OCCUPATIONAL SAFETY

OVERVIEW
SAFETY AND HEALTH OFFICER ENRICHMENT PROGRAM (SHEP)
 Contents

Safety :
– Factory
– Machinery
– Activities
– Risks

Concerns :
– How Can Accidents
Happen ??

2
 Factory

Place : Factory
 Housekeeping
 Fencing
 Slipping And Tripping Hazards
 Ergonomic Hazards
 Ventilation
 Lighting
 Storage

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 The Factory Floor

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 Identify The Hazards

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 Workshop or Store?

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 Housekeeping :
A Place for Everything

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Housekeeping
 Housekeeping

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 Machine Guarding
 Take photographs if you are unable to clearly describe
what you found

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 FACTORIES AND MACHINERY (FENCING OF MACHINERY AND
SAFETY) REGULATIONS, 1970

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 PHOTOELECTRIC &
RADIO FREQUENCY

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 PULLBACK DEVICE &
TWO HAND CONTROL

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 SLIPPING AND TRIPPING
Reactive : Every dog is
allowed one bite ???

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 SLIPPING AND TRIPPING WATCH
YOUR STEP

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 VENTILATION COMPLY WITH
INDOOR AIR QUALITY

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LIGHTING APPROPRIATE
FOR THE OCCASION

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 STORAGE EASY TO
STORE, EASY TO RETRIEVE

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 STORAGE
HEAVY STUFF AT THE BOTTOM, NOTHING
HIGHER THAN EYE LEVEL

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 STORAGE
SEGREGATE, TAG, COVER

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 Machinery

Machinery Requiring Certificate Of Fitness :

 Steam Boilers PMD
 Fired Pressure Vessels PMD
 Unfired Pressure Vessels PMT
 Lifts & Escalators PMA
 Hoists PMA

Other Registration :
 Factory K
 Machinery Installed P

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 Types of Steam Boilers

PMD :
 AUTOCLAVE
 ELECTRODE BOILER
 TUBELESS BOILER
 WATER TUBE BOILERS
 FIRE TUBE BOILERS
 WASTE HEAT BOILERS
 UNDER-FIRED
MULTITUBULAR BOILER
 ALLEN YGNIS
 COMBINATION BOILERS
PREVIOUSLY ALSO INSTALLED
ON SHIPS AND TRAINS

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 The Steam Engine

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 Locomotive Boiler

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25
 Fire
Tube
Boiler

1 Fumace(1 st Gas Pass) 7 Water gauge assembly 13 Spare Connection (steam) Spare
2 Tubes (2nd Gas Pass) 8 Safety Valve 14 Connection (water)
3 Tubes (3nd Gas Pass) 9 Main Steam Stop Valve 15 Water Pump
4 Combustion Chamber 10 Feed Check Valve 16 Control Panel
5 Front Smoke Box 11 Water Level Controls 17 Burner
6 Rear Outlet Box 12 Manways 18 Forced Draught Fan
19 Fan Inlet Silencer

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 Towler / Fraser Watertube

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 Superheater Riser
tube header
Steam
Drum
Roof
Header

Front
header
Downcomer

Side Header FD Fan Mud Drum ID Fan

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 Pressures and MCR
MCR : Maximum Continuous Rating
MCR

0.3 T/hr
< 3 T/hr 3 – 15 tons/hr > 15 – 1,500
PRESSURE tons/hr
Fire tube,
Electrica

Fire tube,
< 150 psi Combi, Watertube
Watertube
Watertube
l

Fire tube,
Firetube, Combi,
150 – 300 psi Watertube Watertube
Watertube

> 300 – 3,000 psi Watertube Watertube Watertube

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 BOILING
WATER
REACTOR

NUCLEAR
POWER
PLANTS

PRESSURISED
WATER REACTOR

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 Three Mile Island

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32
FIRED PRESSURE VESSELS
Thermal Oil Heaters
 Statutory Inspection
 What the DOSH inspectors look for:
– Safety relief valve functions.
– Alarm functions
– Pressure gauge calibration
– Hazards such as sumps and blowdowns
– Engine Driver, Steam Engineer
– Signs of shell wall thinning.
– Cracks at welds and at connections.
– Damage to the shell by impact.
– Leaking gaskets and seals.
– Soundness of foundation support.
– Protective coatings
– Operating records.

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 A4 World
THE BORNEO POST
Five dead, 35 injured as factory’s boiler explodes
AHMEDBAD, India: Five people were
killed and at least 35 others injured
when a boiler exploded in a state run
fertiliser factory in the western Indian
state of Gujarat, an official told AFP
yesterday.
The accident took place Tuesday
night in a nitrogen phosphorus
manufacturing factory belonging to
state owned Gujarat Narmada Valley
Fertiliser Corporation Ltd
BOILER EXPLOSIONS
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THURSDAY 16TH OCTOBER 2003.
(GNFC) at Bharoch, 183 km south of
Gujarat’s commercial capital of
Ahmedabad.
“Five people died on the spot while
at least 35 others were injured, some of
them seriously,” State Home Secretary K.
Nityanandam said.
“The police did manage to rescue
some of the workers on the night shift
who were trapped under the debris
after the boiler explosion.”
-- AFP
 Algerian gas plant explosion kills
27, injures 72
 Mon Jan 19, 2004
6:40 PM
 ALGIERS (AFP) -
At least 27 people
were killed and 74
injured when a huge
explosion, apparently
caused by a defective
boiler, ripped through
a liquefied natural gas
plant near the eastern
Algerian port of Skikda,
a government minister
said. 3 Liquefaction
units were destroyed.

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 Skikda, Algeria 20 Jan 04

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 Types Of Pressure Vessels
PMT :
 Air receiver
 Steam receiver,
steam header
 Heat exchanger
 Reboiler
 Vacuum tank
 Steam-jacketed
conveyor
 Sand/carbon filter
 Softener
 Heater
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 Unfired Pressure Vessels
Safety
Valve

Pressure
Gauge
Name
Plate
Inspection &
Maintenance
Hole

Drain
Cock

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 Air Receiver
Air Filters

Compressor

Main Stop
Valve

Pressure
Gauge

Safety Valve

Air Receiver

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 Pressure Vessel Fabrication

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 From Gebeng to Melaka ...

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 Fractionation

FPV

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 Pom Sterilizers

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 Sterilizer
Explosion

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 Machinery - Requirement
Certificate Of Fitness
HOISTING MACHINES : PMA

 Overhead  Sky lifter

traveling crane :  Cherry picker
monorail, single  One, Two & Four
and double girders Post Lifts
 Gantry Crane  Scissor lift
 Portal Crane / Jib  Table Lifter
crane
 Mechanical car
 Container Crane parking

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 Lifts & Escalators

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 Gondola

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 Scissor Lift

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 Hoists & Cranes

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 Hoists & Cranes

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 Aerial Platform

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 Single Girder OHTC

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 Gantry Crane

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 Quay / Container Crane

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 Mobile Crane

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 Mobile Crane Hazards

 Improper load rating • Working too close to

 Excessive speeds power lines
 No hand signals • Improper exhaust
 Inadequate system
inspection and • Shattered windows
maintenance • No steps/guardrails
 Unguarded parts walkways
 Unguarded swing • No boom angle
radius indicator
• Not using outriggers

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 CRANE
ACCIDENTS

DERRICK
CRANE

LORRY CRANE
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 Hand and Power Tools

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 Hand and Power Tools

9.5" grinder vs 6" grinder

3,400 rpm vs 10,000 rpm

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 The law places
absolute
responsibility
for safety and
health to the
management,

but ultimately it
is the attitude
and behaviour
of the worker
that makes the
final difference.

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 Activities

 Welding
 Manual handling
 Mechanical handling
 Working at height
 Building construction

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 Oxy-acetylene Welding

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 Gas Welding Equipment

Factors to consider:
1. Storage of gas cylinders
2. Handling of gas cylinders
3. Gas leakage from regulators
4. Faulty hoses
5. Mixture of gas and oxygen in the hose
6. Blockage of nozzle and blowpipe

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 Methods of Arc Welding
Three Types of Welding Methods:
a. Tungsten Inert Gas Welding (TIG)
b. Gas Metal Arc Welding (MIG)
c. Shielded Metal Arc Welding (SMAW)
Advantages of SMAW :
a. Low cost, relatively portable equipment
b. Can weld many different metals and alloys
c. Same equipment can weld from 1/16” with different
current settings, with no upper limit on metal thickness
d. Less affected by wind and drafts than gas shielded type
e. Can be performed under most (warm) weather
conditions.

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 SMAW

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 TIG

ARGON

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 MIG

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 Main Hazards
 External eye injuries from cutting sparks, prevented by
safety glasses or safety shields
 Internal eye (retinal) damage from viewing hot metal
and radiation, prevented by using a No 5 tinted lens
 Burns from weld sparks and hot metal, prevented by
leather gloves, leather skins, pocketless shirts, cuffless
pants, welding cap, high top shoes
 Fires from welding process, prevented by moving
flammables away, and having fire fighting equipment
 Fumes from paint, plating vaporized by cutting process
prevented by good ventilation and keeping out of the
cutting plume

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 Inspection

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 PPE

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 Manual Handling

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 Manual Handling

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 Manual Handling
 Factories & Machinery Act
11067
– Section 12 – “No one shall be
employed to lift, carry or move
any load that could cause
bodily injury.”

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 Safe Lifting

 Break load into parts

 Get help with heavy or bulky
items
 Lift with legs, keep back
straight, do not twist
 Use handling aids - such as
steps, trestles, shoulder pads,
handles, and wheels
 Avoid lifting above shoulder
level

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 Mechanical Handling

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 Working at Height

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 What is the Likelihood of the person
falling?

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 Falling from Height

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 Tool Box Meeting : Job Risk Analysis

TAKDIR
ILLAHI

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 Causes Of Accidents : WAH
Tool Box Meeting :
1. JHA
2. PPE, Tools for job
3. Fitness  Warm-up
4. Breakfast
5. Weather
6. Communication
7. Emergencies
8. Stress ??
9. Prayers ???

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 Building Construction Safety

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 On Site Activities
 Transportation of  Brick laying
construction  Tower crane
materials
 Concrete works
 Clearing and
 Superstructure
cleaning works
 Installation of
 Demolition
wires/electric cables
 Excavation and pipes
 Piling  Painting
 Formwork  Finishing
 Scaffolding
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 Hazards On Site

 Heat stress  Mechanical hazards

 Noise  Electrical hazards
 Vibration  Ergonomic hazards
 Mineral dust  Biological hazards
(asbestos)  Working at height
 Cement  Confined space
 Radiation  Lighting
 Chemicals  Drowning

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 Provide stairways, ladders, shoring.

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 Crane contacts overhead power
line during freeway construction

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 Sample Installation :
HeliPad Design
 Determine : SWL (Safe Working Load) or WLL (Work Load
Limit) with at least 450mm margin for people to stand around
the helicopter
 Determine Dead Load, Live Load and Environmental Load
(wind, earthquake, etc).
 PE needs all these info for calculation into the design of the
helicopter landing pad.
 If the helipad is on a building, the building foundation must
be designed to take the loads.
 Whether scaffolding or steel structure is used, competent
persons must be assigned for the tasks : All designs carried out
by a professional Civil Engineer, scaffolding erection and
inspection supervised by a competent scaffolder.

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 Risks
 Fire hazards
 Electrical hazards
 Confined space hazards

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 Fire Hazard

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 What Is Wrong Here …

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 What Is Wrong Here …

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 Manor Hotel,
Quezon City

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 Manor Hotel,
Quezon City

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 Manor Hotel, Quezon City
No Emergency Exits

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 No Fire Safety

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 Layers of Protection
 Alarms
– Smoke alarm, heat detector
 Fire fighting
– Sprinkler
– Fire extinguishers
– Co2 system
– Wet and dry risers
– Water deluge
– Bomba
 Evacuation
– Head count
– Search and rescue

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 Electrical Hazards

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 Electrical Hazards

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 Unsafe installation of electrical
equipment

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 Electrical Hazards

 Faulty Electrical Appliances

 Faulty Three-Pin Plugs
 Illegal Extensions

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 The Water Heater

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 Husband and Wife ...

 and a water heater …

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 ELCB / GFCI

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 Inspections
You may require specific equipment to
measure levels of exposure to chemicals,
noise, radiation or biological agents.

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 Confined Space Entry

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 Confined Space Entry

A Bangladeshi kitchen hand and a Nepalese

security guard died in a manhole. The
Bangladeshi was found lying under 3 other men
slumped over him. The Nepalese guard died on
the way to the hospital. The other two are
reported to be in stable condition.

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 Confined Space Permit System
Permit application
Isolation procedures
Other certificates
Ventilation
Gas testing
Standby person
Emergency response
Permit issuance
Suspension, extension and cancellation,
closure of permit

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THANK YOU FOR YOUR ATTENTION