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 and
Safety 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 of
employees an obvious company objective. The site induction I received being both
extensive and through. Other positive signs where the staff Safety notice boards, the
provision of incident reporting sheets in key locations and the proficient fire alarm checks
which took place whilst I was on site. The site itself is clearly signed with respect to
emergency evacuation and restricted areas. The operation of a key card system is also
distinct Health and Safety advantage.
I did, however, make a number of observations (see attached sheets) the majority of
which can be remedied immediately with little or no cost. There were some areas of
concern and one example of extremely dangerous behavior the details of which are
contained on this report.
Details and Recommendations
1. The exposed pipe work at the side of the walkway presents a number of hazards
from trips, to exposure to hazardous substances and must be addressed urgently.
The high visibility kicks/ trip guards already installed work well but all pipes at
ground level should be similarly protected. (ITEMS 1+2)
COST: $ 1500 + IN HOUSE LABOUR
LEGISLATION: Health and Safety at work etc. ACT (1974) Control of
Substances Hazardous to Health (1999)

2. The noise levels within the maintenance area should be checked. I f , as I

Suspect, they are greater than safe exposure levels the noise level needs to be
reduced. Either by engineering controls or, if this is not possible, issue of hearing
protection and the posting of mandatory signage. (ITEM 6)
COST: $ 400 + 4 hrs In-House Training
LEGISLATION: Work place (Health, Safety and Welfare) Regs. (1996)
3. In 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 is
also some damage and the floor in the clean room are altogether unsuitable. A
Plant wide audit should be carried out to correct all flooring problems.
(ITEMS 7+15+3.1)
COST: UPTO $ 100,000 if clean-room floor replaced
LEGISLATION: Health and Safety at work etc. Act (1974)
4. The perimeter fence is in need of repair and should ideally be replaced. This is a
residential area and it is too easy for local children to get on site. Current
controls such as the use of CCTV and security patrols are not a substitute for
prevention. Until this can be carried out all potential dangers such as the pile of
pallets should be removed or secured. The consequences of a bonfire by the
hydrogen bottles are unthinkable. (ITEMS 2.1+2.2)
COST: In excess of $ 100,000, which should be weighed against prosecution and
compensation claims
LEGISLATION: Health and Safety at work etc. Act (1974)
5. Unsafe practice on the workplace is an organizations problem. If safe systems of
works are provided they should be used. However in failing to provide safe
systems the organization is in breach of the law. If technician need to access
machine they should be provided with safe means to do so. (ITEMS 3.3)
COST: Step up stool $ 50
LEGISLATION: Health and Safety at work etc. Act (1974)
Control of substances Hazardous to health (1999)
Personal protective equipment at work Regs (1993)

Conclusion
Although there is much good practice in evidence throughout the plant there are 2 items
of real concern. The ease of access to the plant and employees contravening the safe
systems of work that exist. These matters need to be addressed urgently. The
expenditure required weighed against the potentially unlimited fines and compensation
not to mention serious injury and even loss of life. However encouragement should be
taken from the willingness of all employees to be involved and recognize their
responsibility to site wide health and safety.

ASSESSMENT
Candidates Observation Sheet
Sheet No. 1 to 21
Candidates Name: _______________________

Add Number: ______________

Place inspected: ________________________

Date of Inspection: ______________

No.

Observations
List hazards, unsafe
Practices and good practice

Priority Action to be taken(if any)

/
Risk
List any immediate or
(H,M,L) longer term action required

Timescale
-immediate
-1 week
-monthly, etc

1.

Exposed pipe work at side of

walkway

High visibility kick guards

to be installed

Within 1
month

2.

Broken pipe leading from

Ammonium Hydroxide
Cabinet

Isolate

Immediately

Replace

1 Week

Shield from further damage

As Item 1

3.

Keys left in chem. Cabinet

allowing unauthorized access

Remove to security

Immediately

4.

Labels on Chem. Cabinet

damaged

Replace

Immediately

5.

Bulk Ammonium Hydroxide

Cabinet not identified as to
contents

Identify as other cabs.

Immediately

6.

Noise level in maintenance

area checked

If found to be outside safe

limits a full risk assessment
should be carried out

Within 1
week

7.

Walkway uneven with

several sections sitting
proud

Repair and relay

Within 1
month

Replace as necessary
Prevent heavy traffic

Rollover door open when not

in use___ Contravenes
mandatory sign.
Unauthorized to site

Keep shut

Immediately

Re-educate staff

Immediately

Check if ventilation is
adequate

Within 3
months
(Summer
Approaching)

9.

Water fire extinguisher not

proper identified

Renew stickers

Immediately

10.

Lagging damaged on (Hot)

humidifier pipes

Repair / Replace

1 month

11.

Low overhead pipe work not

highlighted

Erect suspended sign

1 month

Highlight pipes with high

visibility tape

1 month

12.

Dry scrubber power cable

used in coiled condition

Shorten cable

Immediately

13.

Substance leaking from poly

glass tanks

Check substance

Immediately

Clean up

Immediately

Temporary Repair

Immediately

Full Repair

1 month

Provide adequate

1 Week

Storage for ladders

1Week

Re- Train engineers

1W eek

14.

Step ladders lent against high

voltage cables

15.

Doormat Adjacent to fire

door slippy and present a trip
Hazard

Check if mat needed

Immediately

Replace with inset mat

1 Month

16.

Old pallets and combustible

materials stored against skip

Remove

Immediately

17.

Perimeter fence insecure in

places

Renew fencing

3-6 months

18.

Lagging Damaged on reactor

pipes

Replace / Repair

Before reactor
brought back
into service

19.

Unsuitable, Uneven floor

Repair / Relay

1 Month

Replace

3-6 Months

Fit interlocks if accessed

necessary

1 Month

Re-Train staff

Prohibit

Immediately

Provide suitable steps

Immediately

Provide suitable tools

Immediately

20.

21.

Machine doors left Ajar

during operations

Technician climbing onto

open wet bench

ASSESSMENT
Candidates Observation Sheet
Sheet No. 1 to 27
Candidates Name: _______________________

Add Number: ______________

Place inspected: ________________________

Date of Inspection: ______________

No.

Observations
List hazards, unsafe
Practices and good practice

1.

2.

3.

Open electric water in

security cabin mean gas
cylinder (1st floor) Risk of
fire

Scaffolding gaps between

planks too large & not tied
down
Risk of fire

Tool box and equipment laid

out in walkway
Risk of trips & impact injury

Toilet on first floor (office)

Priority Action to be taken(if any)

/
Risk
List any immediate or
(H,M,L) longer term action required

Timescale
-immediate
-1 week
-monthly, etc

Switch off & remove gas

cylinder

1 month

Provide proper store

1 month

Train & monitor for non rec

1 week

Tie up Planks

Month

Train staff, make them aware

of risks

1 week

Revise work organization

1 month

Remove

1 month

Store properly

1 month

Provide a special tool box

room

1 month

Improve house keeping

standard
No action needed

1 month

clean & tidy

Provide a mirror
5

Chair in front of office door

Remove and store away in

proper place

1 month

6.

Combustible material stored

besides stairs
Mixes stuff used engine oil
bottles etc
Risk of
contamination(Biological)

Remove

1 month
1 week

Increase frequency of waste

collection

Open ducks on ground floor

All sick

7.

L
8.

Have a procedure for waste

segregation & supervision
Place a temporary barrier and Immediately
sign

Metal frame gvotruding in

ground floor store room at
the entrance

Analyze function / use of

duct & install a suitable
unmemorable guard
Reorganize stores

Ladder not tied/ secured on

main ground (unused one)

Improve & monitor

housekeeping
Remove & store properly

1 month
Immediately

1 month

Improve supervision

10.

11.

12.

Open manhole on water tank

There is a tripod placed upon
it for training
.
Unmarked liquid containers
stored away
Risk of chemical
contamination

Unhygienic toilet for staff &

water seepage & slippery
floor

Train staff for non recurre

ence
Enquire use & place a sign
(warning)

1 week

Proper identification &

labeling of containers

1 week

Bring chemical storage,

procedures up to standards

1 month

Place a warning sign or

barrier (Do not enter)
prohibiting sign

1 month

Clean up& spray

disinfectant

1 month

Risk of biological
contamination & slips

Train housekeeping staff

Inform them of risk

1 month
Immediately

13.

Classroom Organized & of

adequate width, ventilation

No action required

1 Year

14.

Water facilities
provided(whole some treated
drinking water)

Redecorate as appropriate
No action required

3 months

Proper signs missing in

premises e.g. Main office,
stores etc.

15.

16.

Managers cabin properly laid

out& organized

17.

Computer room, trialing

cable at entrance
Risk of trips& fall
Electrical main fuse box and
breakers not guarded, water
spraying in small quantities
from above & scattered
wiring.
Risk of short circuits and fire

18.

I
I

L
19

20

21.

Machine area no guard fitted

on moving parts of motors
Risk of cuts, entangle ment
& contact enjury machine in
off position

I
M

Open water tank(large) with

dirty water
Risk of biological
contamination

No PPE for machine

operators

Provide a top cover for

sheltering from sun
Provide adequate signs first
for important areas and
continue
Improve monitoring process
No action needed
Provide a curtain (light
colored)
Remove & tie up cables
Inform staff of hazards &
monitor for non recurrence
Stop flow of water from
above

1 month

3 month
Immediately
Immediately

Provide a warning sign

Danger

Immediately

Reassess location and

provide a fixed guarding
system with locking facility
Monitor
Inform staff of hazards
Do not switch on until a
temporary guarding
arrangement is made

1 Month

Review/reassess work
organization and improve
standards
Provide a barrier & warning
Sign (Do not use )
Disinfect water & monitor
for non recurrence
Provides gloves for machine
operators

Immediately
1 Week

Immediately
Immediately

Immediately

22.

23.

24.

25.

26.

Computer room, computer

table layout improper
Chairs not proper requires
twisting(fixed chair )
Risk of upper limb disorder
& lower back pain

Chairs in walkway to
managers cabin
Ergonomic risk as twisting
required to reach office
Unsecured gate on west side
adjoining dirty water pond
Risk of falls as visitors may
be tempted to explore
Main grounds flooring
improper, uneven & wet
improperly laid out
Lots of obstructions. No
Signage, trip hazards, slip
hazards, collision hazard

Improper storage of PPE

(stores) SCBAS stored in
dusty environment

Improve welfare standards &

monitor
Provide a survival chair
Reassess/ Reorganise work
station

1 week
1 week

Improve monitoring /welfare

standards
Remove chairs & relocate

Immediately

Monitor for reoccurrence

I

I
I

Provide a lock & lock it off

Improve supervision for non
recurrence
Provide a cautious sign
Inform all of hazards
Reassess workplace layout
and carry out repairs

Immediately

Immediately
Immediately

Strengthen risk assessment

procedures
Clean up stores & tidy up

3 Month

Provide suitable lockers for

PPE

3 months

Immediately

Improve supervision for non

recurrence
M
27.

Vehicle movement and

pedestrian movement
No segregation, no layout for
parking

Make a temporary storage

arrangement
Mark pedestrian layout

1 Week

Have a proper segregation

system, planned &
implemented

3 Months

Put up barrier & signs

Immediately

1 week