Occupational Safety and Health Division (OSHD)

Ministry of Manpower (MOM)

AN AID TO HAZARD IDENTIFICATION AND CONTROL IN RISK ASSESSMENT FOR

SOME TYPICAL PROCESSES AND WORK ACTIVITIES
IN CHEMICAL & GAS BOTTLING PLANTS

The information here is intended to assist employers, manufacturers, suppliers and

users conducting risk assessments to identify hazards, possible accidents/ill-health,
and suitable control measures from common work activities in chemical and gas
bottling plants.

The processes and work activities stated here are only some typical examples and
may vary from workplace to workplace.

The possible hazards, accidents/ill-health and suggested control measures supplied

below are not exhaustive. Other possible hazards not indicated should also be
controlled to required standards but are not dealt with here.

It is essential for risks to be eliminated or reduced “at source”. If a risk cannot be

controlled completely by engineering measures, it is necessary to protect the
employees by administrative control@ or personal protection. The control of hazards
and reduction of risks can be accomplished by following the hierarchy of control
methods below. These control measures are not usually mutually exclusive. e.g.
engineering controls can be implemented together with administrative controls like
training and safe work procedures.

@ Training, safe work procedures, scheduling incompatible work, etc.

Eliminate /
Substitute
Most
Engineering preferred
Controls

Administrative
Least
Measures preferred

PPE

For ease of reference in completing the Risk Assessment Form in Appendix 12 of

MOM’s OSH Guidelines on Risk Assessment, the items in the examples provided in
this aid have been arranged and labelled ‘1a.’, ‘1b.’ etc. to indicate the respective
columns in the Risk Assessment Form to which the items apply. The “Possible Risk
Control” items may apply to either Existing Risk Control (2a) or Additional Risk
Control (2b) in the Risk Assessment Form.

-1-
 Occupational Safety and Health Division (OSHD)
Ministry of Manpower (MOM)
Chemical Handling and Blending Process
1a. 1b. 1c. 1d. 2a. or 3a.

No. Work Activity Hazard Possible Accident / Ill- Possible Risk Control
Health
1 Receiving bulk chemicals Moving vehicles Injuries or deaths from • Attend and complete forklift driver training
traffic accident • Abide by speed limit
• Designate loading/unloading bay
• Install warning alarms
Leaking drums / Chemical spill, excessive • Install gas/vapour detection systems
containers inhalation / skin • Place drum/containers on spill control pallets
absorption of chemicals • Build bund walls
• Implement emergency plans
• Conduct regular drills
Inhalation of fugitive Ill-health from chemical • Install gas/vapour detection systems
chemical emissions overexposure • Install ventilation system in storage area
• Provide well-ventilated, non-air-conditioned work area
Inhalation of hazardous Ill-health from chemical • Engage competent person in charge to manage hazardous
products from overexposure substances
undesirable reactions • Segregate incompatibles
upon incompatible mixing • Provide well-ventilated, non-air-conditioned work area
• Label chemicals
• Obtain and use information in MSDSs
• Provide hazard communication training
• Implement safe work procedures
Fire and explosions from Injuries / deaths • Segregate incompatibles
excessive heat produced • Prohibit ignition, heat sources, smoking and open flames
and flammable vapours • Provide well-ventilated, non-air-conditioned work area
• Label chemicals
• Obtain and use information in MSDSs
• Provide hazard communication training
• Implement safe work procedures
• Install deluge / fixed water systems
• Implement emergency plans
• Conduct regular drills
2 Weighing of raw Fire and explosions Injuries / deaths • Install local exhaust ventilation system
materials • Install dilution ventilation
• Provide well-ventilated work area
• Prohibit ignition, heat sources, smoking and open flames

-2-
 Occupational Safety and Health Division (OSHD)
Ministry of Manpower (MOM)
1a. 1b. 1c. 1d. 2a. or 3a.

No. Work Activity Hazard Possible Accident / Ill- Possible Risk Control
Health
• Implement safe work procedures
• Provide and attend training on fire and explosion safety
• Install deluge / fixed water systems
• Implement emergency plans
• Conduct regular drills
Excessive inhalation of Ill-health due to chemical • Install local exhaust ventilation system
solvent vapours overexposure • Build enclosure around weighing scale
• Automate weighing system
• Provide well-ventilated, non-air-conditioned work area
• Implement safe work procedures
• Practice good housekeeping
• Provide and attend training on solvent hazards and control
measures
• Provide, use and maintain respiratory protection
Excessive skin Dermatitis, ill-health due • Automate washing/cleaning system
absorption of solvents to chemical • Implement safe work procedures
overexposure • Provide and attend training on solvent hazards and control
measures
• Provide, use and maintain eye, body and hand protection
Excessive inhalation of Ill-health due to chemical • Install local exhaust ventilation system
dust (from raw materials overexposure • Build enclosure around weighing scale
in powder or solid form) • Automate weighing system
• Implement safe work procedures
• Practice good housekeeping
• Provide and attend training on dust hazards and dust control
measures
• Provide, use and maintain respiratory, eye, face, body and
hand protection
Burnt by corrosive Eye / skin burns • Install local exhaust ventilation system
solutions (e.g. acids, • Build enclosure around weighing scale
alkalis etc) • Automate weighing system
• Implement safe work procedures
• Provide eye wash, emergency shower
• Practice good housekeeping
• Provide and attend training on corrosive hazards and their

-3-

1a. 1b. 1c.
No. Work Activity Hazard
Splashes by chemicals
during agitation / mixing /
blending
3 Mixing/Blending Limbs caught in moving
mechanical parts of
mixer / blender
Fire & explosions
Excessive inhalation of
solvent vapours
produced by agitation,
mixing or blending
Excessive noise
exposure from moving
Occupational Safety and Health Division (OSHD)
Ministry of Manpower (MOM)
1d. 2a. or 3a.
Possible Accident / Ill- Possible Risk Control
Health
control measures
• Provide, use and maintain eye, face, body and hand
protection
Eye / skin irritation, • Install covers on mixer/blender
dermatitis • Build enclosures around mixer/blender
• Implement safe work procedures
• Provide and attend training
• Provide, use and maintain eye and face protection
Amputations, fractures, • Install machine guarding
sprains • Install sensors
• Install warning alarms
• Implement safe work procedures
• Provide and attend training on machine guarding
Injuries / deaths • Install local exhaust ventilation
• Build covers on mixer/blender
• Build enclosures around mixer/blender
• Install dilution ventilation in work area
• Prohibit ignition, heat sources and open flames
• Provide well-ventilated, non-air-conditioned work area
• Implement safe work procedures
• Provide and attend training on fire and explosion safety
• Install deluge / fixed water systems
• Implement emergency plans
• Conduct regular drills
Ill-health due to chemical • Install local exhaust ventilation
overexposure • Build covers on mixer/blender
• Build enclosures around mixer/blender
• Install dilution ventilation in work area
• Provide well-ventilated, non-air-conditioned work area
• Implement safe work procedures
• Provide and attend training on solvent hazards and control
measures
• Provide, use and maintain respiratory protection
Noise induced deafness • Substitute noisy mechanical parts with quieter ones
• Build enclosures padded with noise-absorbing materials
-4-

1a. 1b. 1c.
No. Work Activity Hazard
mechanical parts of
mixer / blender
Splashed by chemicals
during agitation / mixing /
blending
4 Packing into smaller Fire & explosions
containers / drums
Excessive inhalation of
solvent vapours
produced during packing
Splashed by chemicals
during packing
Repeated lifting of
packed containers /
Occupational Safety and Health Division (OSHD)
Ministry of Manpower (MOM)
1d. 2a. or 3a.
Possible Accident / Ill- Possible Risk Control
Health
around mixer/blender
• Maintain mechanical parts regularly
• Provide and attend hearing conservation training
• Implement safe work procedures
• Put up warning signs
• Provide, use and maintain hearing protection
Eye / skin irritation, • Install covers on mixer/blender
dermatitis • Build enclosures around mixer/blender
• Implement safe work procedures
• Provide and attend training
• Provide, use and maintain eye and face protection
Injuries / deaths • Automate packing system
• Install local exhaust ventilation system
• Install dilution ventilation in work area
• Prohibit ignition, heat sources and open flames
• Provide well-ventilated, non-air-conditioned work area
• Implement safe work procedures
• Provide and attend training on fire and explosion safety
• Install deluge / fixed water systems
• Implement emergency plans
• Conduct regular drills
Ill-health due to chemical • Automate packing system
overexposure • Install local exhaust ventilation system
• Install dilution ventilation in work area
• Provide well-ventilated, non-air-conditioned work area
• Implement safe work procedures
• Provide and attend training
• Provide, use and maintain respiratory protection
Eye / skin irritation, • Automate packing system
dermatitis • Build enclosures around packing system
• Implement safe work procedures
• Provide and attend training
• Provide, use and maintain eye and face protection
Back aches, strains • Automate packing system
• Use pallets with adjustable heights that respond to weight of
-5-
 Occupational Safety and Health Division (OSHD)
Ministry of Manpower (MOM)
1a. 1b. 1c. 1d. 2a. or 3a.

No. Work Activity Hazard Possible Accident / Ill- Possible Risk Control
Health
drums packed containers/drums
• Provide mechanical lifting aids
• Implement safe work procedures
• Provide and attend ergonomics training
• Use proper lifting posture
• Provide adequate breaks
5 Maintenance of Electrocution Electric shock, deaths • Implement log out/tag out
mixer/blender • Implement safe work procedures
• Provide and attend training
• Put up warning signs
Limbs caught in moving Amputations, fractures, • Implement log out/tag out
mechanical parts of sprains • Implement safe work procedures
mixer / blender • Provide and attend training on machine guarding
• Put up warning signs
6 Cleaning/washing of Electrocution Electric shock, deaths • Implement log out/tag out
mixer/blending • Implement safe work procedures
• Provide and attend training
• Put up warning signs
Limbs caught in moving Amputations, fractures, • Implement log out/tag out
mechanical parts of sprains • Implement safe work procedures
mixer/blender • Provide and attend training on machine guarding
• Put up warning signs
Excessive skin Dermatitis • Automate washing/cleaning system
absorption of solvents • Implement safe work procedures
• Provide and attend training
• Provide, use and maintain eye, body and hand protection
Excessive inhalation of Ill-health due to chemical • Install local exhaust ventilation
solvent vapours overexposure • Install dilution ventilation in work area
• Provide well-ventilated, non-air-conditioned work area
• Implement safe work procedures
• Provide and attend training on solvent hazards and control
measures
• Provide, use and maintain respiratory protection

-6-
 Occupational Safety and Health Division (OSHD)
Ministry of Manpower (MOM)
Typical Process for Pipe Maintenance
1a. 1b. 1c. 1d. 2a. or 3a.

No. Work Activity Hazard Possible Accident / Ill- Possible Risk Control
Health
1 Isolate and purge Scalded from contact Burns on skin / eye • Monitor isolation and purging with Distributed Control
pipeline with heated piping System
with steam • Put up warning signs
• Communicate hazard to others in the vicinity prior to work
commencement
• Barricade area
Excessive noise Noise induced deafness • Put up warning signs
exposure from steam • Communicate hazard to others in the vicinity prior to work
emission commencement
• Barricade area
• Provide, use and maintain hearing protection
2 Remove pipe Inhalation of residue Ill-health due to acute • Ensure adequate purging
chemicals in pipe chemical overexposure • Ensure temperature and pressure within pipes are lowered
to ambient temperature
• Install gas/vapour detection systems
• Implement permit-to-work systems
• Put up warning signs
• Implement safe work procedures
• Provide and attend training on chemical safety
• Barricade area
• Provide, use and maintain respiratory, body, face and hand
protection
Burnt by corrosive Burns on skin / eye • Ensure adequate purging
chemical residue in pipe • Ensure temperature within pipes are lowered to ambient
temperature
• Implement permit-to-work systems
• Put up warning signs
• Implement safe work procedures
• Provide and attend training on chemical safety
• Barricade area
• Provide, use and maintain respiratory, body, face and hand
protection
Hit by pipes and other Bruises, sprains • Place warning tape on low overhead protrusions and pipes
protrusions • Barricade area
• Provide, use and maintain head protection

-7-
 Occupational Safety and Health Division (OSHD)
Ministry of Manpower (MOM)
1a. 1b. 1c. 1d. 2a. or 3a.

No. Work Activity Hazard Possible Accident / Ill- Possible Risk Control
Health
3 Maintenance of pipe off- Excessive noise due to Noise induced deafness • Substitute noisy machines with quieter ones
site machining works • Enclose noisy processes
• Use silencers and mufflers
• Put up warning signs
• Provide and attend hearing conservation training
• Provide, use and maintain hearing protection
Excessive inhalation of Ill-health due to chemical • Install local exhaust ventilation system
cleaning solvent vapours overexposure • Cover and build enclosures around degreasing machines
• Install dilution ventilation in work area
• Implement safe work procedures
• Provide and attend training on solvent hazards and control
measures
• Put up warning signs
• Provide, use and maintain respiratory protection
Excessive skin Dermatitis, ill-health due • Mechanise degreasing machines
absorption of cleaning to chemical • Implement safe work procedures
solvents overexposure • Provide and attend training
• Put up warning signs
• Provide, use and maintain eye, body and hand protection
4 Re-install pipe Hit by pipes and other Bruises, sprains • Place warning tape on low overhead protrusions and pipes
protrusions • Barricade area
• Provide, use and maintain head protection

Typical Process for Loading Chemicals into Isotankers

1a. 1b. 1c. 1d. 2a. or 3a.
Possible Accident / Ill-
No. Work Activity Hazard Possible Risk Control
Health
1 Connect transfer pipes Hit by falling valve Body / head injuries • Substitute heavy valves with lighter ones
from vessel to isotanker • Use mechanical lifting aids
• Practice good housekeeping to ensure valve surface is kept
clean and is not slippery
• Implement safe work procedures
• Provide and attend training
• Provide, use and maintain PPE

-8-
 Occupational Safety and Health Division (OSHD)
Ministry of Manpower (MOM)
1a. 1b. 1c. 1d. 2a. or 3a.
Possible Accident / Ill-
No. Work Activity Hazard Possible Risk Control
Health
Falling from heights Deaths, fractures, • Provide a secure work platform
sprains • Install barricades
• Provide, use and maintain fall arrest devices
Chemical splash as valve Skin / eye burns • Use a quick connect valve instead of one with a handle that
is accidentally opened can easily twist open upon impact on ground
upon impact with the • Implement safe work procedures
ground • Provide and attend training
• Provide, use and maintain PPE
2 Load chemicals into Fugitive emissions of Ill-health due to chronic • Implement bottom-loading isotankers to minimise agitation
isotanker chemicals created in chemical overexposure during filling
headspace of isotanker • Provide and attend training on chemical safety
during filling • Implement safe work procedures
• Provide, use and maintain PPE
Chemical leaks due to Spills, ill-health due to • Engage a competent person to be in charge of hazardous
corrosion or wear and chemical overexposure substances to ensure compatibility of pipe material with
tear of transfer pipes chemicals transferred
• Conduct periodic checks and maintenance
• Implement safe work procedures
• Provide and attend training
• Provide, use and maintain PPE
Undesirable hazardous Ill-health due to chemical • Label all chemical drums/containers
products from mixing of overexposure • Ensure isotankers are clean before topping up/charging
incompatible chemicals • Provide and attend chemical safety training
Fire and explosion Deaths, injuries • Install solvent vapour recovery system
• Implement bottom-loading isotankers to reduce solvent
vapour emissions
• Prohibit ignition, heat sources and open flames
• Implement safe work procedures
• Provide and attend training on fire and explosion safety
• Install deluge / fixed water systems
• Implement emergency plans
• Conduct regular drills
3 Uncouple transfer pipes Hit by falling valve Head / body injuries • Substitute heavy valves with lighter ones
from isotanker • Use mechanical lifting aids
• Practice good housekeeping to ensure valve surface is kept
clean and is not slippery

-9-
 Occupational Safety and Health Division (OSHD)
Ministry of Manpower (MOM)
1a. 1b. 1c. 1d. 2a. or 3a.
Possible Accident / Ill-
No. Work Activity Hazard Possible Risk Control
Health
Falling from heights Deaths, fractures, • Provide a secure work platform
sprains • Install barricades
• Implement safe work procedures
• Provide and attend training
• Provide, use and maintain fall arrest devices
Chemical splash as valve Eye / skin burns or • Use a quick connect valve instead of one with a handle that
is accidentally opened irritation can easily twist open upon impact on ground
upon impact with the • Implement safe work procedures
ground • Provide and attend training
• Provide, use and maintain PPE

Typical Process for Unloading Chemicals from Isotankers

1a. 1b. 1c. 1d. 2a. or 3a.
Possible Accident / Ill-
No. Work Activity Hazard Possible Risk Control
Health
1 Connect transfer pipes Hit by falling valve Head / body injuries • Substitute heavy valves with lighter ones
from isotanker to • Use mechanical lifting aids
receiving vessel • Practice good housekeeping to ensure valve surface is kept
clean and is not slippery
• Implement safe work procedures
• Provide and attend training
• Provide, use and maintain PPE
Chemical splash as valve Eye / skin burns, eye / • Use a quick connect valve instead of one with a handle that
is accidentally opened skin irritation can easily twist open upon impact on ground
upon impact with the • Implement safe work procedures
ground • Provide and attend training
• Provide, use and maintain PPE
2 Load chemicals into Undesirable hazardous Ill-health due to • Use pipes with different diameters for incompatible
receiving vessel products from mixing of inhalation of hazardous chemicals
incompatible chemicals chemicals • Colour code pipes
• Label pipes clearly
• Ensure hazard communication between driver and plant
personnel
• Provide and use Material Safety Data Sheets
• Provide and attend chemical safety training
Fire and explosions from Deaths, injuries • Install solvent vapour recovery system

- 10 -
 Occupational Safety and Health Division (OSHD)
Ministry of Manpower (MOM)
1a. 1b. 1c. 1d. 2a. or 3a.
Possible Accident / Ill-
No. Work Activity Hazard Possible Risk Control
Health
heat produced and • Implement bottom-loading isotankers to reduce solvent
flammable vapours vapour emissions
• Prohibit ignition, heat sources and open flames
• Implement safe work procedures
• Provide and attend training on fire and explosion safety
• Install deluge / fixed water systems
• Implement emergency plans
• Conduct regular drills
Hit by falling valve Head / body injuries • Substitute heavy valves with lighter ones
• Use mechanical lifting aids
• Practice good housekeeping to ensure valve surface is kept
clean and is not slippery
• Implement safe work procedures
• Provide and attend training
• Provide, use and maintain PPE
Chemical splash as valve Eye / skin burns, eye / • Use a quick connect valve instead of one with a handle that
is accidentally opened skin irritation can easily twist open upon impact on ground
upon impact with the • Implement safe work procedures
ground • Provide and attend training
• Provide, use and maintain PPE
3 Uncouple transfer pipes Hit by falling valve Head / body injuries • Substitute heavy valves with lighter ones
from receiving vessel • Use mechanical lifting aids
• Practice good housekeeping to ensure valve surface is kept
clean and is not slippery
• Implement safe work procedures
• Provide and attend training
• Provide, use and maintain PPE
Chemical splash as valve Eye / skin burns, eye / • Use a quick connect valve instead of one with a handle that
is accidentally opened skin irritation can easily twist open upon impact on ground
upon impact with the • Implement safe work procedures
ground • Provide and attend training
• Provide, use and maintain PPE

Typical Process for the Changeover of Gas Cylinders

1a. 1b. 1c. 1d. 2a. or 3a.

- 11 -

No. Work Activity
1 Disconnect line from
cylinder
2 Remove gas cylinder
after checking it is empty
Occupational Safety and Health Division (OSHD)
Ministry of Manpower (MOM)
Possible Accident / Ill-
Hazard Possible Risk Control
Health
Inhalation of residue gas Ill-health due to chemical • Isolate and purge line upstream
in line overexposure • Monitor isolation and purge through computerised system
• Build enclosures around gas cylinders
• Install local exhaust ventilation system
• Implement safe work procedures
• Inform and train chemical suppliers / contractors
• Provide and attend training
• Provide, use and maintain PPE
Inhalation of remaining Ill-health due to chemical • Install on-line gas level indicator
gas in cylinder overexposure • Install gas detection system
• Isolate and purge cylinder before disconnection
• Monitor isolation and purge through computerised system
• Install local exhaust ventilation system
• Implement safe work procedures
• Inform and train chemical suppliers / contractors
• Provide and attend training
• Provide, use and maintain PPE
Uncontrolled leak of Ill-health due to chemical • Isolate and purge line upstream
upstream gas into gas overexposure, • Install local exhaust ventilation system
cylinder storage area unconsciousness, deaths • Install gas detection system
• Install pressure indicator
• Install warning alarm
• Implement emergency shutdown system
• Inform and train chemical suppliers / contractors
• Provide and attend training
• Conduct emergency planning
• Provide, use and maintain PPE
Hit by flying hose Bruises • Isolate line upstream
• Install pressure indicator
• Provide and attend training
Hit by toppling/falling Head / body injuries • Secure cylinders
cylinder • Install pallets with mounted rollers for ease of moving
cylinders
• Implement safe work procedures
• Provide and attend training
• Provide, use and maintain PPE
Manual lifting of heavy Back aches / pains • Use mechanical lifting aids
- 12 -
 Occupational Safety and Health Division (OSHD)
Ministry of Manpower (MOM)
1a. 1b. 1c. 1d. 2a. or 3a.
Possible Accident / Ill-
No. Work Activity Hazard Possible Risk Control
Health
cylinder • Install pallets with mounted rollers for ease of moving
cylinders
• Use proper lifting posture and method
• Implement safe work procedures
• Provide and attend training
• Provide, use and maintain PPE
3 Replace empty cylinder Hit by toppling/falling Head / body injuries • Secure cylinders
with filled cylinder cylinder • Install pallets with mounted rollers for ease of moving
cylinders
• Implement safe work procedures
• Provide and attend training
• Provide, use and maintain PPE
Manual lifting of heavy Back aches / pains • Use mechanical lifting aids
cylinder • Install pallets with mounted rollers for ease of moving
cylinders
• Use proper lifting posture and method
• Implement safe work procedures
• Provide and attend training
• Provide, use and maintain PPE
Excessive inhalation of Ill-health due to chemical • Install local exhaust ventilation system
gas due to leaking overexposure • Install gas detection system
cylinder • Install pressure regulator and indicator
• Implement safe work procedures
• Inform and train chemical suppliers / contractors
• Provide and attend training
• Provide, use and maintain PPE

- 13 -