SAFETY ASSESSMENT OF THE MACHINE HOUSE AREA IN LINDE INDUSTIAL

GAS PLANT

Abstract
The Machine house area of Linde Industrial Gas Plant is located in WCIP,
Balamban, Cebu. The Machine house area is the heart of the plant.This is where the
process takes place. This study assesses the safety practices present in the Machine
House Area based on the Safety Management Manual and the Occupational Safety
and Health Administration (OSHA) Manual. This paper presents the recommendations
including the appropriate programs to be implemented on improving the current
practices that are being done in the area.

1.0 Introduction.

Safety has traditionally been defined as a condition where the number of adverse
outcomes was as low as possible (Erik Hollnagel,2018). Safe machines make a major
contribution to personnel safety on the workplace. Safety of machines is often
guaranteed or enhanced by safety devices. The choice of a safety device involves
multiple criteria decision making and a ranking of alternatives according to often
contrasting performance measures(Antonio C Caputo, Pacifico M Pelagagge, Paolo
Salini, 2013). As such, it is to your every advantage that you ensure the functionality of
every piece of equipment, as well as prevent issues as soon as they crop up. The
occurrence of accidents and trip in the machine area is a great indication that safety
program and maintenance is not well-implemented. This paper intends to assess and
analyze the safety of the workplace in the Air separation Unit Area.

Cryogenic Air Separation Units (ASUs) frequently supply oxygen and nitrogen to
chemical, petroleum and manufacturing customers. Typically, the ASU is located
remotely from the use point, and the products are supplied via a pipeline(William P
Schmidt, Karen S Winegardner, Martin Dennehy, Howard Castle‐Smith,2001).
Atmospheric air contains many trace components which are process contaminants or
equipment fouling agents in a cryogenic air separation process unit (ASU) (WP
Schmidt, KW Kovak, WR Licht, SL Feldman,2000 ) .Based on the potential problems
that they may cause, the trace contaminants are categorized as corrosive, plugging or
reactive species. Machines in the ASU are exposed to an array of operations, this
causes the industrial machine failure that includes things like bearing failure, metal
fatigue, misalignment, and general surface degradation.

Air Separation process is a high-risk line of work, accidents in the workplace

Cannot be avoided by every worker. The human factor theory of accident causation
attributes accidents to a chain of errors ultimately caused by human error. Occupational
Safety and Health Standard (OSHS) will be used to protect every Workingman in the
company against the dangers of injury, sickness or death through safe and healthful
working conditions, hence the importance of this assessment. The Department of Labor
and Employment (DOLE) in the Philippines offers safety regulations that can be applied
in any business. For this notion, the said industry must target strategic plan in reducing
risks and malfunctions, allowing workers to have working conditions that do not Pose
serious harm and receive trainings and information about workplace hazards. Machine
ethics is concerned with ensuring that the behavior of machines toward human users,
and perhaps other machines as well, is ethically acceptable (Michael Anderson, Susan
Leigh Anderson, 2007).

The researchers will acquire information by conducting interviews, making

observations, and looking over records in the Machine Area. The accident investigation
form, job and site hazard analysis, safety management criteria, and general safety
practices check list are the questionnaires that should be used to identify hazards in
work processes and on the job site and to assess the safety performance of the area.
Each of these has different scoring criteria.

2.0 Results and Discussion

ASSESSMENT 2.1: SAFETY MANAGEMENT

The assessment comprises the accountability arrangements, safety statement,

competent persons, Instruction, Training, Supervision and emergency plans
assessments.
2.1.1 Accountability arrangements

Safety can help a company reduce injury and costs, have loyal workers and
improve quality (WorkSafeMT, 2017). Safety is not only the responsibility of
management but also the employees. The assessment presented above show how the
management executes their duties as the people who are in charge delegate, inform
and provide general provisions regarding safety and sanction of such rules being not
followed. Shown in Table 2.1.1, the criterion with least scores indicates the non-
compliance and non-execution of the organization's directors and employees (and the
equivalents) to their roles. Although they document accidents in the company it is a far
cry from being a proper safety policy with relationships not being clearly defined and
such. From the assessment is it clear as day that they don’t have a safety and health
policy. Management needs a lot of work in terms of safety management.

Table 2.1.1 Accountability Arrangements Criterion

Specific Score Interpretation
Organization has a documented safety and health policy 10 No need for improvement
Safety and health policy signed off by the Chief Executive 10 No need for improvement
Safety and health integrated into the organization’s strategic plan 8 Needs slight improvement
Reporting relationships clearly defined in the organization 8 Needs slight improvement
Managers, supervisors and employees made aware of their responsibilities with 8 Needs slight improvement
regard to safety and health
Managers, supervisors and employees have a clear understanding of their 9 Needs slight improvement
responsibilities with regard to safety and health
Managers, supervisors and employees accountable for not meeting their 10 No need for improvement
responsibilities for workplace safety and health
Safety and health responsibilities detailed in the job descriptions of managers, 4 Needs a lot of improvement
supervisor, and employees
Management ensured that adequate resources are provided in place to manage 5 Needs improvement
safety and health
Safety and health an agenda at management team meetings 10 No need for improvement
Safety and health objectives incorporated as part of the safety and health policy 8 Needs slight improvement
Safety and health policy express a commitment to the safety of employees, service 10 No need for improvement
users, contractors and visitors
Management team has a mechanism in place to facilitate planning required for 10 No need for improvement
effective safety and health management
Average 8.46 Needs slight improvement

2.1.2) Safety Statement

Any organization must offer a written program to protect workers' health and
safety as well as the health and safety of anybody else who could be present in the
workplace, such as users, visitors, or members of the public (Health and Safety
Authority, 2016). The machine area has not have a clear major accidents, they do
prioritize safety and every morning the hold meetings so that employees can share a
risk of the Machine to spread awareness to fellow employees.
Table 2.1.2 Safety Statement Criterion
Specific Score Interpretation
Documented safety and health policy 8 Needs slight
improvement
Content of the safety statement has been brought to the attention of all employees 9 Needs slight
improvement
Revision history of the safety statement to reflect evidence of regular review and update 10 No need to
improve
Safety statement includes a review mechanism, which recognizes the need to monitor and 7 Needs slight
review performance. improvement
Clear commitment in safety statement to allocate appropriate resources to manage safety and 8 Needs slight
health improvement
Safety statement specifies the process in place for identifying hazards, assessing risks, 9 Needs slight
implementing controls and review improvement
Safety statement state the means by which information on safety and health is communicated 8 Needs slight
to all employees improvement
Safety statement specifies the arrangements in which the safety, health & welfare of employees 9 Needs slight
are secured and managed improvement
Safety statement specifies the arrangement in which the safety, health & welfare of other 9 Needs slight
persons are secured and managed improvement
Average 8.55 Needs slight
improvement

2.1.3.) Instruction, Training and Supervision

The Safety, Health and Welfare at Work Act 2005, strongly emphasizes the need
to provide employees with instruction, information and training necessary to ensure their
health and safety (Health and Safety Authority, 2017). As shown in the table 2.1.4, the
machine shop needs a lot of improvement because there is no documentary about on
the specific instruction, training, and supervision with regards to safety and health of the
workers.

Table 2.1.3 Instruction, Training and Supervision

Criterion
Specific Score Interpretation
Safety and health training was made available for all employees. 10 No need to improve
All employees are aware of their duties to attend safety and health training. 8 Needs slight improvement

Employees are released from their duties to attend safety and health training. 9 Needs slight improvement

Non-attendance at training programs are recorded/managed. 5 Needs improvement

All employees understand the training /instruction provided. 10 No need to improve
A training needs analysis is carried out for all employees. 7 Needs slight improvement

All employees understand the limitations and uses of personal protective equipment. 9 Needs slight improvement

There is a training program in place 7 Needs slight improvement

The management ensure the implementation of the training program 10 No need to improve
Training programs are evaluated 8 Needs slight improvement
Training records are maintained0 10 No need to improve
Refresher training is provided 10 No need to improve
There is a formal induction program for all new employees 10 No need to improve
There is a system for flagging refresher training 8 Needs slight improvement

Safety and health is adequately addressed in this induction program. 9 Needs slight improvement
 There is a mechanism in place to ensure that those providing training are competent 8 Needs slight improvement

Employees are given instruction, training and supervision in a form, manner and as 7 Needs slight improvement
appropriate, language that is reasonably likely to be understood by the employee
instruction, training and supervision is provided to employees in the following Needs slight improvement
situations:
• recruitment
• transfer 8
• change of task
• on the introduction of new work equipment
• changes in work equipment or systems of work
• introduction of new technology
There is adequate supervision in place to ensure the safety and health of employees 7 Needs slight improvement

Average 8.95 Needs slight improvement

2.1.4) Emergency Plans

The lack of an emergency plan could lead to severe losses such as multiple
casualties and possible financial collapse of the organization (Canadian centre for
Occupational Health and Safety, 2014). An emergency plan is a procedure for handling
sudden or unexpected situations. The objective is to be prepared to prevent fatalities
and injuries. It also protects the environment and the community (OHS, 2017). The
machine shop does not have an emergency plans even if there is the possibility to
experienced danger during work. Based on the assessment the shop needs a lot of
improvement for they have no emergency plan.

Table 2.1.4 Emergency Plans Criterion

Specific Score Interpretation
Competent persons appointed of emergency plans 8 Needs slight improvement

Emergency plans in place 10 No need to improve

Emergency plans communicated to employees 7 Needs slight improvement

Competent persons to implement emergency plans 9 Needs slight improvement

Evaluation of management for emergency plans 8 Needs slight improvement

Suitable and effective plans in place for all foreseeable events of serious imminent 10 No need to improve
danger
Sufficient number of competent persons to implement procedure relating to 5 Needs improvement
evacuation of people from premises
Liaison with local fire authority in relation to the fire safety plan 8 Needs slight improvement

Emergency plans tested locally 8 Needs slight improvement

Adequate first-aid arrangements in place 10 No need to improve

Awareness of employees with regard to the provision of first-aid, location of 9 Needs slight improvement
equipment, facilities and personnel
Average 8.36 Needs slight improvement
ASSESSMENT 2.2: SHOP FLOOR INDUSTRIAL HYGIENE AND WORK
ENVIRONMENT CONTROL

This assessment comprises Housekeeping, Hygiene and Environment

Control, Facilities and Equipment Maintenance & Engineering Controls, Safety
Procedures, Emergency Action Plans, safety training, safety kits and Fire Safety
Practices and Facilities

2.2.1 Housekeeping

Cleanliness of the building, yards, machineries, and equipment, regular waste

disposal, and an organized setup of the processes, operations, storage, and filing of
materials are all required to be maintained at all times in accordance with RULE 1060 of
OSHA. Metal sheets, pipes, and other working supplies were positioned close to or
even in the middle of the pathways in the machine shop, obstructing them and possibly
increasing the risk of accidents. Rule 1063.01, which states that portions of floors shall
be free from other projections or obstructions that create stumbling hazards, and Rule
1063.02, which states that stairways, ramps, elevator platforms, and similar places
where slipping may be especially hazardous shall be provided with non-slip walkway,
are not being complied with, according to the assessment shown in Table 2.1.1.

Table 2.2.1 Housekeeping Assessment

Specifics Score Interpretation
Exits kept free of obstruction 10 No need to improve
Stairs kept unobstructed 10 No need to improve
Worksites kept clean and orderly free from tripping and slipping hazards 8 Needs slight improvement
Work surface free of sharp edges and sharp protrusion 10 No need to improve
Air free of dust, fumes, and gas, that could be dangerous to the health 8 Needs slight improvement
Trash kept in proper containers and removed regularly 10 No need to improve
Scraps and waste material that are flammable, explosive, acidic, caustic, toxic 10 No need to improve
materials dispose on safe storage area
Mills, shapers, cutters, borers, presses, lathe machines kept clean daily N/A

Work area surrounding the mills, shapers, cutters, borers, presses, lathe machines N/A
kept clean after use
Aisles, ramps, docks, roadways are kept clean and unobstructed 10 No need to improve
All protective covers for gears, pulleys, belts, drives, chains, in workstations, kept 9 Needs slight improvement
clear of wastes, tools, and litter.
Safety valves, emergency switches, cutoffs, warning systems, limit switches, mirrors, 10 No need to improve
sirens, signs kept clean and operational
Average score 9.5 Needs slight
improvement