Control Measures

Item
01
01
Observation
Hazards and Consequences
Control Measures
Immediate/longer term action
Observation:
Immediate action:
Worker was working in the

hazardous Chemical area.
Provide PPE to the workers
Time Scale
Immediate
Short term:
Hazard & Consequences:
Health surveillance
Chemicals hazard, i.e, Calcium
Carbonate, Hydro-Chloric Acid,
Calcium Chloride, coal and
Flocculent.
One week
Long Term:
Exposure limit to chemical will
decrease by job rotation.
Regularly
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.
03
02
Observation
Immediate action:
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.
On urgent basis clean the floor

clean and keep it clean all the
time.

Slip hazards, collision hazards
between forklift and pedestrian and
forklift with fixed structure.
Can cause severe injury to
pedestrian or damaging of forklift
truck.
Immediate
Short term:
One week
Ensure proper housekeeping of
the Workplace on daily basis.
Long Term:
Regular
Monitor and check workplace
regularly. Make employees aware
of the hazards by providing
information and training.
Item
03
04
Observation
Control Measures
Observation
Immediate action:
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.
Provide signages stop , speed

limit 5 km
Long Term:
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 separate entry & exit

routes with solid partition in
between pedestrian and vehicle.
Observation
Immediate action:
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.
Install adequate lighting within

the Workplace so that people can
able to see any hazards.

Trip and slip hazards
Due to slip or trip, a severe injury
can be happened.
Time Scale
Immediate
Short term:
Segregate the area for vehicles &
pedestrians by barriers
Two Days
One Week
Immediate
Short term:
Use natural lights such as roof
lights, Where natural light is not
satisfactory. Use artificial lighting.
Two Days
Long Term:
Periodic maintenance and
inspections of artificial lighting
and replacing them from time to
time.
Ongoing
Item
05
Observation
Control Measures
Observation
Immediate action:
Blowers were creating a large noisy

sound during Operation.
Minimise work exposure limit
Time Scale
Immediate
Short term:
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).
06
Two Days
Fit sound-proof enclosure,
Acoustic shielding. Fit silencers,
balance machine, or mount on
anti-vibration mountings.
One Week
Long Term:
Eliminate/ Substitute with less
noise blower.
Observation
Immediate action:
Calcium Chloride dust was coming

out from many damaged or leaked
lines, from fine collector and from
dust blower.
Welding of the lines those have

leakages.
Replace the lines those are too

much damaged with new lines.
Immediate
Short term:
Two Days
Dust hazard.
Calcium Chloride Power
Long Term:
Irritant, Causes irritation to skin, eyes
and respiratory organs. Harmful if
Keep routine monitoring and
inhaled or swallowed. Effects can be inspection of the lines
possible coughing, sneezing, asthma
and blocked filters of machines.
07
Observation
Immediate action:
Worker was working in the carpenter

workshop to form wooden material
for pallet formation.
Provide PPE to the worker.
Provide safeguard to the sander.
Contact Hazards
Regularly
Immediate
Long Term:
One Week
Can cause injury to worker

Item
08
Observation
Control Measures
Observation
Immediate action:
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.
Provide job rotation with other

riggers
Short term:
Time Scale
Immediate
One Day
Provide trolley
Long Term:
Manual Handling,
Can cause back bone problem, slip
disc issue, Hernia, can cause
musculoskeletal disorders (MSDs).
09
Observation
Employee using hand drill machine
with broken handle & corroded flex
Electrical hazard
Electric shock, Fire & explosion
Hand vibration syndrome, Noise
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
One Week
Install conveyer from heap of

lime to lime tank.
Immediate action:
Repair the handle & change the
flex
Immediate
Short term:
Inform the maintenance staff to
do the pre use check before
using electrical equipments
Daily
Long Term:
Conduct monthly inspection of all
electrical equipments & repair if
needed.
Immediate action:
Immediately barricade the open
points.
Short term:
Close the open points by sanitary
work or by keeping covers made
of any material
1 Week
Immediate
Two Days
Long Term:
One Week
Erect proper and good sewage
drain system & properly out of

passage area.
Item
11
Observation
Observation
Observed one employee sitting in
office in odd posture in front of
computer
Ergonomic Hazard,
WRULD, Eyes strain, Back pain,
Cervical spondylosis
Control Measures
Immediate action:
Provide frequent breaks
Short term:
Make the assessment of
workplace to provide standard
DSE arrangements to suit the
worker.
Long Term:
Time Scale
Immediate
One day
One Week
Provide DSE instead of

Computer.
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.
13
Observation
There were no proper washing areas
for workers.
Biological Hazard.
Biological hazards due to poor
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:
Following good hygiene practices.
Short Term:
Training to employees and give
them information about personal
hygiene.
Immediate
Two days
Ongoing
Immediate
One Day
personal hygiene can cause health

problems such as infections and
diseases.
Item
14
Observation
Long Term:
Build up a washing area for
workers nearby workers
changing room/ locker area and
provide proper ventilation
system.
Control Measures
Observation
Immediate:
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.
Provide PPE to the worker and

shower water in the leakage point
to avoid from fumes.

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.
One Week
Time Scale
Immediate
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.
Two days
Long Term:
One Week
Shift acid storage tanks to away
from the workplace and with
strong foundation and proper
fumes collection system.
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.
Item
16
Observation
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:
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.
Immediate
One day
Short Term:
Adopting good hygiene practices.
Minimize the frequency and
duration of
Being exposed to mist.
One week
Long Term
Provide mist collector or mist
absorber at the discharge of
scrubber.
Control Measures
Time Scale
Immediate:
Provide awareness to every
worker at workplace about it. And
provide personal protective
equipments
Short Term:
Immediate
Two Day
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.
One Week
17
Observation
Immediate:
Trailing Cables were laid down on

the floor and leading to the panel of
welding work.
Secure
trailing
cables
left
unattended on the floor surfaces.
remove
Obstructions in the walkway.
Immediate
Short Term:
Two days

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

the
Workplace on daily basis. Make
plans to reroute electrical cables.
7 Days
Long Term:
Monitor and check cables. make
employees aware of the hazards
by
Providing instructions and
supervision.
Item
18
Observation
Observation
Few fire extinguishers are empty.
This can cause delay while
extinguishing fire during any fire
emergency.
Control Measures
Time Scale
Immediate:
Inspection of all fire
extinguishers,
Immediate
Short Term:
Replace empty fire extinguisher
with new fire extinguisher.
Two days

Long Term:
19
Discipline Hazards.
Can increase the severity of
accident.
One Week
Indent new fire extinguishers.
Observation
Immediate:
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.
Rigger should be present at the

worksite all the time during lifting
process; tag line should be
attached with the suspended load
to control.
Immediatel
y
Short Term:
All personnel should be trained
for lifting safety process.
one Week
Proper lifting practice should be

prepared and should be followed
by all personnel.
Long Term:
Item
20
Observation
Monitor lifting activities regularly.
Regular
Control Measures
Time Scale
Observation
Immediate:
Duct was cracked so scaffolding

work was carried out to maintenance
work on duct between prill tower and
cyclone.
Fixed the guard rail & toe board
Immediate
Short Term:
Scaffold training (erection &
dismantling )
Substandard scaffolding guard rail & Long Term:

toe board are missing which will
allow the workers, tools or material to Strict monitoring & supervision of
fall from height thereby seriously
scaffolding operation.
injuring the other workers.
One Week
Regular
21
Observation:
Immediate:
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.
Making people aware of the

hazard.
Providing
personal
protective equipments such as
safety goggles to protect against
ultra violet radiations emitted.
Short Term:
Risk of inhaling welding fumes which

can cause the disease known as blue
metal fever and high temperatures
during welding activity can cause
burns.
Redesign the workplace and

ensure sufficient ventilation to
avoid the danger of inhaling
welding fumes
Immediate
One day
Long Term:
One week
Install local exhaust ventilation to

eliminate
the
possibility of
breathing welding fumes.
Item
Observation
Control Measures
Time Scale
22
Observation:
Immediate:
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.
Provision of adequate welfare

facilities such as drinking water.
Providing refugees and moderate
environment to worker after
coming out that heated confined
space.
Immediate
Short Term:
Three days
Install strainer in the feed line, if

any blockage piece came in feed
line can remove outside the Prill
Environment Hazard and confined

space hazard.
May cause heat exhaustion and heat
stroke.
or drying tower to provide safe

work system to worker.
One week
Long Term:
Install camera inside the Prill or
drying tower to watch the fluidized
bed height and condition of
spoilage or non spoilage.
23
Observation:
Immediate:
Excavation work was carried out for

the installing new ID fan blower in
the coal furnace plant. And area was
not barricade.
Use stop blocks to prevent

vehicles
Overrunning. Barriers and signs
to
Prevent people falling into
excavations.
Immediate
One day
Falling Hazard
Risk of people, material and Short Term:
equipments
falling
into
the
excavations and the possible results Organizing
a
good
traffic
could be fatalities.
management system in place.
Traffic routes should be clearly
marked.
One week
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.
Item
Observation
Control Measures
Time Scale
24
Observation:
Immediate:
The electrical system in the main The electrical system should be

electrical panel room was open & always locked & secured
unattended
Immediate
Lock out tag out procedure should

be used in case of any
maintenance or troubleshooting
Fire & explosion

Electrocution
Short circuit
It should be under control of

permit to work system
Observation:
Immediate:
To install filter pressure in the

chemical area, the construction work
was under progress and worker was
using drill machine.
Provide Gloves to the worker
25
Immediate
Short Term:
Provide training and supervision
One Week

Vibration Hazard
Hand arm vibration syndrome,
numbness and blanching of fingers,
reduction in the dexterity
Long Term:
Observation:
Immediate:
Worker was smoking in the

warehouse of fuel storage.
Place prohibition sign for no

smoking
Short Term:
Fire hazard and discipline hazard.

Result in severe injuries and
property damage
Provide training and supervision

to the employees
Provide job rotation after intervals
Regular
26
Immediate
One day
Long Term:
one week
Install smoke detector in the
warehouse
The Travancore-Cochin Chemicals Ltd

Udyogamandal P.O.
Kochi 683 501, India
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.

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.

practice.
Keep up
Drinking water filters changed after

regular intervals is a good practice to maintain
good health of employees.

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.

practice.
Keep up
Canteen was near to rest rooms and

well maintains and comfort and cleaned and
hygienic foods were provided.

practice.
Keep up
Introduction
This inspection was done at Travancore Cochin chemicals, Kochi on 08/02/2015 near to
Eloor.its a heavy chemical industry engaged in the manufacturing & marketing of
Caustic soda, Chlorine & allied chemicals. The methodology used was observation.
Purpose of conducting an observation with the help of manager was to identify
significant hazards and risks in the above mentioned locations/ areas and to make
recommendations and improvement. The main activity during the time of inspection was
production of Hydrochloric Acid & Liquid Chlorine. The average size of the company is
500 and during the inspection there were around 300 people. Equipment used at site
include Wheel barrow, Forklift etc. Language being used at site includes Malayalam and
Hindi some times. TCC is accredited with ISO 9001 : 2008 certification.
Executive Summary
The aim of this report is to identify significant hazards and risks in the above
mentioned locations/ areas and to make recommendations and improvement. While
observation, those inspected areas were noticed that need of serious commitment from
the management to improve the area into safe working condition. During our inspection
we observed the presence of danger to life and health of the operatives due to unsafe
acts and unsafe condition of Chemical processing, unguarded machines, dust and noise
are not reasonably uncontrolled, poor house keeping some of places, stacking of
materials and equipment not well organized, misused of PPE such as personal fall
arrest system or harness, flammable materials stored inappropriately.
These numbers of observation have been recorded with the corresponding appropriate
recommendations for early improvement. The nonattendance of competent workers and
supervisor to oversee the whole processing/handling operation resulted operatives cut
corners, by using a defective and without evidence of monthly inspection of chemicals

to hoist risks. Recommendation is to plan training for the month this is to include
workers training, this is to ensure that the Chemical activities should be carried out
under the supervision of competent supervisor to ensure that all processing/handling
accessories that have been thoroughly examined by a competent person and deemed
to be in a condition that is safe to use must be clearly identifiable.
Main Findings
Inadequate illumination, improper Transport design, Biological hazard, Health &
Chemical Hazard, Discipline Hazards these were the major five hazards which
observed during inspection.
Inadequate Illumination
Inadequate illumination on plant area as well as in work place can cause injury to
worker. Inadequate illumination will cause poor visibility in that area it can lead to cause
hazards like slip, trip & fall. Employee as well as employer will be harmed by this
hazard. Employee may affect the consequences directly by loss of income during these
days, or even it can lead to the death of the person too. Employer may affect it either
directly or indirectly, we can consider direct events such as legal punishment
,compensation to victim, loosing further orders, credibility of organisation etc, and
indirect events such as loss of time , recruitment & training of new employee etc. so
from this we can conclude it as High risk hazard. It is crystal clear that violation of
regulations such as ILO C 155 and ILO R 164. Short term action to correct the hazards
is to provide adequate illumination by installing more lighting facilities in plant as well as
work area. Long term action to correct the hazard is to conduct periodic inspection and
maintenance of lighting system. Approximate cost for taking above corrective is Rs
15,000. Supervisor/manager is responsible for taking the a corrective action. Corrective
action should take as soon as possible and should be within one week.
Improper Traffic Design
Movement of vehicles and the pedestrian and equipments such as forklift truck in
the same route can lead to collide with vehicles and pedestrian, it can cause hazards
like Collision hazard. Employee as well as employer will be harmed by this hazard.
Employee may affect the consequences directly by loss of income during these days, or
even it can lead to the death of the person too. Employer may affect it either directly or
indirectly, we can consider direct events such as legal punishment ,compensation to
victim, loosing further orders, credibility of organisation etc, and indirect events such as
loss of time , recruitment & training of new employee etc. so from this we can conclude
it as High risk hazard. It is crystal clear that violation of regulations such as ILO C 155,
ILO R 164 & LORER 1998. Short term action to correct the hazards is to engage a
banksman, provide proper signals & insist the drivers to follow the speed limits in the
particular areas. Long term action to correct the hazard is to provide separate entry and
exit routes with separation between pedestrian and vehicle as well as equipments.
Approximate cost for taking above corrective is Rs 25,000. Supervisor/manager is
responsible for taking the a corrective action. Corrective action should take as soon as
possible and should be within one week.
Biological Hazard
Lack of facility for an employee to be in hygiene after handling the harmful chemicals, it
can lead to cause biological hazard by if the employee cannot wash his hand properly
after handling it by hand he may use the same hand for eat his food too. Thus chemical
may go inside his body and will cause biological hazard. Poor personnel hygiene can
cause health problem such as infection and diseases. Employee as well as employer
will be affected by this hazard. Employee may affect the consequences directly by loss
of income during these days, or even it can lead to the death of the person too.
Employer may affect it either directly or indirectly, we can consider direct events such as
legal punishment ,compensation to victim, loosing further orders, credibility of
organisation etc, and indirect events such as loss of time , recruitment & training of new
employee etc. so from this we can conclude it as High risk hazard. It is crystal clear that
violation of regulations such as ILO C 155, ILO R 164 & COSHH 2002. Short term
action to correct the hazards is to provide proper hand wash facilities as well as
cleaning liquids and train their employees to practice it. Long term action to correct the
hazard is to build up washing area, changing area, locker facility etc. Approximate cost
for taking above corrective is Rs 10,000. Supervisor/manager is responsible for taking
the a corrective action. Corrective action should take as soon as possible and should be
within one week.
Health & Chemical Hazard
Chemical mist from the exhaust vent of the scrubber will generate droplets of liquids
and it may fell on the surroundings and it will cause chemical & health hazard. These
liquids may fall on the skin, hair and other parts. This will cause skin problems such as
dermatitis and irritations. Employee as well as employer will be affected by this hazard.
Employee may affect the consequences directly by loss of income during these days, or
even it can lead to the death of the person too. Employer may affect it either directly or
indirectly, we can consider direct events such as legal punishment ,compensation to
victim, loosing further orders, credibility of organisation etc, and indirect events such as
loss of time , recruitment & training of new employee etc. so from this we can conclude
it as High risk hazard. It is crystal clear that violation of regulations such as ILO C 155,
ILO R 164 & COSHH 2002. Short term action to correct the hazards is to wear Personal
Protective Equipments such as coveralls and gloves. Long term action to provide mist
collector at the discharge of scrubber. . Approximate cost for taking above corrective is
Rs 20,000. Supervisor/manager is responsible for taking the a corrective action.
Corrective action should take as soon as possible and should be within one week.
Discipline Hazards
Some of the fire extinguishers were found empty during the inspection, with these fire
extinguishers if any fire occurs in the plant then the availability of this will not help to
reduce the fire instead of it will increase the risk.so such hazard should be avoided.
Instead of reducing risk these empty fire extinguishers increase the severity of risk.
Employee as well as employer will be affected by this hazard. Employee may affect the
consequences directly by loss of income during these days, or even it can lead to the
death of the person too. Employer may affect it either directly or indirectly, we can
consider direct events such as legal punishment ,compensation to victim, loosing further
orders, credibility of organisation etc, and indirect events such as loss of time ,
recruitment & training of new employee etc. so from this we can conclude it as High risk
hazard. It is crystal clear that violation of regulations such as ILO C 155, ILO R 164.
Short term action is replacing the empty with new one. Long term action to Intend for
new fire extinguishers. Approximate cost for taking above corrective is Rs 30,000.
Supervisor/manager is responsible for taking the a corrective action. Corrective action
should take as soon as possible and should be within one week.

Control Measures

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Item

Worker was working in the

Provide PPE to the workers

Calcium Chloride is irritant to skin

House-keeping was not good in the

On urgent basis clean the floor

Hazard & Consequences:

From main gate to plant area there

Provide signages stop , speed

Hazard & Consequences:

Provide separate entry & exit

Light was inadequate in the plant

Install adequate lighting within

Hazard & Consequences:

Blowers were creating a large noisy

Minimise work exposure limit

Calcium Chloride dust was coming

Welding of the lines those have

Hazard & Consequences:

Replace the lines those are too

Worker was working in the carpenter

Provide PPE to the worker.

Hazard & Consequences:

Provide safeguard to the sander.

Can cause injury to worker

Worker was lifting the large buckets

Provide job rotation with other

Install conveyer from heap of

drain system & properly out of

Provide DSE instead of

personal hygiene can cause health

Observed that in the reaction area to

Provide PPE to the worker and

Hazard & Consequences:

Provide temporary cover to the

Trailing Cables were laid down on

Hazard & Consequences:

Ensure proper housekeeping of

Hazard & Consequences:

Rigger was not present during lifting

Rigger should be present at the

Proper lifting practice should be

Monitor lifting activities regularly.

Duct was cracked so scaffolding

Fixed the guard rail & toe board

Hazard & Consequences:

Substandard scaffolding guard rail & Long Term:

Welding work was carried out in the

Making people aware of the

Hazard & Consequences:

Risk of inhaling welding fumes which

Redesign the workplace and

Install local exhaust ventilation to

During process of drying of calcium

Provision of adequate welfare

Hazard & Consequences:

Install strainer in the feed line, if

Environment Hazard and confined

or drying tower to provide safe

Excavation work was carried out for

Use stop blocks to prevent

Hazard & Consequences: