ACHIEVERS UNIVERSITY, OWO

NAME: IBRAHIM SALIHU

MATRIC NUMBER: AU24EB7423

DEPARTMENT: BIOMEDICAL ENGINEERING

COURSE TITLE: INTRODUCTION SAFETY

ENGINEERING

MAY, 2025
 ASSIGNMENT

WORKPLACE SAFETY AND REGULATORY ASSESSMENT

1. Risk Assessment in a Chemical Manufacturing Facility

A) PROPOSED CONTROL MEASURES (HIERARCHY OF CONTROLS)

1. Chemical Exposure

PPE: Use of respirators and chemical-resistant gloves.

Feasibility: Substitution and engineering controls are cost-intensive but long-term effective. PPE
is low-cost but least reliable if used alone.

Elimination/Substitution: Replace hazardous solvents with less toxic alternatives where feasible.

Engineering Controls: Install local exhaust ventilation at source points.

Administrative Controls: Rotate shifts to limit exposure duration.

2. Noise

PPE: Provide earplugs or earmuffs.

Feasibility: Engineering solutions are effective and durable; PPE provides immediate protection
but depends on compliance.

Engineering Controls: Enclose noisy machinery and install sound-dampening materials.

Administrative Controls: Limit time in high-noise areas.

3. Biological Agents

Engineering Controls: Regular maintenance and cleaning of HVAC systems.

Administrative Controls: Implement scheduled inspections.

PPE: Gloves and masks during cleaning.

Feasibility: Preventive maintenance is cost-effective and eliminates the hazard at the source.
4. Manual Handling

Engineering Controls: Use trolleys, hoists, or powered lifters.

Administrative Controls: Ergonomics training and job rotation.

PPE: Back support belts (with limited effectiveness).

Feasibility: Equipment investment has high upfront cost but greatly reduces injury rates.

5. Work-Related Stress

Administrative Controls: Implement mental health support programs and adjust workloads.

Training: Stress management workshops and supervisor training.

Feasibility: Low cost and highly beneficial for morale and productivity.

B) REPORT SUMMARY

Executive Summary: This report evaluates key hazards in a chemical manufacturing facility.
Five major hazards were identified across physical, chemical, biological, ergonomic, and
psychosocial categories. Risks were prioritized using a standard risk matrix and addressed
through controls based on the hierarchy of hazard control.

Findings: Chemical exposure and work-related stress pose the highest risks. Noise and manual
handling are medium risks, while biological hazards are relatively low risk. Controls were
proposed for each, emphasizing engineering solutions and administrative changes over PPE
reliance.

C) IDENTIFICATION OF POTENTIAL HAZARDS

As a safety engineer, the following five types of hazards have been identified at the facility:

1. Chemical Hazard (Chemical exposure): Workers are regularly exposed to volatile organic
compounds (VOCs), corrosive substances, and flammable solvents.

2. Physical Hazard (Noise): Machinery such as pumps and mixers generate high noise levels
exceeding 85 dB.
3. Biological Hazard (Mold/Bacteria in cooling systems): Poorly maintained HVAC systems can
harbor biological agents.

4. Ergonomic Hazard (Manual handling): Workers manually transport heavy chemical drums
without adequate aids.

5. Psychosocial Hazard (Work-related stress): High work pressure and long shifts contribute to
mental fatigue and stress.

D) RISK EVALUATION USING RISK MATRIX

HAZARD LIKELIHOOD SEVERITY RISK LEVEL

Chemical exposure Likely Severe High

Noise Likely Moderate Medium

Biological Agents Unlikely Moderate Low

Manual handling Likely Moderate Medium

Work-related Stress Possible Major High

Risk Matrix:

Low: Acceptable; monitor and review

Medium: Address with controls

High: Immediate action required

Recommendations:

Invest in exhaust systems and safer chemical alternatives.

Upgrade equipment to reduce noise and manual lifting strain.

Maintain HVAC systems regularly to control biological risks.

Risk Assessment Matrix & Control Prioritization Chart:

Hazard Risk level Top control measures Priority

Chemical exposure High Substitution, ventilation 1

Work stress High Mental health programs 2

Manual handling Medium Lifting aids 3

Noise Medium Soundproofing, PPE 4

Biological Hazards Low HVAC maintenance 5

A) PROPOSED IMPROVEMENTS

1. Mental Health Regulations:

Introduce mandatory stress and fatigue management plans.

2. Dynamic Chemical Hazard Training:

Require annual training updates based on emerging data.

3. Incentives for SME Compliance:

Provide grants or tax breaks for small businesses to implement PSM protocols.

B) ANALYSIS OF CURRENT SAFETY REGULATIONS

1. OSHA Hazard Communication Standard:

Ensures labeling and SDS availability.

Effectiveness: Highly effective in awareness, but gaps in worker comprehension remain.

Targets prevention of chemical releases through engineering and procedures.

Effectiveness: Strong framework, but many small firms lack resources for full compliance.

3. EPA Risk Management Plan Rule:

Focuses on offsite impact reduction.

Effectiveness: Ensures emergency preparedness but weak in frequent facility audits.

Gaps Identified:

Lack of mental health and stress-related regulations.

Inadequate training on evolving chemical hazards.

Inconsistent enforcement in smaller facilities.

CONCLUSION

The assessment of the chemical manufacturing facility has revealed a range of hazards that span
chemical, physical, biological, ergonomic, and psychosocial categories. Among these, chemical
exposure and work-related stress represent the highest risks, requiring urgent and comprehensive
control measures. By applying the hierarchy of controls, it is clear that long-term solutions such
as substitution, engineering controls, and administrative strategies offer the most sustainable
impact, while PPE serves as an essential but last-line defense.