ASSIGNMENT 2- RISK ASSESSMENT

BY SRI STUTHI RAGHAVAN, A0108001E

A factory intends to convert a used 44-gallon oil drum into waste bins. AFitter was instructed to use an oxy-acetylene gas cutting
equipment to cut the oil drum into to halves with each half forming a bin. You have been tasked by the Factory Manager to ensure that
a) the operation is carried out safely; and
b) the requirements of the Workplace Safety and Health (Risk Management) Regulations are complied with

1. Describe how your company could comply with the Workplace Safety and health (Risk Management) Regulations with reference to
aforesaid operation of converting the oil drum.

The following needs to be done in order to ensure that Workplace safety and health (Risk Management) Regulations have been
complied with before performing the operation of converting the oil drum:
 Plan a Risk Assessment: Before any sort of industrial work is performed, a risk assessment should first be performed on the
operation
 Form RA & RM teams :
 For this a Risk assessment & Risk Management team should be formed, wherein the members are of multidisciplinary
domains; e.g. the operators performing activity, the oil drum handlers, the safety manager/inspectors, the vendors of the oxy-
acetylene equipment
 The leaders of both the teams should be experienced and should have attended the RM course by MOM Training provider or
an equivalent to prove competency and risk assessment should be performed using the Risk assessment form
 Conduct Risk Assessment (as performed under Question 2):
 The basic steps in risk assessment include:
 Identifying the hazards;
 Considering who may be affected and how;
 Evaluating the risks arising from the hazards, and considering whether existing safety measures are adequate or more
should be done;
 Recording the findings unless it is easily explicable; and
 Reviewing the assessment from time to time and revising if necessary.
 During the risk assessment, the hazards and risk of using a gas torch on converting a previously filled out oil drum into a
waste bin needs to be assessed thoroughly and hazards need to be identified along with mitigation measures to ensure that
the hazardous consequences are prevented from happening. A few hazards are listed below :
 fire/explosion due to leak overpressure from acetylene
 flashback from blowpipe
 Burns & injuries
 Radiation health hazards of hot works like eye irritation and cataract and skin irritation
 Inhalation of toxic fumes from performing hot work on a metal drum
  Impact of surrounding environment on the activity also needs to be assessed
 Risks caused by each the oil drum and the oxy/acetylene equipment need to separately be assessed too, to ensure that
before its operation and during the transport/arrangement for the operation, hazardous scenarios should be avoided
 Existing preventive measures should be taken into account while assessing the severity and likelihood of the risk. If it is low,
then the risk is kept under control, whereas if the risk is moderate or high, the severity or likelihood needs to be brought
down to low risk or to the ALARP range to prevent accidents from taking place.
 Risk Management Team :
 Ensure that the recommendations are carried out before the activity is scheduled, hence proper fire fighting and first aid
equipment need to be installed before the start of the operation , and must assign inspection of these measures from time to
time by the concerned safety authorities every time before for the operation to be performed
 Safety officers must ensure establishing emergency response procedures, instructing the ERP team during emergency
situations and arranging for the necessary drills to keep the employees aware of the proper routes to reaching the marshalling
point
 It is the employee’s responsibility to ensure learning the operating procedures, the safe work procedures and performing the
required checks along with training competently for the task to be performed efficiently and with reduced risk.
 Competent Safety supervisor should ensure that the operating procedures, safe work procedures and permit to work system for
hot work are being followed on a daily basis and must oversee each step of the activity being performed
 The employers and the management’s responsibility to encourage safety and health in the workplace, arrange for training,
ensure accidents and near-miss incidents are investigated and constantly build a safe environment by implementing preventive
and mitigation measures
 Proper Training along with safe operating procedures should be followed. Permit to work should be granted to trained personnel
and must be supervised for reduced injuries and consequences. Training should also be giving on how to fight fire to the
Department Emergency response Team members.

2. Conduct a risk assessment of the operation using a 5*5 Risk Matrix

ACTIVITY-BASED RISK ASSESSMENT

Gather risk assessment members and conduct a risk assessment with RA and RM team(multi-disciplinary employees) to discuss the following
sequence of steps and the associated hazards involved. The risk matrix followed shall be as shown below:
 INVENTORY OF WORK ACTIVITIES
Company:
No. Process/Location Work
1 Preparation of Oil drum for hot work Emptying/draining the oil drum

Cleaning the Oil drum by degreasing /steam cleaning the oil drum

Housekeeping in cleaning booth

2 Oxy-acetylene cutting work at Work shop Moving drums after cleaning to the hot work location

Checking the equipment for fittings before use and following the
safe work procedures
 Carry out cutting of the oil drum into 2 waste bins by gas cutting
torch

Shut off the gas torch and Disassemble the hose connection

Housekeeping after completion of job

Following should be ensured to be considered in safe working procedure for hot work:

 Visually Examine all equipment and fittings before use

 Check hoses for cuts, cracks and other defects

 Wear the necessary personal protective equipment

 Check that there is no flammable substances nearby

 Purge the hoses individually before lighting the gas torch

 Use only flint guns or spark lighters to light the gas torch

 Layout hoses properly to prevent coming into contact with heat sources

 Secure all gas cylinders to prevent from being knocked down and keep them at a safe distance from heat sources

 Ensure firefighting equipment are readily available for immediate use

 Shut off gas valves at cylinders and disconnect hoses from supply valves when operation ceases

ACTIVITY-BASED RISK ASSESSMENT FORM

Company: XYZ Factory
Conducted by:
Converting oil drum into waste
Process/ Location: (Names, designations)
bins
(Date)
Approved by:
(Name, designation)
Last Review Date: Next Review Date:
(Date)

1. Hazard Identification 2. Risk Evaluation 3. Risk Control

1a. 1b. 1c. 1d. 2a. 2b. 2c. 2d. 3a. 3b. 3c.
Resi Action
dual Officer,
Possible Accident / Ill Existing Risk Control Risk Designati
Sev- Likeli Risk Additional Risk
No. Work Activity Hazard Health & Persons-at- on
(if any) erity -hood Level Control
Risk
(Follow-
up date)
1. Emptying/draining 1.1. Dispersion of 1.1.1 Inhalation of 1. Proper 4 3 12 1. Face masks or 2*2
the oil drum (manual) HC/ flammable the toxic vapours housekeeping and respirator =4
gases/pool of oil and contact with the draining of pool 2. Separate area
oil which can affect 2. PPE like helmet for
the health of the and safety and emptying/draining
employee gloves which the remaining oil
1.1.2 Potential pool reduces the severity 3. Installation of fire
of oil of fall and irritation fighting system
Potential on skin 4. Fire & gas
fire/explosion detection & alarm
scenario system should be
1.1.3 Injuries/burns installed
1.1.4 Possible slips 5. Emergency
or trips due to greasy Response &
surface Evacuation plan
6. Control of
ignition source by
classifying
electrical
equipment
intrinsically safe
2 Cleaning the oil drum 2.1 Dispersion of 2.1.1 Toxic inhalation 1. Separate 3 2 6 1. Avoid using toxic 2*2
using degreaser/ HC/ flammable of vapors from the oil designated area for degreasers and =4
steam cleaning gases/pool of oil 2.1.2 Pool of oil can cleaning to ensure substitute with less
be formed draining of excess toxic ones
2.1.3 Potential inventory 2. Proper
 1. Hazard Identification 2. Risk Evaluation 3. Risk Control
fire/explosion 2. PPE: Safety shoes housekeeping to
scenario and gloves ensure no residue
2.1.4 Slips and trips of oil left in the
due to greasy cleaning area that
surface can act as fuel for
2.2 Accidental 2.2.1 Injuries/burns 2 3 6 fire 2*3
contact with steam 3. Installation of fire =6
2.3 Toxic degreaser 2.3.1 Possible slips 2 3 6 adequate fighting 2*2
spill or trips due to greasy system =4
surface 4. Emergency
2.3.2 Inhalation of Response &
toxic vapors from Evacuation plan
degreaser fighting system
2.4 Improper 3 2 6 5. Fire & gas 2*2
cleaning which leads 2.4.1 Potential detection & alarm =4
to flammable gas still fire/explosion system should be
being contained scenario installed
within the drum 6. Control of
ignition source by
classifying
electrical
equipment
intrinsically safe
7. HC sensors to
be placed for
checking within the
drum to measure
the flammable
vapour content
before proceeding
to cutting by hot
works

3 3.1 Toxic and 3.1.1 Respiratory 1. local exhaust 2 3 6 1. Face mask 2*2
hazardous degreaser and skin irritation ventilation system for respirators =4
and oil problems cleaning area 2. Safe
2. PPE like helmet work procedure
and safety shoes 3. Substitute toxic
 1. Hazard Identification 2. Risk Evaluation 3. Risk Control
Housekeeping in 3.2 Flammable 3.2.1 Potential Fire which help to protect 2 3 6 degreaser with 2*2
cleaning and oil atmosphere in and explosion head and feet water based one =4
drum area presence of ignition scenario 4. Installation of fire
source 3.2.2 Personnel adequate fighting
injury and asset system
damage 5. Emergency
Response &
Evacuation plan
fighting system
6.Fire & gas
detection & alarm
system should be
installed
7.Control of ignition
3.3 Slips and trips 3.3.1 Minor to 2 3 6 source by 2*2
due to greasy serious injury to the classifying =4
surface person on the fallen electrical
area equipment
intrinsically safe

4 4.1 Obstacles 4.1.1 Possible slips 1.PPE to be worn 2 3 6 1. Installation of fire 2*2
encountered or trips causing (rubber gloves, rain adequate fighting =4
Moving drums after minor to severe coat, rubber boots & system
cleaning to the hot injury on the fallen especially eye & face Emergency
work location area protection) Response &
4.2 4.2.1 Toxic 2. Local exhaust 3 3 9 Evacuation plan 2*2
 1. Hazard Identification 2. Risk Evaluation 3. Risk Control
Unclean/improperly inhalation of provided for 2.Fire & gas =4
cleaned drums flammable vapour extracting the indoor detection & alarm
and dispersion of air to outside system should be
flammable vapour 3. Permit to work installed
from oil which can 4. Safety signs that 3.Control of ignition
lead to potential fire indicate hot work source by
or explosion scenario going on classifying
in presence of electrical
ignition source equipment
intrinsically safe
4.3 Spark or ongoing 4.3.1 Potential fire 3 4 12 4.Supervision to 2*3
ensure no =6
hot work while scenario if drum
obstruction of
transporting uncleaned and pathway and
cautious entry and
possible accidental
exit from hot work
radiation exposure to area
5. Provide
the transporter
mechanical lifting
devices eg.
6.Forklift by
competent
personnel for
moving oil drums

5 Checking the 5.1 Possible existing 5.1.1 Oxygen leak 1. Regular inspection 3 3 9 1.Install a double
equipment for fittings leak from oxygen or can lead to and check check valve since
before use and acetylene hoses malfunctioning 2. Safe operating one check valve is
following the safe during the hot work procedures during susceptible to
work procedures operation checks failure and 2 NRVs
5.1.2 Potential 3. PPE will be more
dispersion of 4.Local exhaust reliable
acetylene gas which provided for 2.Installation of fire
can lead to fire or extracting the indoor adequate fighting
explosion scenario in air to outside system 2*3
presence of ignition 3.Emergency =6
sources nearby Response &
Evacuation plan
5.2 Gas torch tip 5.2.1Overpressure 1.Regular inspection 3 3 9 4.Fire & gas 2*2
clogged which can lead to and checks detection & alarm =4
rupture and potential 2.Non-return valves system should be
 1. Hazard Identification 2. Risk Evaluation 3. Risk Control
fire and explosion 3.Local provided for installed
scenario with severe extracting the indoor 5.Control of ignition
injuries and air to outside source by
escalation will lead to classifying
asset damage electrical
5.2.2 Backflow and equipment
hose rupture and intrinsically safe
potential fire and
explosion scenario
with injuries and
escalation will lead to
asset damage
5.3Valve 5.3.1 Possible 1.Safe operating 3 2 6 2*2
malfunctioning backflow which lead procedures during =4
to hose rupture and checks

6 Carry out cutting of 6.1 Inspection Check 6.1.1 Potential 1. Flashback arrestor 2 2 4 1.Install a double 2*1
not performed fully flashback 2.PPE and hot work check valve since =2
the oil drum into 2
Fire and explosion goggles, gloves with one check valve is
waste bins by gas scenario in the safety shoes and susceptible to
presence of ignition helmet failure and 2 NRVs
cutting
sources with injuries 3. Safe work will be more
and asset damage procedures reliable
6.2 External 6.2.1Potential fire Permit to work 2 3 6 2.Installation of fire 2*2
4. Local exhaust adequate fighting =4
flammable gas and explosion
provided for system
release scenario in the extracting the indoor 3.Emergency
air to outside Response &
presence of ignition
5.Operating Evacuation plan
sources coupled with procedures fighting system
6.Trained personnel 4.Fire & gas
personnel injuries
for hot work detection & alarm
and asset damage system should be
 1. Hazard Identification 2. Risk Evaluation 3. Risk Control
6.3 Oil drum not 6.3.1Potential fire 3 3 9 installed 2*2
5.Control of ignition =4
cleaned fully and explosion
source by
scenario in the classifying
electrical
presence of ignition
equipment
sources coupled with intrinsically safe
6.Mandatory
personnel injuries
supervision of the
and asset damage whole process by a
6.4 Not performed as 7.4.1Potential 4 3 12 competent safety 2*3
flashback officer/supervisor =6
per the safe work
7.4.2Fire and
procedures
explosion scenario in
the presence of
ignition sources with
injuries and asset
damage
Irritation and injury to
eye and Skin
irritation without
safety goggles and
gloves
7 Shut off the gas 7.1.1 Dispersion of 1. Trained personnel 4 3 12 1.Safety supervisor 3*2
7.1 Disassembling for hot work to ensure safe work =6
torch and flammable gas which
before shutting off 2.PPE procedures are
Disassemble the the gas torch in the presence of an followed and keep
records
hose connection and ignition source leads
2. Installation of fire
return the equipment to fire and explosion, adequate fighting
system
to its designated injuries and possible
Emergency
area asset damage Response &
 1. Hazard Identification 2. Risk Evaluation 3. Risk Control
7.2 Leaving the 7.2.1Can act as an 4 4 9 Evacuation plan 3*2
equipment around 3.Fire & gas =6
obstacle and lead to
without putting it detection & alarm
back in the accidents which if system should be
designated area installed
harms or cracks the
4.Control of ignition
cylinders , it can lead source by
classifying
to an explosion in
electrical
presence of an equipment
intrinsically safe
ignition source

8 Housekeeping after 8.1 Dust from hot 8.1.1 Air pollution 2 3 6 1. Ensure proper 2*2
housekeeping is =4
completion of the job work and particles and respiratory
done by supervisor
not cleaned properly problems watching the whole
sequence of
or disposed properly
actitvities
3. Develop a Hot-work Permit to control any hot work to be carried out in the factory

Sample hot work permit template: