GC3 THE HEALTH AND Candidates observation
SAFETY PRACTICAL APPLICATION sheet
Sheet number 1 of ___9__
Student name Shahzeb Tariq ________________________ Student number 00389881 __________
Place inspected Etihad Sugar Mills ltd. Rahim yar Khan Date of inspection 25 /05 /2017
Observations Control measures Timescale
Hazards and consequences Immediate and longer term actions
1. Near clarifiers naked wires Immediate action:
of a portable drill were Use of plug and cover exposed part of 1 day
being plugged in to a socket cable
instead of using a plug.it
can Cause sparking and Mid Term action:
electrical shock on contact Regular Inspection and maintenance of
electrical equipment and cables. 2 weeks
resulting in skin burns,
muscle cramps, heart
Long Term action:
fibrillation, involuntary Provide information instruction and
muscle grip and cardiac training to workers and use of RCDs and
arrest. earthing to prevent electrical shock to 1 month
users.
Immediate action:
Stop the job. Remove the cylinders from immediate
2. Welding work was being
carried out near compressed area to proper storage.
gas cylinders. Burning
Mid-term action:
embers from welding could 2 weeks
Fire watcher to be present in area of hot
result in fire and explosion work and adequate fire extinguishing
causing damage to plant, equipment must be available.
workers and equipment.
Long-Term action:
Develop Safe systems for hot work and
train the staff regarding the procedure. 1 month
Purpose built storage area for Cylinders.
Immediate action:
Operate machine according to its design 1 day
3. Centrifugal machine operator capacity to reduce vibration
was exposed to high vibration
of machine because of feed Intermediate action:
Job rotation and frequent breaks to 3 weeks
overload. It can cause hand
arm vibration syndrome and reduce time of exposure.
whole body vibration syndrome.
Long-term action:
Setup an inspection and maintenance 1 month
regime for all machines being used at
plant.
GC3 THE HEALTH AND Candidates observation
SAFETY PRACTICAL APPLICATION sheet
Sheet number 2 of ___9__
Student name Shahzeb Tariq ________________________ Student number 00389881 _________
Place inspected Etihad Sugar Mills ltd. Rahim yar Khan Date of inspection 25 /05 /2017
Observations Control measures Timescale
Hazards and consequences Immediate and longer term actions
4. Globe valve was lying on an Immediate action: immediate
unprotected edge of crystallizer Transfer the valve, to a safe place.
platform and could fall on Barricade the area underneath.
someone working or passing
under the platform resulting in Intermediate action:
head injury, bruises and other Conduct a thorough inspection of entire 1 week
physical injuries. plant to for similar hazards and general
housekeeping arrangements.
Long-term action:
Provide toe boards and brick guards on 1 month
such platform to avoid objects falling
down.
5. Dismantled electrical panel and
cables were lying on the floor Immediate action:
unattended and without any Safely remove cables in form of a bundle. Immediate
signs. Tripping over the
cables/panel would result in Intermediate action:
bruises, cuts, broken bones. Place warning signs and barriers around 1 day
dismantling work to highlight the hazard.
Long-term action:
Inspection and scheduling of dismantling
of panels after peak hours to reduce 2 weeks
contact with cables/panels.
6. Worker unbolting a feed line
valve of a centrifugal machine
while standing near an Immediate action:
unprotected edge at height Stop the work, provide PPEs to workers
without any PPEs. and strictly instruct them to work safely. 1 Day
Intermediate action:
Proper work platform with guard rails and
toe-boards to be provided. 2 Weeks
Long-term action:
Train workers regarding safe work at
height and importance of using fall
protection equipment. 1 Month
GC3 THE HEALTH AND Candidates observation
SAFETY PRACTICAL APPLICATION sheet
Sheet number 3 of __9___
Student name Shahzeb Tariq ________________________ Student number 00389881 _________
Place inspected Etihad Sugar Mills ltd. Rahim yar Khan Date of inspection 25 /05 /2017
Observations Control measures Timescale
Hazards and consequences Immediate and longer term actions
7. Floor was being washed with Immediate action:
water in refine sugar area, Stop the work. immediate
using water pipes/hoses, Barricade the wet area before resuming.
causing slip and trip hazards.
This could result in personal Intermediate action:
injury such as bruises, cuts, Provide slip resistant footwear to workers. 1 week
broken bones and in some Who are required at work in wet zones.
cases serious personal injuries
such as disc slippage. Long-term action: 1 Month
Slip resistant floor tiles and cleaning work
to be scheduled after peak work hours.
8. Workers were observed Immediate action:
grinding a chute near bagasse Stop activity and perform grinding away immediate
elevator carrying bagasse from Bagasse source.
which is used in boiler as a fuel.
Burning Embers from grinding Intermediate action:
can cause fire with possible Fire watcher with fire extinguishing 5 Days
damage to plant, equipment equipment must be present near hot
and injury to workers. work.
Long-term action:
Develop a permit to work system for hot 1 month
works.
Routine inspection and maintenance of
fire extinguishers.
9. Foul tubes of evaporators were Immediate action: 1 day
being cleaned using Provide rest frequent rest breaks to
mechanical brushes the reduce increased damage.
activity involved stooping and
reaching out for long periods of Intermediate action: 4 days
time which can cause handling Develop a system of job rotations.
injuries such as muscle strain,
back pain, tendons and tissue Long-term action:
damage. Mechanize the cleaning of tubes to 2 Months.
eliminate the hazard.
GC3 THE HEALTH AND Candidates observation
SAFETY PRACTICAL APPLICATION sheet
Sheet number 4 of ___9__
Student name Shahzeb Tariq ________________________ Student number 00389881 _________
Place inspected Etihad Sugar Mills ltd. Rahim yar Khan Date of inspection 25 /05 /2017
Observations Control measures Timescale
Hazards and consequences Immediate and longer term actions
Immediate action:
10. Steam flashing from storage Provide rest breaks to worker near 1 day
tanks at various locations in storage areas.
process area results in
increased temperature and Intermediate action:
affect the efficiency of workers. Use of isotonic drinks and PPEs to
It can also result in skin reduce contact with steam vapors. 2 days
rashers, burns, headaches,
dehydration and muscle Long-term action:
cramps. Cover open storage tanks and provide
cool refuges to escape from heat. 1 month.
11. Sugar graders are used to Immediate action: 1 day
separate sugar crystals of Provision of rest breaks and PPEs.
different sizes. Workers were
exposed to sugar dust from Intermediate action:
graders. It can cause health Damping down the dust with portable 1 week
effects such as irritation to sprinklers.
eyes, nose, redness of eyes
and repeated skin contact can Long-term action:
cause dermatitis. It can also Local exhaust ventilation system on 2 months
cause breathing difficulties. graders for removal of dust
Immediate action: immediate
12. Centrifugal machines were Provide rest breaks and frequent job
used to separate sugar from rotations to worker
Massecuite. Operators were Ear plugs must be provided.
exposed to loud noise from
centrifugal machines due to Intermediate action: 3 days
loose parts. It can cause Damping down noise by stiffening,
temporary hearing loss, repairing or changing the loose parts.
temporary ringing in ears, NIHL
and Tinnitus after prolonged Long-term action: 3 weeks.
exposure. Routine inspection and maintenance
programme of machines according to
manufacturers recommendations.
Acoustic havens can be provided.
GC3 THE HEALTH AND Candidates observation
SAFETY PRACTICAL APPLICATION sheet
Sheet number 5 of ___9__
Student name Shahzeb Tariq ________________________ Student number 00389881 _________
Place inspected Etihad Sugar Mills ltd. Rahim yar Khan Date of inspection 25 /05/2017
Observations Control measures Timescale
Hazards and consequences Immediate and longer term actions
13. In process house workers were Immediate action: 1 day
often subject to manual Divide load in to small parts and rest
handling. This included pushing breaks.
and pulling of loads and jerry
cans without any mechanical Intermediate action:
assistance. It can cause back Provision of mechanical aids to reduce 1 week
pain, disc dislocation, muscle force required to perform job.
and tissue damage, hernias
and cuts, bruises due to sharp Long-term action:
edges. Mechanise by using pulleys and hoists to
transfer cans and bags. 1 month
14. Steam vapours from mixers Immediate action:
placed on ground floor rise and Cleaning of stairs two or more times a 1 day
condense on stairs in form of day and general housekeeping.
mist in process area which can
result in slipping and falling Intermediate action: 1 week
from stairs.it can cause serious Use of hazard signs and provision of slip
physical injuries such as head resistant shoes.
fracture, broken bones and in
instances death. Long-term action: 1 month
Cover remelters stop escape of vapours
and line stairs with slip resistant material.
15. . Continuous evaporation and . Immediate action: 1 day
boiling causing worker Rest breaks and cool drinks for workers.
exposure to high temperature
in area near evaporators which
can cause dehydration, fatigue, Intermediate action:
drowsiness and muscle Cool refuges and proper workplace 1 week
cramps, and skin redness ventilation to reduce temperature.
Long-term action:
Shielding and insulation must be done of 2 months.
more premium quality to reduce heat
radiation from evaporator shell.
GC3 THE HEALTH AND Candidates observation
SAFETY PRACTICAL APPLICATION sheet
Sheet number 6 of ___9__
Student name Shahzeb Tariq ________________________ Student number 00389881 _________
Place inspected Etihad Sugar Mills ltd. Rahim yar Khan Date of inspection 25 /05 /2017
Observations Control measures Timescale
Hazards and consequences Immediate and longer term actions
16. In an electrical panel room Immediate action: 1 day.
damaged cable from a pedestal Stop fan and repair the damaged cord.
fan was lying on floor. It could
result in electric shock and Intermediate action: 2 weeks
electric burns on contact. Ensure visual inspection and
Which can cause heart maintenance of all portables appliances
fibrillation, muscle cramp, before use.
involuntary muscle grip and
secondary injuries such as fall Long-term action: 1 month.
on ground. Set up a regime for portable appliance
testing and frequent inspections of old
17. Steam pipe lagging material equipment.
containing asbestos was lying
unattended behind evaporators Immediate action:
which can cause dermatitis, Signage and barriers around area
trouble breathing and other containing asbestos. 1 Day
serious health effects are lung Restrict access, provision of RPE.
cancer and asbestosis.
Intermediate action:
Purpose built storage of asbestos and 3 weeks.
safe handling methods.
Long-term action:
Disposal of asbestos which is not 40 days.
required and provision of health
surveillance of workers.
18. Air conditioning and seating
arrangement in DCS control
room was of good standard Continue and maintain
with frequent rest breaks for On-going.
users.
GC3 THE HEALTH AND Candidates observation
SAFETY PRACTICAL APPLICATION sheet
Sheet number 7 of __9___
Student name Shahzeb Tariq ________________________ Student number 00389881 _________
Place inspected Etihad Sugar Mills ltd. Rahim yar Khan Date of inspection 25 /05/2017
Observations Control measures Timescale
Hazards and consequences Immediate and longer term actions
19. Conveyer belts were being Immediate action: 2 days
used to transport bags from Guardrails and barriers on sides of
process area to warehouse and conveyer.
then hand lifted from belts.
There is a risk of drawing in at Intermediate action:
in-running nip-points on belt. It Instruction and training to workers about 1 week
can cause Bruises, abrasion hazards of conveyer belt and
and amputation. precautions.
Signage and prohibit loose clothing near
belts.
Long-term action: 1 month
Trip devices such as pressure mats and
trip bars to automatically turn off the
system in the presence of people.
20. Bags used to fill sugar crystals Immediate action:
are sewed manually with the Frequent short rest breaks. 1 Day
help of machines. Workers
sewing bags are subjected to Intermediate action:
prolonged repetitive movement Reduce working hours and job rotations.
of hands. This can cause 1 week
fatigue back pain, headaches, Long-term action:
WRULDs such as tennis elbow. Mechanise the sewing process by
automated machines. 2 months.
21. Tubes cleaning steel shafts use
to clean evaporators were lying Immediate action:
down on the floor without any Barriers around shafts and proper 1 Day
barriers or signs. This can signage.
cause trip hazard resulting in
bruises, cuts and broken Intermediate action:
bones. Storage of shafts under storage sheds
with signs. 3 Days
Long-term action:
General workplace inspection and
housekeeping routines. 2 weeks
GC3 THE HEALTH AND Candidates observation
SAFETY PRACTICAL APPLICATION sheet
Sheet number 8 of __9___
Student name Shahzeb Tariq ________________________ Student number 00389881 _________
Place inspected Etihad Sugar Mills ltd. Rahim yar Khan Date of inspection 25 /05 /2017
Observations Control measures Timescale
Hazards and consequences Immediate and longer term actions
22. Sufficient number of Toilets and Good practice to be maintained On-going
washroom were available for
workers with proper lighting and
cleaning routines.
23. Cooling towers are used to cool Immediate action:
waters from process house and Avoid storage of water between 20 and 2 days.
then reused for generating 40 degrees centigrade in ponds.
vacuum in pans. This water is
stored in large ponds. Intermediate action:
Legionella bacteria are cultured Use minimum quantities of water and 1 week
between 20 and 40 degree water analysis for signs of bacteria.
Centigrade and can cause
muscle pain, fever, headache, Long-term action:
dengue and pneumonia. Routine cleaning of ponds, equipment 1 month
and water distribution lines.
Chemical treatment schedule to be
developed.
Immediate action:
24. Forklifts and pedestrians have Warning signs and speed limit near 1 day
same access and egress entrance.
routes in warehouse and there
is increased risk of collision Intermediate action:
with pedestrians. This can Proper lighting weeks
cause serious physical injuries High visibility clothing and reversing
to both driver and pedestrians. alarms.
Install speed limiters in FLTs.
Long-term action: 1 month
Designated pathways and separate
access and egress routes.
GC3 THE HEALTH AND Candidates observation
SAFETY PRACTICAL APPLICATION sheet
Sheet number 9 of __9___
Student name Shahzeb Tariq ________________________ Student number 00389881 _________
Place inspected Etihad Sugar Mills ltd. Rahim yar Khan Date of inspection 25 /05 /2017
Observations Control measures Timescale
Hazards and consequences Immediate and longer term actions
Workers eating food near working area Immediate action:
without washing hands this can cause Make hand washing routines compulsory 2 days.
bacterial and viral diseases such as and prohibit eating in work areas.
hepatitis from viruses. Provision of sanitizers and hand washing
facilities
Intermediate action: 1 week
Information instruction and training to
workers about personal health care and
hygienic environment
Long-term action: 2 months
Provide health surveillance to workers.
Provision of canteen and cafeteria mess.
