chloride prills and mud had combined to form the slippery surface.

Slip hazards, collision hazards between forklift and pedestrian and forklift with fixed structure.

Can cause severe injury to pedestrian or damaging of forklift truck.

On urgent basis clean the floor clean and keep it clean all the time.

Short term:

Ensure proper housekeeping of the Workplace on daily basis.

Long Term:

Monitor and check workplace regularly. Make employees aware of the hazards by providing information and training.

Immediate

One week

(2)

Item

Observation

Time Scale

03

Observation

From main gate to plant area there was two ways route for the vehicle and the pedestrian was using the same route. The forklift truck was running in the way and collision with vehicles and pedestrian can cause injury.

Collision hazard

Personal Injury, pedestrian injury, , property damage,

Because of one way from main gate to plant area, collision with pedestrian, vehicles, can cause injury

Provide signage’s ‘ stop ‘ , speed limit 5 km

Short term:

Segregate the area for vehicles & pedestrians by barriers

Long Term:

Provide separate entry & exit routes with solid partition in between pedestrian and vehicle.

Immediate

Two weeks

One month

04

Observation

Light was inadequate in the plant area and in workplace, and can cause injury to worker. Inadequate lighting can cause a hazard of slip or trip due to uneven ground, due to slippery action of calcium chloride on the floor.

Trip and slip hazards

Due to slip or trip, a severe injury can be happened.

Install adequate lighting within the Workplace so that people can able to see any hazards.

Short term:

Use natural lights such as roof lights, Where natural light is not satisfactory. Use artificial lighting.

Long Term:

Periodic maintenance and inspections of artificial lighting and replacing them from time to time.

Immediate

Two Week

(3)

Item

Observation

Time Scale

05

Observation

Blowers were creating a large noisy sound during Operation.

Noise Hazard.

Noise at work can cause hearing loss that can be temporary or permanent. Hearing loss is not the only problem. People may develop tinnitus (ringing, whistling, buzzing or humming in the ears).

Minimise work exposure limit

Short term:

Fit sound-proof enclosure, Acoustic shielding. Fit silencers, balance machine, or mount on anti-vibration mountings.

Long Term:

Eliminate/ Substitute with less noise blower.

Immediate Two Week

Six Month

06

Observation

Calcium Chloride dust was coming out from many damaged or leaked lines, from fine collector and from dust blower.

Dust hazard.

Calcium Chloride Power

Irritant, Causes irritation to skin, eyes and respiratory organs. Harmful if inhaled or swallowed. Effects can be possible coughing, sneezing, asthma and blocked filters of machines.

Welding of the lines those have leakages.

Short term:

Replace the lines those are too much damaged with new lines.

Long Term:

Keep routine monitoring and inspection of the lines

Immediate

Two Week

Regularly

07

Observation

Worker was working in the carpenter workshop to form wooden material for pallet formation.

Contact Hazards

Can cause injury to worker

Provide PPE to the worker.

Long Term:

Provide safeguard to the sander.

Immediate

(4)

Item

Observation

Time Scale

08

Observation

Worker was lifting the large buckets of lime powder from the lime heap and was mixing with calcium chloride solution to neutralize it in neutralization tank repeatedly.

Manual Handling,

Can cause back bone problem, slip disc issue, Hernia, can cause musculoskeletal disorders (MSDs).

Provide job rotation with other riggers

Short term:

Provide trolley

Long Term:

Install conveyer from heap of lime to lime tank.

Immediate One week Two Month

09

Observation

Employee using hand drill machine with broken handle & corroded flex

Electrical hazard

Electric shock, Fire & explosion Hand vibration syndrome, Noise

Repair the handle & change the flex

Short term:

Inform the maintenance staff to do the pre use check before using electrical equipments

Long Term:

Conduct monthly inspection of all electrical equipments & repair if needed.

Immediate

Weekly

1 month

10

Observation

Chemical sewage drain system was made of sanitary and at some points cover was not installed and light was not good at those Points.

Falling hazard into sewage drains. Can cause serious injury or death

Immediately barricade the open points.

Short term:

Close the open points by sanitary work or by keeping covers made of any material

Long Term:

Erect proper and good sewage drain system & properly out of passage area.

Immediate Two week

(5)

Item

Observation

Time Scale

11

Observation

Observed one employee sitting in office in odd posture in front of computer

Ergonomic Hazard,

WRULD, Eyes strain, Back pain, Cervical spondylosis

Provide frequentbreaks

Short term:

Make the assessment of workplace to provide standard DSE arrangements to suit the worker.

Long Term:

Provide DSE instead of Computer.

Immediate One month

One month

12

Observation

Observed that there was no notice board to give the information about procedures and different information to workers to update.

Disciplinary Hazard.

Lack of knowledge and information (Regulatory, Company policies, & working procedures), un competent workers, and development of negative culture.

Immediate:

There must be a supervisor who

informed to workers about rules and laws about their specific job.

Short Term:

There must be one notice board containing company policy, Rules & Regulations and other information.

Long Term:

Conduct inspection and provide training to employee and keep them update about company rules, laws and job related information.

Immediate

One week

Ongoing

13

Observation

There were no proper washing areas for workers.

Biological Hazard.

Biological hazards due to poor personal hygiene can cause health problems such as infections and diseases.

Immediate:

Following good hygiene practices.

Short Term:

Training to employees and give them information about personal hygiene.

Long Term:

Build up a washing area for workers nearby workers changing room/ locker area and provide proper ventilation system.

Immediate

One week

(6)

Item

Observation

Time Scale

14

Observation

Observed that in the reaction area to form calcium chloride solution from hydro chloric acid and calcium carbonate. The hydro chloric storage tank foundation was damaged and fumes were coming out from top of tanks and acid drain valve was leaked.

Falling, Health hazard and chemical hazard. Can cause severe injury to worker in case of falling of tank because of weak and damaged foundation.

Exposure to high fumes can cause breathe problem & can lead to chronic injury, worker can be senseless before reach to safe place, or can slip/ trip or fall on same level in running to take breathe in safe environment.

Immediate:

Provide PPE to the worker and shower water in the leakage point to avoid from fumes.

Short Term:

Install line at top of tank and put the line in the vessel filled with water so fumes could absorb in water and water can be drained. And install new valve.

Long Term:

Shift acid storage tanks to away from the workplace and with strong foundation and proper fumes collection system.

Immediate

Three week

One Month

15

Observation

The Chemical mist from the exhaust vent of scrubber was generating liquid droplets and those were falling around the plant area and on the worker at workplace, such mist being absorbed through the skin and mucus membrane of eye and can cause skin problems such as dermatitis and irritation.

Health and chemical hazard,

The Chemical liquids such solvents being absorbed through the skin and mucus membrane of eye and can cause skin problems such as dermatitis and irritation.

Immediate:

Wear personal protective equipments Such as coveralls and gloves.

Using cream to form a barrier to prevent hazardous chemical getting into the body and skin.

Short Term:

Adopting good hygiene practices. Minimize the frequency and duration of Being exposed to mist.

Long Term

Provide mist collector or mist absorber at the discharge of scrubber.

Immediate

One week

Three Month

(7)

Item

Observation

Time Scale

16

Observation

Combustion air fan and moving parts cover was open in hot air coal furnace plant.

Entanglement hazard

Worker can came in entanglement with the moving parts of the combustion air fan and can cause sever injury.

Immediate:

Provide awareness to every worker at workplace about it. And provide personal protective equipments

Short Term:

Provide temporary cover to the moving parts of the combustion air fan

Long Term:

Install proper fixed safe guard to the moving parts of the combustion air fan.

Immediate

Two Day

One Month

17

Observation

Trailing Cables were laid down on the floor and leading to the panel of welding work.

Risk of slip, trip and fall of workers in the workplace area which may cause cuts and bone fractures.

Immediate:

Secure trailing cables left unattended on the floor surfaces. remove

Obstructions in the walkway.

Short Term:

Ensure proper housekeeping of the Workplace on daily basis. Make plans to reroute electrical cables.

Long Term:

Monitor and check cables. make employees aware of the hazards by Providing instructions and supervision.

Immediate

Two days

(8)

Item

Observation

Time Scale

18

Observation

Few fire extinguishers are empty. This can cause delay while extinguishing fire during any fire emergency.

Discipline Hazards.

Can increase the severity of accident.

Immediate:

Inspection of all fire extinguishers,

Short Term:

Replace empty fire extinguisher with new fire extinguisher.

Long Term:

Indent new fire extinguishers.

Immediate Two days One Month

19

Observation

Rigger was not present during lifting of pipes also there was no tag lines attached with the suspended load.

Falling and collapse Hazard

Can lead to personal injury due to improper lifting, persons caught between pipe and pipe layer during lifting and equipment damage.

Immediate:

Rigger should be present at the worksite all the time during lifting process; tag line should be attached with the suspended load to control.

Short Term:

All personnel should be trained for lifting safety process.

Proper lifting practice should be prepared and should be followed by all personnel.

Long Term:

Monitor lifting activities regularly.

Immediately

Two Week

(9)

Item

Observation

Time Scale

20

Observation

Duct was cracked so scaffolding work was carried out to maintenance work on duct between prill tower and cyclone.

Substandard scaffolding guard rail & toe board are missing which will allow the workers, tools or material to fall from height thereby seriously injuring the other workers.

Immediate:

Fixed the guard rail & toe board

Short Term:

Scaffold training (erection & dismantling )

Long Term:

Strict monitoring & supervision of scaffolding operation.

Immediate

One Week

Regular

21

Observation:

Welding work was carried out in the erection of new quench cooler design, burner duct designing and cooling tower fan cover designing in the welding house.

Risk of inhaling welding fumes which can cause the disease known as blue metal fever and high temperatures during welding activity can cause burns.

Immediate:

Making people aware of the hazard. Providing personal protective equipments such as safety goggles to protect against ultra violet radiations emitted.

Short Term:

Redesign the workplace and ensure sufficient ventilation to avoid the danger of inhaling welding fumes

Long Term:

Install local exhaust ventilation to eliminate the possibility of breathing welding fumes.

One week

Two week

(10)

Item

Observation

Time Scale

22

Observation:

During process of drying of calcium chloride solution to form calcium chloride prills, problem came inside the prill or drying tower, there was one way to go and come from inside prill tower. Worker entered to prill tower to check nozzle and also fluidized bed checking was required due to parameters variation. Inside bed environment was hot and temperature was too high.

Environment Hazard and confined space hazard.

May cause heat exhaustion and heat stroke.

Immediate:

Provision of adequate welfare facilities such as drinking water. Providing refugees and moderate environment to worker after coming out that heated confined space.

Short Term:

Install strainer in the feed line, if any blockage piece came in feed line can remove outside the Prill or drying tower to provide safe work system to worker.

Long Term:

Install camera inside the Prill or drying tower to watch the fluidized bed height and condition of spoilage or non spoilage.

Immediate

Three week

Six Month

23

Observation:

Excavation work was carried out for the installing new ID fan blower in the coal furnace plant. And area was not barricade.

Falling Hazard

Risk of people, material and equipments falling into the excavations and the possible results could be fatalities.

Immediate:

Use stop blocks to prevent vehicles Overrunning. Barriers and signs to Prevent people falling into excavations.

Short Term:

Organizing a good traffic management system in place. Traffic routes should be clearly marked.

Long Term:

Excavations must be inspected at the Beginning of the shift on daily basis. All personnel need to be trained and competent to carry out their tasks safely.

Immediate

One week

(11)

Item

Observation

Time Scale

24

Observation:

The electrical system in the main electrical panel room was open & unattended

Fire & explosion Electrocution Short circuit

Immediate:

The electrical system should be always locked & secured

Lock out tag out procedure should be used in case of any maintenance or troubleshooting

It should be under control of permit to work system

Immediate

25

Observation:

To install filter pressure in the chemical area, the construction work was under progress and worker was using drill machine.

Vibration Hazard

Hand arm vibration syndrome, numbness and blanching of fingers, reduction in the dexterity

Immediate:

Provide Gloves to the worker

Short Term:

Provide training and supervision

Long Term:

Provide job rotation after intervals

Immediate

One Week

Regular

26

Observation:

Worker was smoking in the warehouse of fuel storage.

Fire hazard and discipline hazard. Result in severe injuries and property damage

Immediate:

Place prohibition sign for no smoking

Short Term:

Provide training and supervision to the employees

Long Term:

Install smoke detector in the warehouse

Immediate

One Week

(12)

Good Practices:

Good Practices

Maintain

Keep it up

 Providence of door to door pick and drop service to workers service from company side is a good practice, it must be continue and maintain.

Maintain it because it is good

practice.

Keep up

 Store house and maintenance workshop was away from hazardous area and it was well ventilated and managed everything in good order is a good practice.

Maintain it because it is good

practice.

Keep up

 Chemical and flammable chemical store house was separated and was little away from the plant area and was out of any hazards range, and was well cleaned.

Maintain it because it is good

practice.

Keep up

 Drinking water filters changed after regular intervals is a good practice to maintain good health of employees.

Maintain it because it is good

practice.

Keep up

 Medical facilities are good and quick service in case of any emergency is a good thing to maintain good standard of health and safety standards.

Maintain it because it is good

practice.

Keep up

 Canteen was near to rest rooms and well maintains and comfort and cleaned and hygienic foods were provided.