practical assessment sample 5 - chemical plant

7/26/2019 Practical Assessment Sample 5 - Chemical Plant

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ASSESSMENT

Management Report on Gas Compound, Bulk Acid Store and Clean Room

Introduction

The purpose of this inspection was to identify hazards and/or breaches of Health andSafety legislation and to highlight the findings and action recommendations to the

management of the organization.

Summary

The plant is kept in very good condition, well lit and with the Health and Safety ofemployees an obvious company objective. The site induction received being bothe!tensive and through. "ther positive signs where the staff Safety notice boards, the provision of incident reporting sheets in key locations and the proficient fire alarm checkswhich took place whilst was on site. The site itself is clearly signed with respect toemergency evacuation and restricted areas. The operation of a key card system is also

distinct Health and Safety advantage.

did, however, make a number of observations #see attached sheets$ the majority ofwhich can be remedied immediately with little or no cost. There were some areas ofconcern and one e!ample of e!tremely dangerous behavior the details of which arecontained on this report.

Details and Recommendations

! The e!posed pipe work at the side of the walkway presents a number of hazardsfrom trips, to e!posure to hazardous substances and must be addressed urgently.

The high visibility kicks/ trip guards already installed work well but all pipes atground level should be similarly protected. #T%&S '()$

*"ST+ '- ( H"0S% 123"04

1%5S12T"+ Health and Safety at work etc. 2*T #'678$ *ontrol ofSubstances Hazardous to Health #'666$



"! The noise levels within the maintenance area should be checked. f , as

Suspect, they are greater than safe e!posure levels the noise level needs to bereduced. %ither by engineering controls or, if this is not possible, issue of hearing protection and the posting of mandatory signage. #T%& 9$

*"ST+ 8 ( 8 hrs n:House Training

1%5S12T"+ ;ork place #Health, Safety and ;elfare$ 4egs. #'669$

#! n several areas the floors are uneven, usually where inspections of under floor pipe work have taken place and the floor relayed in the incorrect order, there isalso some damage and the floor in the clean room are altogether unsuitable. 2

<lant wide audit should be carried out to correct all flooring problems.#T%&S 7('-(=.'$

*"ST+ 0<T" ', if clean:room floor replaced

1%5S12T"+ Health and Safety at work etc. 2ct #'678$

$! The perimeter fence is in need of repair and should ideally be replaced. This is aresidential area and it is too easy for local children to get on site. *urrentcontrols such as the use of **T> and security patrols are not a substitute for prevention. 0ntil this can be carried out all potential dangers such as the pile of pallets should be removed or secured. The conse?uences of a bonfire by thehydrogen bottles are unthinkable. #T%&S ).'().)$

*"ST+ n e!cess of ',, which should be weighed against prosecution andcompensation claims

1%5S12T"+ Health and Safety at work etc. 2ct #'678$

%! 0nsafe practice on the workplace is an organizations problem. f safe systems ofworks are provided they should be used. However in failing to provide safesystems the organization is in breach of the law. f technician need to accessmachine they should be provided with safe means to do so. #T%&S =.=$

*"ST+ Step up stool - 1%5S12T"+ Health and Safety at work etc. 2ct #'678$ *ontrol of substances Hazardous to health #'666$ <ersonal protective e?uipment at work 4egs #'66=$



Conclusion

2lthough there is much good practice in evidence throughout the plant there are ) itemsof real concern. The ease of access to the plant and employees contravening the safesystems of work that e!ist. These matters need to be addressed urgently. Thee!penditure re?uired weighed against the potentially unlimited fines and compensationnot to mention serious injury and even loss of life. However encouragement should betaken from the willingness of all employees to be involved and recognize theirresponsibility to site wide health and safety.



ASSESSMENT

*andidates "bservation SheetSheet o. ' to )'

*andidates ame+ @@@@@@@@@@@@@@@@@@@@@@@ 2dd umber+ @@@@@@@@@@@@@@

<lace inspected+ @@@@@@@@@@@@@@@@@@@@@@@@ Aate of nspection+ @@@@@@@@@@@@@@

No! &'ser(ations

List hazards, unsafe

Practices and good practice

)riority

*

Risk

+,M,-.

Action to 'e taken+if any.

List any immediate or

longer term action required

Timescale

:immediate:' week :monthly, etc

'. %!posed pipe work at side of walkway

1 High visibility kick guardsto be installed

;ithin 'month

). 3roken pipe leading from

2mmonium Hydro!ide*abinet

&

solate

4eplace

Shield from further damage

mmediately

' ;eek

2s tem '

=. Beys left in chem. *abinetallowing unauthorized access

4emove to security mmediately

8. 1abels on *hem. *abinetdamaged

4eplace mmediately

-. 3ulk 2mmonium Hydro!ide*abinet not identified as tocontents

dentify as other cabs. mmediately

9. oise level in maintenancearea checked

& f found to be outside safelimits a full risk assessmentshould be carried out

;ithin 'week



7. ;alkway uneven withseveral sections sittingCproudD

1 4epair and relay

4eplace as necessary

<revent heavy traffic

;ithin 'month

E 4ollover door open when notin use@@@ *ontravenesmandatory sign.0nauthorized to site

1

Beep shut

4e:educate staff

*heck if ventilation isade?uate

mmediately

mmediately

;ithin =months#Summer2pproaching$

6. ;ater fire e!tinguisher not

proper identified

4enew stickers mmediately

'. 1agging damaged on #Hot$humidifier pipes

1 4epair / 4eplace ' month

''. 1ow overhead pipe work nothighlighted

1

1

%rect suspended sign

Highlight pipes with highvisibility tape

' month

' month

'). Ary scrubber power cable

used in coiled condition

Shorten cable mmediately

'=. Substance leaking from polyglass tanks

1

*heck substance

*lean up

Temporary 4epair

Full 4epair

mmediately

mmediately

mmediately

' month

'8. Step ladders lent against high

voltage cables

&

&

&

<rovide ade?uate

Storage for ladders

4e: Train engineers

' ;eek

';eek

'; eek



'-. Aoormat 2djacent to firedoor slippy and present a tripHazard

1

*heck if mat needed

4eplace with inset mat

mmediately

' &onth

'9. "ld pallets and combustiblematerials stored against skip 4emove mmediately

'7. <erimeter fence insecure in places

1 4enew fencing =:9 months

'E. 1agging Aamaged on reactor pipes

4eplace / 4epair 3efore reactor brought backinto service

'6. 0nsuitable, 0neven floor 1

1

4epair / 4elay

4eplace

' &onth

=:9 &onths

). &achine doors left 2jarduring operations

1

Fit interlocks if accessednecessary

4e:Train staff

' &onth

)'. Technician climbing ontoopen wet bench

<rohibit

<rovide suitable steps

<rovide suitable tools

mmediately

mmediately

mmediately



ASSESSMENT

*andidates "bservation SheetSheet o. ' to )7

*andidates ame+ @@@@@@@@@@@@@@@@@@@@@@@ 2dd umber+ @@@@@@@@@@@@@@

<lace inspected+ @@@@@@@@@@@@@@@@@@@@@@@@ Aate of nspection+ @@@@@@@@@@@@@@

No! &'ser(ations

List hazards, unsafe

Practices and good practice

)riority*

Risk

+,M,-.

Action to 'e taken+if any.

List any immediate or

longer term action required

Timescale:immediate:' week :monthly, etc

'. "pen electric water insecurity cabin mean gascylinder #'st floor$ 4isk offire

1

1

1

Switch off G remove gascylinder

<rovide proper store

Train G monitor for non rec

' month

' month

' week

). Scaffolding gaps between planks too large G not tieddown4isk of fire

1

1

Tie up <lanks

Train staff, make them awareof risks

4evise work organization

&onth

' week

' month

=. Tool bo! and e?uipment laidout in walkway

4isk of trips G impact injury

1

1

1

4emove

Store properly

<rovide a special tool bo!room

mprove house keepingstandard

' month

' month

' month

8 Toilet on first floor #office$ 1 o action needed ' month



clean G tidy<rovide a mirror

- *hair in front of office door 1 4emove and store away in proper place

' month

9. *ombustible material stored besides stairs&i!es stuff used engine oil bottles etc4isk ofcontamination#3iological$

1

4emove

ncrease fre?uency of wastecollection

Have a procedure for wastesegregation G supervision

' month

' week

7. "pen ducks on ground floor 2ll sick

1

<lace a temporary barrier andsign

2nalyze function / use ofduct G install a suitableunmemorable guard

mmediately

' month

E. &etal frame gvotruding inground floor store room atthe entrance

4eorganize stores

mprove G monitorhousekeeping

mmediately

6 1adder not tied/ secured onmain ground #unused one$

1 4emove G store properly

mprove supervision

Train staff for non recurreence

' month

'. "pen manhole on water tank There is a tripod placed uponit for training.

& %n?uire use G place a sign#warning$

' week

''. 0nmarked li?uid containersstored away4isk of chemicalcontamination

&

1

1

<roper identification Glabeling of containers

3ring chemical storage, procedures up to standards

<lace a warning sign or barrier #Ao not enter$ prohibiting sign

' week

' month

' month

'). 0nhygienic toilet for staff Gwater seepage G slipperyfloor

1 *lean upG spraydisinfectant

' month



4isk of biologicalcontamination G slips

Train housekeeping staff nform them of risk

' monthmmediately

'=. *lassroom "rganized G ofade?uate width, ventilation

1 o action re?uired

4edecorate as appropriate

' ear

'8. ;ater facilities provided#whole some treateddrinking water$

1 o action re?uired

<rovide a top cover forsheltering from sun

= months

'-. <roper signs missing in premises e.g. &ain office,stores etc.

1 <rovide ade?uate signs firstfor important areas andcontinue

mprove monitoring process

' month

'9. &anagers cabin properly laid

outG organized

1 o action needed

<rovide a curtain #lightcolored$

= month

'7. *omputer room, trialingcable at entrance4isk of tripsG fall

& 4emove G tie up cablesnform staff of hazards Gmonitor for non recurrence

mmediately

'E. %lectrical main fuse bo! and breakers not guarded, waterspraying in small ?uantitiesfrom above G scatteredwiring.4isk of short circuits and fire

1

Stop flow of water fromabove

<rovide a warning sign IAangerJ

4eassess location and provide a fi!ed guardingsystem with locking facility&onitor

mmediately

mmediately

' &onth

'6 &achine area no guard fittedon moving parts of motors4isk of cuts, entangle mentG contact enjury machine inoff position

&

nform staff of hazardsAo not switch on until atemporary guardingarrangement is made

4eview/reassess workorganization and improve

standards

mmediately

' ;eek

) "pen water tank#large$ withdirty water 4isk of biologicalcontamination

& <rovide a barrier G warningSign #Ao not use $

Aisinfect water G monitorfor non recurrence

mmediatelymmediately

)'. o <<% for machineoperators

& <rovides gloves for machineoperators

mmediately



mprove welfare standards Gmonitor

)). *omputer room, computer

table layout improper*hairs not proper re?uirestwisting#fi!ed chair $4isk of upper limb disorderG lower back pain

&

&

<rovide a survival chair

4eassess/ 4eorganise workstation

mprove monitoring /welfarestandards

' week

' week

)=. *hairs in walkway tomanagers cabin%rgonomic risk as twistingre?uired to reach office

1 4emove chairs G relocate

&onitor for reoccurrence

mmediately

)8. 0nsecured gate on west sideadjoining dirty water pond4isk of falls as visitors may be tempted to e!plore

<rovide a lock G lock it off

mprove supervision for nonrecurrence

mmediately

)-. &ain grounds flooringimproper, uneven G wetimproperly laid out1ots of obstructions. oSignage, trip hazards, sliphazards, collision hazard

<rovide a cautious signnform all of hazards4eassess workplace layoutand carry out repairs

Strengthen risk assessment procedures

mmediately

mmediately

= &onth

)9. mproper storage of <<%#stores$ S*32JS stored industy environment

1

1

&

*lean up stores G tidy up

<rovide suitable lockers for<<%

mprove supervision for nonrecurrence

&ake a temporary storagearrangement

mmediately

= months

' ;eek

)7. >ehicle movement and

pedestrian movement o segregation, no layout for parking

&

1

&ark pedestrian layout

Have a proper segregationsystem, planned Gimplemented

<ut up barrier G signs

' week

= &onths

mmediately

practical assessment sample 5 - chemical plant

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