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S.

NO

THA for Soap Centrifuge Particulars 1 Lye feeding & start of CF 2 CF shut down 3 Soap Conditioning for CF 4 Oening of CF for mud Cleaning 5 Assembling of CF

SN

SEQUENCE OF BASIC STEPS

HAZARD / PERSON AT RISK

POTENTIAL EXISTING CONTROL AND HARM SAFE PROCEDURES

EVALUATION OF RISK S
4

L
2

R
8

ACTION & ADDITIONAL CONTROLS

11 12 13 14 15 16 17 18

Open steam valves to clear the oil line to weigh tank tops and after complete cleaning close the steam Pressurised steam, Operator Minor injury valve. Finally close all relevant valves in the oil inlet line. Hot oil, one person. Repeat step 1 - 11 for other grades of oils for blending Set the outlet of the weigh tank in such a way that Hot oil, Operator the oil can be re-circulated. Start the pump and continue re-circulation for 1 Electric shock, Operator hours. Close the outlet of the weigh tank. Blow steam through the re-circulation line. Close all relevant valves. Hot oil, operator Minor injury LTA.

Helmet,Hand gloves,goggles

Helmet,Hand gloves,goggles

4

2

8

Helmet,Hand gloves,goggles Visual Earthling ,Rubber Hand gloves Helmet,Hand gloves,goggles Helmet,Hand gloves,goggles Helmet,Hand gloves,goggles

4

2

8 Routine checking of the switchboards to ensure that no water can enter.

Fatality Minor injury

8 4 6 4

2 2 2 2

16 8 12 8

Pressurised steam, Operator Major injury Hot oil, operator Minor injury

Environmental Control: Regular check up of pipe, tank and valve condition Multiple fat trap Operator presence during oil transfer. Consumer Safety: . Isolated from toilet circuit

Safety Control: Hand Gloves Gum boots Visor Helmets

Reviewed by:Zia Uddin,Robiul,Shahadate Date :09/03/2008

Bleaching:
SN SEQUENCE OF BASIC STEPS HAZARD / PERSON AT RISK POTENTIAL HARM EXISTING CONTROL AND SAFE PROCEDURES
Lather hand gloves,Helmet,Goggles Lather hand gloves,Helmet,Goggles

EVALUATION OF RISK S
4

L
2

R
2

28 29 30 31 32 33

Continue heating until the oil has reached a temperature of 105 oC & continue bleaching upto 30 minutes at 105 deg. C

steam, operator.

Major injury

Close the steam inlet valve to the heating / cooling coils. steam, operator.

Major injury

4

2

8

Open the water inlet valve to the heating /cooling coils.

No hazards identified. Lather hand gloves,Helmet,Goggles Lather hand gloves, Helmet,Goggles Lather hand gloves, Helmet,Goggles

Allow the hot condensate to pass from the system. Close the condensate outlet from the heating /cooling coils. Open the water outlet valve from the heating / cooling coils.

steam, operator. Hot condensate, one person. Hot condensate, one person.

Major injury Major injury Major injury

4 4 4

2 2 2

8 16 16

Break Vacuum:
35 36 37 38 39 40 41
Stop the liquid ring mazda vacuum pump. Open the bleaching vessel vacuum breaker valve. Leakage, electric shock. No hazards identified. Air,Hot oil,slippery Hot oil,operator Electrical shock,operator Major Injury Major Injury Fatality Lather hand gloves,Helmet,Goggles Lather hand gloves,Helmet,Goggles Physical Earthling 4 4 8 2 2 1 8 8 16 Fatality Physical Earthling 8 1 16

Line setting from bleacher to buffer tank & checking with air from the bottom of bleacher Open the bottom valve of bleacher Switch on the transferring pump to buffer tank Start the vacum pump & line setting to buffer tank

Electrical shock,operator

Fatality

Physical Earthling

8

1

8

Start the agitator motor of buffer tank

Electrical shock,operator

Fatality

Physical Earthling

8

1

8

Environmental Control: Regular check up of pipe, vessel and valve condition Multiple fat trap Operator presence during operation.

Safety Control: Hand Gloves Visor Helmets

Consumer Safety:

Goggles

ACTION & ADDITIONAL CONTROLS

Routine checking of the switchboards to ensure that no water can enter. Industrial Switch and switch board earthing

Routine checking of the switchboards to ensure that no water can enter. Industrial Switch and switch board earthing Routine checking of the switchboards to ensure that no water can enter. Industrial Switch and switch board earthing Routine checking of the switchboards to ensure that no water can enter. Industrial Switch and switch board earthing

TASK BASED RISK ASSESSMENT RECORD FORM TASK NO A-37
DATE OF PREP April,2008 PREPARED BY M. Probeer,Ziauddin, Shahadat, Ashoke kumar Nandi POTENTIAL HARM Single death. minor burn injury Minor injury. Minor injury.

TASK NAME Leaf Filter Operation
REVISION NO DATE OF REVISION June,2009 EXISTING CONTROL AND SAFE PROCEDURES Use of Safety shoes,Rubber handgloves.Double earthing system. Trained operator. Use of Hand Gloves Standard spanners used. Trained operator.use hand gloves,Helmet Standard spanners used. Trained operator.use hand gloves,Helmet Trained operator. Use of Hand Gloves Standard spanners used. Trained operator.use hand gloves,Helmet Trained operator. Use of Hand Gloves Trained operator. Use of Hand Gloves Trained operator,use of goggles,handgloves Use of Safety shoes,Rubber handgloves.Double earthing system. Trained operator,use of goggles,handgloves Trained operator,use of goggles,handgloves Trained operator. Standard collector REVIEWED BY Sahadat,Hashim Hasnat,Murshidul,SA khan,Zia,Pulak
EVALUATION OF RISK

SN

SEQUENCE OF BASIC STEPS If the pressure around 4 bar then stop the feed pump Close the filter inlet valve Open the steam valve slowly.

HAZARD / PERSON AT RISK Electrical shock ( operator) Contact with hot oil .(Operator ) Steam leakage thru glands, (Operator)

S 8 2 2 2

L 2 4 4 4

R 16 8 8 8

ACTION & ADDITIONAL CONTROLS Provide rubber sheet foot insulating mat at standing position around ON / OFF panel.

14 15 16 17 18 19 20 21 22 23 24 25 26

Periodic maintenance of steam valves Periodic maintenance of steam valves & PSV of the plant

Continue steaming and collect oil to bleached oil Steam leakage thru glands, tank & buffer tank (depending on colour & moisture (Operator) condition) If colour & moisture appears much then transfer oil to dirty oil tank & drain the bottom contents to Contact with hot oil .(Operator ) bleacher If steam apperas in outlet header then open the cyclone valve & partially close the dirty oil valve Spanner slippage. operator )

minor burn injury Minor injury. minor burn injury minor burn injury minor injury Single death. minor injury LTA minor burn injury

2 2 4 2 2 8 4 4 2

4 4 2 4 4 2 2 2 4

8 8 8 8 8 16 8 8 8 maximum air supply 6 kg/cm2,Ensure clean & dry air Provide rubber sheet foot insulating mat at standing position around ON / OFF panel. maximum air supply 6 kg/cm2,Ensure clean & dry air maximum air supply 6 kg/cm2,Ensure clean & dry air Water spray by opening water valve before sample collection

when the drain will be completed then close the valve through bleacher.After this partially open the Contact with hot oil .(Operator ) dirty oil tank valve. When side glass of outlet header is clear then close Contact with hot oil .(Operator ) the steam valve & wait for pressure dropping. Open the air valve for butterfly valve opening Swith on for buetterfly valve opening Open the air valve very quickly for vibrator. Pressurized air,(Operator) Electrical shock ( operator) Pressurized air,(Operator)

Close the air valve for vibrator after removing spent Pressurized air,(Operator) earth from leaf filter. Collect sample of spent earth for Lab analysis Hot earth.(Operator)

Environmental Control: NA Consumer Safety:

Process Control:

NA
Quality Control: N/A Occupational Health and safety control: Proper tools and stair

NA
Safety Control: Hand Gloves Visor Helmet

26177875.xls

TASK BASED RISK ASSESSMENT RECORD FORM TASK NO A-38
DATE OF PREP April,2008 PREPARED BY M. Probeer,Ziauddin, Shahadat, Ashoke kumar Nandi

TASK NAME Starting & Closing of Leaf Filter
REVISION NO DATE OF REVISION June,2009 REVIEWED BY Shahadat,Hashim Hasnat,Murshidul,SA khan,Zia,Pulak EVALUATION OF RISK S Nil 8 2 L Nil 2 2 R Nil 16 4 Use of rubber mate,Trained fitter

SN 1 2 3 4

SEQUENCE OF BASIC STEPS PTW for the job. Isolate feed pump

HAZARD / PERSON AT RISK

POTENTIAL HARM

EXISTING CONTROL AND SAFE PROCEDURES No Use of PPE,Double Earthing system Trained Fitter. Use of proper spanner. Use of Hand gloves. No

ACTION & ADDITIONAL CONTROLS

No hazard No hazard Electrical shock. Electricians. Single death Brouse on hand No hazard

Islolate,air, steam,oils charge line Spanner slippage. fitters. Check the condition of vassel (Zero pressure on guage),Ambient temp. Open the lock nuts of top cover,lift the cover thru jack Turn the cover Open the vibrator assemble Lift the top shaft with spacer No hazard

Nil Heavy object hit. fitters. Major injury Heavy object. fitters. Spanner slippage. fitters. Spanner slippage. fitters. Major injury Brouse on hand Brouse on hand Brouse on hand Minor injury Brouse on hand Brouse on hand Brouse on hand Burn injury Trained Fitter. Use of Hand gloves. Trained Fitter. Use of Hand gloves. Trained Fitter. Use of Hand gloves. Trained Fitter. Use of Hand gloves. Trained Fitter. Use of Hand gloves. Trained fitter. Trained Fitter. Use of Hand gloves. Trained Fitter. Use of Hand gloves. Trained Fitter. Use of Hand gloves. Trained fitter,Use of PPE

Nil

Nil Do not move under suspended load

5

4 8 2 2 8 4 2 2 2 4

2 2 2 2 2 2 2 2 2 2

8 16 4 4 Arrange to provide lead hammer as mentioned in 16 manual. 8 4 4 4 8 Arrange to provide proper platform for the job. Arrange to provide proper platform for the job. Arrange to provide proper platform for the job. Do not move under suspended load

6 7 8 9 10 11 12 13 14

Lift the leaf one by one thru chain Leaf slippage. fitters. block Fix the leaf one by one with cahin Fall down. block safely. (Contractual fitter) Fall down. fitters Fix the top shaft and spacer Fix the vibrator assembly Close the top cover,tighting the nut & bolt Open air,steam & oil line Environmental Control: NA Consumer Safety: NA Safety Control: Hand Gloves Visor Helmet Fall down. fitters Spanner slippage. fitters. Pressurized air,steam,Hot oil,Fitter

Process Control: NA Quality Control: N/A Occupational Health and safety control: Proper tools and stair