Unit IG2: Risk assessment

Part 1: Background

Include in here the organisation’s name* and location* and number of workers. You must then go on to give a description of the main
activities/products/services carried out. You must also describe the area to be risk assessed eg, whole site, and anything else that you
consider relevant (approximately 150 to 200 words):

For detailed inspection I have selected ENGRO Fertilizers, which is an emerging fertilizer company in Pakistan. ENGRO fertilizer was
founded in 2010. ENGRO fertilizer company is located in GOTHKI district of Pakistan. It is an emerging company which is improving
productivity and lifestyles of thousands of farmers all across Pakistan ENGRO fertilizer is producing Potash based blended NPK
fertilizers they are also providing MOP (Muriate pf Potash) that can be applied as fertilizer on straight bases for the improvement of
productivity of plants. There are 3500-4500 workers are working in ENGRO fertilizer company on which includes contractor as well as
permanent employees .Main goal of organization is to provide workers proper health and safety system to eliminate the risk of
accidents in organization and improving products of the organization. Organization is certified ISO 14001:2004 OHSAS and 1800:1999
and SA 8000:2001.

There are three shifts for workers, Morning (6am-2pm) and evening(2pm-10pm) ,and night and evening(10pm-06am ).Also there is
general shift for management which is from 9am to 5 pm . I visited this organization in general shift on 5 th July,2020.I visited the
Production area. When I visit there were many activities going on in which confined space entry, work at height, construction and
modification of product line .The Responsible persons was safety manager and Production manager.

You must now give a brief outline on how you completed the risk assessment (approximately 200 words):
For the completion of risk assessment I have reviewed about the accidents of the organization which have occurred in organization. I
have also checked for the preventive actions which are being followed at that time. I also noticed the hazards which are being
neglected by workers and safety department.
https://www.ilo.org/dyn/normlex/en/f?p=NORMLEXPUB:12100:0::NO::P12100_ILO_CODE:C167
https://www.ilo.org/dyn/natlex/natlex4.detail?p_lang=en&p_isn=94933
file:///C:/Users/SWEET%20HOME/Desktop/SGP90098%20(1).pdf
There was a complete safety department for the welfare of workers but there were some serious issues and hazards which are being
neglected and can cause serious accidents. I also checked the organization policy for workers in case of emergency and health
services of workers. All accidents and their corrected reasons were investigated by me for this risk assessment. I made a record for
financial, legal, moral and

Learner number: Learner name: Page 1 of 20

 Ethical arguments about suggestion that I gave to the organization for improvement of safety plan for the complete safety and
protection of the workers. To gain information about steps of safety I keenly observed workers either they are following the rules of
safety or not. Safety plans and preventive measures were being followed by workers and in some cases they are neglected I made a
record for this to notice the previous mistakes to avoid near misses and accidents. I also has checked OSHA for control measures.
https://www.osha.gov/SLTC/firesafety/hazards.html
https://www.ilo.org/dyn/natlex/docs/WEBTEXT/35384/64903/E97PAK01.htm#c1

* If you’re worried about confidentiality, you can invent a false name and location for your organisation but, all other information provided must be
factual.

Learner number: Learner name: Page 2 of 20

 Part 2: Risk Assessment

Organisation name: ENGRO Fertilizers

Date of assessment: 5th July,2020
Scope of risk assessment: Production department

Hazard category and hazard Who might be harmed What are you already doing? What further controls/actions are Timescal
and how? required? es for
further Responsible
actions to person’s job
be title
complete
d
(within …)
Fire All the Workers present Personal Protective 1. If reasonably Possible 2 months Production
in the plant can be Equipment were Provided eliminate this hazardous Manager
There was a modification harmed by fire. (Safety activity in running plant it (1-5)
(Extension line) require on Sheield,goggles,shoes,gloves should be during
main product stream line When there is hot work , turnaround or shutdown.
for this hot work (Welding, in running plant which is Safety helmet). 2. If it’s not possible to 2 weeks Safety
Cutting, Grinding) was highly flammable Fire Extinguishers were Postpone there must be manager
going on line in a Running environment it will Provided according to fire Fire brigade available at (4,5)
Plant. defiantly cause fire which Class. work site so fire can be
can leads to serious First Aid Kit Was provided. control at initial stages.
disastrous injuries and Permit to work was done. 3. There must be Fire 1 week
fatality. blanket around the hot
work site because there
is highly flammable
environment.
4. There must be health and 3 months
safety plan for hot work at
running plant.
5. There must be Job

Learner number: Learner name: Page 3 of 20

Hazard category and hazard Who might be harmed What are you already doing? What further controls/actions are Timescal
and how? required? es for
further Responsible
actions to person’s job
be title
complete
d
(within …)
Hazard analysis before 1 month
Activity.

Fire All the Workers present Fire Extinguishers were 1. If reasonably possible 2 months Production
in the plant can be Provided according to fire elimination of this Manager
Hot wok was going on in harmed by fire. Class. hazardous activity (1-5)
Running plant and Welding Permit to work was done because its Risk is high
Machine cable available When short Circuit occur Personal Protective in running plant it should
was without insulation it will get spark and in Equipment were Provided be during turnaround or Safety
which can cause Fire due highly flammable (Safety shutdown. manager
to short circuit because environment its chances Sheield,goggles,shoes,gloves 2. There must be 2 weeks (4,5)
there was lot of wires increases. , replacement of Welding
intermingling each other. Safety helmet). machine and it should be
First Aid Kit Was provided. 3rd party certified.
3. There must be Proper 1 week
cable management
system.
4. There must be health and 3 months
safety plan for welding
work at plant in
operational conditions
5. There must be Job 1 month
Hazard analysis before
Activity.

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Hazard category and hazard Who might be harmed What are you already doing? What further controls/actions are Timescal
and how? required? es for
further Responsible
actions to person’s job
be title
complete
d
(within …)

Confined space. Workers working inside Fire Extinguishers were 1. There must be Flushing 2 months Production
the Vessel can be Provided before entering inside the Manager
There was choking occur in harmed. Vessel with Fire Brigade (1-5)
Main sludge catcher PTW was done . Jet Nozzle because if any
(Vessel) for cleaning and Due to sludge available pyrophoric material
for removing of blockage in inside the vessel there Personal Protective available it can handle at Safety
the vessel Workers were might be pyrophoric Equipment were Provided initial stages . manager
Working inside the Vessel, material which can catch (disposable coveralls, 2. There must be N2 purging 2 weeks (4,5)
there can be pyrophoric fire immediately and goggles,shoes,gloves,Safety of Vessel so can remove
material available inside leads to injuries and helmet). toxic gases inside the
the vessel . fatality . vessel .
First Aid Kit Was provided. 3. There must be 1 week
mechanical isolation
done before going inside
the vessel . 3 months
4. Confined space Health
and safety plan must be
devised for pyrophoric
material . 1 month
5. There must be Job
Hazard analysis before
Activity.

Confined Space Workers working inside Permit to Work was done If Reasonably possible it should 2 months Production

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Hazard category and hazard Who might be harmed
and how?
Workers were working
inside the vessel due to
choking of sludge catcher
(vessel ) without installing
proper ventilation source.
Work at Height
There was Extension of
production Line was going
on but for fixing the line
there need work at height
for which Uninspected
Learner number:
What are you already doing? What further controls/actions are Timescal
required? es for
further Responsible
actions to person’s job
be title
complete
d
(within …)
the Vessel can be be avoid confined space entry 2 weeks Manager
harmed. Gas test was Done before and there must be done 1 week (1-5)
entering inside the vessel. through flushing through Jet 3 months
Without installation of First Aid Kit was Provided Nozzles. 1 month
ventilation Working PPEs were Provided Safety
There must be Venturi Installed
inside the confined (disposable coveralls, manager (5)
before entering the vessel so
space there can be toxic goggles, shoes, gloves,
can vent the toxic gases
gases available and can Safety helmet). available inside the vessel.
cause immediate action
which leads to fatality. There must be Hole watcher
available outside the vessel for
Proper Communication.
Workers entering should be 3rd
party Certified .
There must be Job Hazard
analysis before going inside the
vessel .
All the workers who are Personal Protective 1. If reasonably possible 2 months Production
involved in the activity Equipment (Safety Helmet, There must be Manager
can be harmed. shoes, goggles, coverall)were elimination of scaffolding (1-5)
Provided . instead of this Permanent
Uninspected scaffolding platform should be used. 2 weeks
means it may or may not Permit to work for work at 2. There must be Proper Safety
be completed or suitable height was done. scaffolding and it should manager
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Hazard category and hazard Who might be harmed What are you already doing? What further controls/actions are Timescal
and how? required? es for
further Responsible
actions to person’s job
be title
complete
d
(within …)
scaffolding was used. for particular activity .if it be Inspected and Green (4,5)
falls it will leads to head First aid kit was provided. tagged.
or back bone injury to Scaffolding
the workers who are 3. Scaffolding Supervisor 1 week supervisor
standing on it . should be present at site (3).
so can modify
immediately where
require so can avoid any
accident by extending the
leg or body .

4. There must be health and 3 months

safety plan for workers
working at height.

5. All workers working on 1 month

height should be 3rd party
certified.

Work at Height The workers who is Permit to work for work at 1. If reasonably possible 2 months Production
working at height and height was done. there must be elimination Manager
Workers working at height who is standing beneath of work at height at (1-5)
for Maintenance of Level the Work at height First aid kit was provided. scaffolding and there
Transmitter of Vessel must be permanent
without Safety harness on Workers who are Personal Protective platform. Safety

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Hazard category and hazard Who might be harmed What are you already doing? What further controls/actions are Timescal
and how? required? es for
further Responsible
actions to person’s job
be title
complete
d
(within …)
scaffolding . working at height without Equipment (Safety Helmet, 2. There must be safety 2 weeks manager
safety harness can fall if shoes, coverall) were harness provided to (3,4,5)
they will lose Provided. workers who are working
balance ,and they will fall at height
,There might be head or 3. All safety harnesses 1 week
back bone injury . should be 3rd party
Workers who are certified, also scaffolding
standing beneath can be must be inspected.
harmed if tools fall on 4. All workers must have 1 month
beneath worker . attended work at height
training.
5. There must be Job safety 3 months
analysis of work at height
activity.

Load handling
Equipment
Crane Was used for
movement of pipe which
have to install for extension
of Production line crane
was Placed on uneven
surface.
All the Workers who are PPEs were provided (safety 1. There must be removal of 2 months Production
involved in that activity. helmet, shoes, goggles). Crane from uneven Manager
Permit to work system was surface if reasonably (1-5)
When crane was done for critical lifting activity possible and place where
placed on uneven there can be easy excess
surface and crane load Vehicle Entry Permit was also to place where have to Safety
can be unbalanced and done. place the PIPE. manager
fall on one side which Check list of Crane was also 2. There must be separate 2 weeks (3,4,5)
can be hazardous for done. lifting plan for lifting
workers working under activity. Rigging

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Hazard category and hazard Who might be harmed What are you already doing? What further controls/actions are Timescal
and how? required? es for
further Responsible
actions to person’s job
be title
complete
d
(within …)
crane it can also leads to 3. Crane and crane operator 3 weeks supervisor.
head injury or may be must be 3rd party certified. (2,4)
fatality. 4. There should be 3rd party 2 months
certified Rigging
supervisor available for
carryout the Lifting
activity safely and
through proper way.
5. There must be Soil test 2 months
Perform before the crane
has been placed.

Load handling All the workers working Permit to work system was 1. If reasonably possible 2 months Production
Equipment in lifting activity can be done for critical lifting activity there must be stoppage Manager
harmed. of crane activity until wind (1-6)
Crane Operation was going Vehicle Entry Permit was also speed will get normal.
on which was on high wind During high wind speed done. 2. If possible use Chain 2 weeks
speed more the 25mph more than 20mph there PPEs were provided (safety Block for Lifting if any Safety
which was exceeding the is chance that load will helmet, shoes, goggles). Hook available near the manager
limit. swing in air and crane Production line. (1,4)
boom may be unbalance Check list of Crane was also 3. There must be separate 3 weeks
and fall which leads to done. lifting plan for lifting Rigging
injuries and may be lead activity. supervisor.
to fatality if fall on some 4. Crane and crane operator 2 months (2,5,6)
worker .. must be 3rd party certified.
5. There must be double 1 week

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Hazard category and hazard Who might be harmed What are you already doing? What further controls/actions are Timescal
and how? required? es for
further Responsible
actions to person’s job
be title
complete
d
(within …)
check on rigging
techniques for make
Suring the load lifting way
is right or not.

6. There should be 3rd party

certified Rigging 2 months
supervisor available for
carryout the Lifting
activity safely and
through proper way.

Hazardous Substance All the workers working PPEs were Provided (Safety 1. There must be 2 months Production
inside the feed stock helmet ,safety shoes ,goggles elimination of rock Manager
Raw material used for area can be harmed. ) offloading inside the feed (1-5)
NPK(Nitro Phosphorous Dust mask were also stock, instead of this
Potassium) production was Rock phosphate is Provided. there must be bring in
Rock Phosphate which injurious to human health bags. Safety
was offloaded ,but during as it will leads to skin First Aid kit was provided. 2. There must be water 2 weeks manager
offloading the dust of Rock infection, also lungs and shower during offloading (4,5)
phosphate were inhaling by eyes irritation. so can settle down the
workers through breathing . dust.
3. There must be covered 3 weeks
area where offloading the
rock phosphate.
4. Workers who are doing

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Hazard category and hazard Who might be harmed What are you already doing? What further controls/actions are Timescal
and how? required? es for
further Responsible
actions to person’s job
be title
complete
d
(within …)
this Job must be provided 2 months
with proper welfare
facility and good food so
they can survive in dusty
environment.
5. There must be health and 3 months
safety plan for hazardous
environment.

Hazardous Substance All the workers working TBT (tool box talk ) was done 1. There must be 2 months Production
inside the feed stock Elimination of leakage of Manager
There was ammonia gas area can be harmed. ammonia and workers (1-5)
(which is intermediate Safety posters were who are fixing this must
product of NPK) leakage in Ammonia is highly toxic available. be skilled and
Production area which is a and corrosive gas which PPEs were provided (Safety experienced and fully Safety
toxic gas. can leads to Lung injury helmet ,safety shoes ,goggles equipped. 2 weeks manager
and several respiratory ) 2. If reasonably possible (4,5)
problem. .Face mask were also there must be limited
provided. access to workers
through area from where 3 months
First Aid Kit was provided. ammonia is coming.
3. There must be Control

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Hazard category and hazard Who might be harmed What are you already doing? What further controls/actions are Timescal
and how? required? es for
further Responsible
actions to person’s job
be title
complete
d
(within …)
system for stopping the
leakage of ammonia 2 months
4. Safe system of work must
be develop for workers
working inside the
production area so they
can feel secure and job
satisfaction. 3 months
5. There must be Job
hazard analysis of
hazardous substances.

Manual handling All the workers involved PPEs were provided (Safety 1. There must be 2 months Production
in manual handling can helmet ,safety shoes ,goggles elimination of unloading Manager
The Workers were be harmed. Gloves ). of machine manually (1-5)
offloading the welding There can be First Aid Kit was Provided . there must be Boom truck
machine manually from ergonomics problem by Permit to Work system was or crane must be used for
loading vehicle . manually handling the done offloading. Safety
welding machine, and Tool Box talk was conducted . 2 weeks manager
also can cause foot 2. If reasonably possible (4,5)
injury if machine get Use Pulley system for
unbalanced and fall on offloading by using
feet . certified pulley and Rope.

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Hazard category and hazard Who might be harmed What are you already doing? What further controls/actions are Timescal
and how? required? es for
further Responsible
actions to person’s job
be title
complete
d
(within …)
2 days
3. There can be share
weight between 3-4
workers if easy otherwise
increase no of persons so
can weight will divide and
there will be safe
offloading .
2 months
4. There must be safe
system of work for
workers inside the
premises.

5. There must be training 3 months

arrangements for workers
so they can be aware of
hazards of manual
handling.

Slip and Trip All the workers can be Tool box talk was conducted 1. There must be 2 months Production
harmed who are working barricading around the Manager
There was mechanical in that area and who is First Aid kit was provided . working place. (1-5)
work going on and tools passing though that area 2 weeks

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Hazard category and hazard Who might be harmed What are you already doing? What further controls/actions are Timescal
and how? required? es for
further Responsible
actions to person’s job
be title
complete
d
(within …)
were not properly placed . 2. There must be separate
on right place and there If there is no proper path should be provided Safety
was poor house keeping. housekeeping and tools for pedestrians . manager
There can be tripping were spread everywhere 2 days (4,5)
hazards. workers will hit them and 3. There must be proper
fall it will leads to knee house keeping of work
and head injury . place and tools should be
managed orderly .

4. There must be training of

workers so they can work 2 months
safely and with manners.

5. There must be health and

safety policy for tripping 3 months
hazards .

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 Part 3: Prioritise three actions and justification for the selection

You must pick the three highest priority/most urgent actions and justify your choice. Your justification must include moral, legal and
financial arguments (500 to 700 words); consideration of likelihood and probable severity of injury, ill-health and/or harm (150 to 250 words);
description of how effective each action is likely to be in controlling the risk (250 to 350 words).
I have prioritized following three actions
1. There must be Fire blanket around the hot work site because there is highly flammable environment.(Fire)
2. There must be N2 purging of Vessel so can remove toxic gases inside the vessel. (Confined Space).
3. There must be Proper scaffolding and it should be Inspected and Green tagged. (Work at height).

 Moral Arguments:
It is anticipation of all workers to work in an organization where there are properly safety plans and
security environment While working in an organization which is producing fertilization there are lot of hazards and risks
which can harm workers All these hazards can cause accidents Workers who are working in the organization deserve
proper safety and protection while doing work in organization.

During work around the hot work place there is high risk of flammable environment. It is moral duty of
organization to provide fire blankets for protection from fire hazard. Morally all workers who are working within that space need
protection and safety from organization and organization should fulfil its duty of safety properly. It is not suitable for a person to
sacrifice someone’s life for the organizational activities.
Within the confined space there is high risk of gases which are toxic and can harm the workers. It is moral
duty of organization to take precautions for the safety of workers who are working within the confined space. N2 Purging of
vessel can remove toxic gases from the vessel. When workers enter into the confined space then it is moral responsibility of
Organization to ensure his life security. While working at height it is moral responsibility of organization to
provide complete safe working environment. Scaffolding should be checked properly and there should be proper inspection of
scaffolding before the start of work. It is moral duty of organization to provide green tagged scaffolding for the safety of workers .

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  Legal Arguments:
ENGRO Fertilizer is one of the largest group in Fertilizer organization in Pakistan which is in
compliance with national and international laws and standards and liable to follow them .By acting upon above Control measures
its good for company`s reputation ,otherwise in case of any accident happening it will face legal charges which will defame it and
business and share value will be down.
As ENGRO is liable to ILO recommendations ,ILO has recommendations for Fire safety R164 - Occupational
Safety and Health Recommendation, 1981 (No. 164) . ILO has also has convention and recommendations for fire health and
safety for any EPC(Engineering ,Procurement ,Construction ) Work C167 - Safety and Health in Construction Convention,
1988 (No. 167) Its good enough for ENGRO to take actions on Control measures and save company’s reputation .

ILO has Recommendations for Confined space as confined space is critical activity which will be followed by The
Confined Spaces Regulations 1997 (1997 No. 1713). Also has recommendations about Confined space Workplace Safety
and Health (Confined Spaces) Regulations 2009 .By acting upon above rules and regulations it will be beneficial for ENGRO
fertilizer .

For work at height ILO has also many recommendations for which organization has to follow C167 - Safety and Health
in Construction Convention, 1988 (No. 167 There is also health and safety policy for workers for UK and all over the world The
Work at Height Regulations 2005 (2005 No. 735). By acting upon the above regulations of work at height it will be good
enough for company`s business and reputation.

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  Financial Arguments:
Every company based on Profit and earning and all things should be smooth if nothing is
going to be non-routine activity i.e. high risk and non-routine activity .As above mentioned control measures there can be cost
control which will come when there is accident happens inside the premises .The cost which will be due to accident is much
greater then the cost which will come on control measures.
The Following direct and indirect Costs will be Controlled by taking above control measures.
Medical cost which will defiantly come after accident happens.
 Ill health cost
 Insurance costs which has to be faced by company
 Equipment cost which will be damaged if accident happens.
 Property damage which costs money
 Production Loss due to accident
 Loss time Injury which will occur
 Accident will effect Customer`s trust on company.
 It will increase turnover rate .
 Costs to hire new employees and train them .
All above costs have to bear by company so its better to spend money on control measures and save above costs .

 Likelihood and severity

 Likelihood in working without fire blanket is high because there is high risk of fire while hot work without fire blankets
within the flammable environment. In the working area there are flammable vapours which can catch fire. All workers who
are working around the hot work can be harmed. Severity, if fire accident occurs it is highly risky because it will harm all
workers working within that area. Workers may be injured or even death can occur.

 Likelihood in working within confined space without the removal of toxic gases is high because there are more chances of
accidents within the confined space in presence of toxic gases . Toxic gases can harm all workers who are working in the
confined space. Severity , if workers work within the toxic gasses environment they may suffer with serious diseases and
in some cases fatality can occur.

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 Likelihood of working on height without proper inspection of scaffolding is medium because workers can fall and get
injured but there is no high risk of all workers. Severity of falling from height due to false scaffolding is high and worker
may get harmed seriously. There are risks of being injured throughout life, bone fracture and in some cases death or
worker can occur.
 Effectiveness in Controlling Risk :

1. By using fire blankets fire hazard risk can be reduced. Without the use of fire blanket while doing hot work within the
working area risks are higher as compared to the use of fire blanket. By using this preventive action fire
accidents can be lessened as there are many flammable vapours that can catch fire and workers may get harmed .It is
also important in sense of high quality safety planning shows positive culture of health and safety of the organization. By
using proper safety action for workers worker will be relaxed , fear of hazard will be less and rate of absentee will be low.
According to likelihood and severity there time scale has been given 1 week .

2 In the confined space for the removal of toxic gases from the vessel N2 purging is used which removes all toxic gases
from the vessel and the working environment is safe for workers.N2 is an inert gas and removes other gases from the
confined space therefore it is effective to be used for the safety of workers within the confined space. It is a quick and
easy preventive method for the removal of toxic gases for the protection of workers within the confined space. According to
likelihood and severity there time scale has been given 2 week .

3 While working at height workers are given proper scaffolding to avoid any kind of accident. Proper inspection of
scaffolding is effective to ensure worker’s safety. Green tag on scaffolding shows that it is in its good condition to use. By
using inspected and properly checked scaffolding risks for falling of the workers is lessened and workers are provided
proper safety precaution. When there is highly controlled safety system regarding to work at height workers will be
satisfied and there will be no any fear of getting harmed during work. According to likelihood and severity there time scale
has been given 1 week .

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Part 4: Review, communicate and check

You must now give a review date for your risk assessment and say why you have chosen this date (10 to 50 words).

As per the policy of the organization I will check the organization after one year on 5 th July ,2021 . Besides this there must
review of risk assessment in case if any accident ,incident or near miss happens .

You must now indicate how the risk assessment findings will be communicated (including who needs to know the information) (100 to 150
words).

For the complete discussion of my risk assessment report I will call meeting of Safety manager, General manager and production
manager. I will explain them all points and logics which are being discussed in my report. I will explain them about the accidents
and causes of that accidents why they occurred and responsible persons for this. I will explain them each step of my report and
make them aware about previous mistakes and negligence of safety measures. I will present my suggestions about safety
measures that will be effective to use and will be in low budget. After this meeting and approval from these authorities I will
explain my preventive actions in front to workers to make them aware about the possible hazards

You must now indicate how you will follow-up on the risk assessment to check that the actions have been carried out (100 to 150 words).

For checking the implementation of preventive actions I will visit the organization keenly and notice each hazard risk and
preventive actions either they are followed or not. I will make a complete list for each hazard risk and likelihood of accident
caused by these hazards. If there is no obeying of preventive actions then I will try to find the basic reason behind it. After It I will
talk to safety manager and production manager about it . If there is not positive response from these persons I will discuss it with
General manager and explain him about the severity of the hazard and elaborate him effectiveness of preventive action with a
précised and easy way.

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