iosh Managing safely v3.1 - project

Introduction

As part of the Managing safely course, you have to complete a project and have itassessed. You will be expected to carry out a risk assessment based on your own workenvironment. You need to record the results on the attached sheets and submit them formarking. Do not submit any additional material in support of your project work as only thesix parts of the A4 project will be assessed. The project can be word processed or handwritten.

When you have completed your work you should return it to

There is a two week time limit for the return of the project. Your project must be completedand returned by

Instructions

Please read all of the instructions before starting work on your project.

The project is broken down into a number of parts. Please complete each section asdetailed below.

Part 1 - description of the work tasks that are your responsibility

Record a brief description of all the work tasks within your work environment including:

• description/labelled sketch of the location(s)• people who work in or visit the area on a regular basis or from time to time. (Think

about the different groups of people who may be in the area and how often theymay be there.)

• permanent and temporary items of equipment and substances• activities carried out within your work environment

MS ProjectPack version 3.1

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Part 2 - a hazard checklist of the location(s)

Record a brief description of three location hazards that may arise in your workenvironment. For example, car park, stairs, uneven floor. For each of these hazardsplease include:

• a description of the location• a description of the hazard - in relation to the location• the number and occupation of people who could be affected by the hazard - in

relation to the location• whether a risk assessment is recommended

Part 3 - a hazard checklist of permanent and/or temporary items of equipment andsubstances used in your work environment

Record a brief description of three hazards that may arise from equipment or substancesused. For each of these hazards please include:

• a description of permanent and/or temporary items of equipment and substancesused

• a description of the hazard - in relation to the equipment/substance• the number and occupation of people who could be affected by the hazard - in

relation to the equipment/substance• whether a risk assessment is recommended

Part 4 - a hazard checklist of the activities carried out within your work environment

Record a brief description of three hazards that may arise from within your workenvironment. For each of these hazards please include:

• a description of the work activity• a description of the hazard - in relation to the work activity• the number and occupation of people who could be affected by the hazard - in

relation to the work activity

Note: for the purpose of this exerc;:ise all three activity hazards that you areassessing on part 4 must require a risk assessment.

Part 5 - carrying out a risk assessment

Please carry out a risk assessment on all three of the activity hazards you have listed onpart 4. Please make sure you include:

• a description of the work activity• a description of the hazard, hazardous event and expected consequence - in

relation to the work activity• the number and occupation of people affected - in relation to the work activity• an assessment of risk (please use the 5 x 5 matrix) - in relation to the work activity

Note: for the purpose of this exercise all three activity hazards that you areassessing on part 5 must require risk controls.

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Part 6 - risk control recommendations

Please complete the risk control form for all three activity hazards you have listed on part5. Please make sure you include:

• a description of the work activity and risk level from the risk assessment• existing risk controls• any further risk controls required - in relation to the work activity• the residual risk (please use the 5 x 5 matrix) - in relation to the work activity• a description of the type of monitoring required and how often - in relation to the

residual risk

Note: where you have large numbers of hazards in your work environment you will nothave space to record them all. In these circumstances, select a representative sample ofhazards for the purposes of this project and record only these. Remember that only threehazards are required for parts 2, 3, and 4.

Each part has a maximum number of marks which can be awarded and details are givenin the table below.

Part Maximum marks

1 18

2 16

3 16

4 13

5 30

6 30

Total 123

Minimum mark 62

Finally, before returning your project check that your name, the end of course date, thename of your company, the site name and the name of your training provider are recordedon the first sheet. '

Please also ensure that you sign each sheet to confirm that the work you submit is yourown.

Please note: the small square boxes in the bottom right hand corner of each sectionon parts 2 to 6 are for the markers use only.

MS ProjectPack version 3.1

Part 1 - description of the work tasks that are yourresponsibility (continued on the next page)

Delegate name HAMID All End of course date 18-11-13

Company EMAL Site name EMAL Aluminium Smelter, Taweela

Training provider Green World Group

A descriptionllabelled sketch of the location(s)

Maaden Aluminium Plant contains 4 areas1. Pot line in one pot line 4 Pot rooms2. Cathode sealing3. Anode sealing4. Casting facilities

A description of the people who work in or visit the area on a regular basisor from time to time and how often they're therePeople on regular basis

1. Civil Engineers Supervisor Operator Workers12 10 20 55

2. Mechanical Engineers Supervisor Operator Workers10 12 18 30

3. Electrical Engineers Supervisor Operator Workers11 11 22 40

4. Construction Engineers Supervisor Operator Workers10 10 05 20

5. Safety Manager Supervisor Officer01 ; 4 08

People on Visit

IManagers Administration

IVisitors

I05 06 20

ITotal

I270

I

Please sign to confirm that this is your own work: 9W

Marksallocated

¥

MS ProjectPack version 3.1

iosh Part 1 - description of the work tasks that are yourresponsibility

A description of permanent and temporary pieces of equipment andsubstances used in your work environment

Permanent Equipment Temporary Equipment1. Cranes 06 022. Bobcat 08 033. Dump Trucks 09 014. Mobile Elevator 10 015. Worker Vehicle 07 02

Substances

Raw Materials :

1. Alumina 60000 (MT)2. Coke 70000 (MT)3. Pitch 5000 (MT)

Product:

1. Aluminium 20000 (MT)

A description of the activities carried out within your work environment

This is a continuous process plant that will produce AluminiumUsing Alumina and coke first of all Coke will processed in Anode Baking ShopAfter baking in Carbone area after processed its shape would be rectangleThan it will go through in Pot Lines there giving high voltage electricity it will meltAnd would be refined. After that it will move into Cathode Baking Furnace buildingThere also it will refine after melting process and shaped as required. After thisprocess Aluminium blocks will be moving into cast house facilities for casting

All Equipment are using to moving the aluminium and also for housekeeping

~

Please sign to confirm that this is your own work:_-""---I-"'1"F'----t-+ __

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Marksallocated

iosh Hazard Checklist: locatlonsts)The location(s) you manage

Part 2

De artment: Field En Site name: EMAL ALMUNIUM

Description of the Description of the hazard Number and occupation of Risk assessmentlocation (in relation to the location) people affected recommended?

(in relation to the location) (If no, please explain)

5. Heavy Vehicles movement Engineers 01 LlYes ONaCoke raw materials carbon 6. Carbon dust Vehicles Operators 04plant area 7. Ground uneven Workers 18

8. Vehicle collision Operators 03

0 n Total 26 0 01. Inclement weather sun, rain, Sand Engineers 02 LlYes ONa

storm Vehicles Operators 03Installing Bus Bars in Pot 2. Noise of generator Workers 12rooms 3. Live services like electrical cables Operators 04

4. Manual material handling

0 0 Total 21 0 01. Vehicle collision Engineers 03 LlYes ONa2. Insufficient lighting Vehicles Operators 06

Anode rod shop in 3. Ergonomic hazard Workers 19maintenance area 4. Fire hazard during melting Operators 05

alumina

0 0 Total 33 0 0Please sign to confirm that this is your own work:~# MS Project

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Hazard Checklist: equipment and substancesPermanent and temporary pieces of equipment and substances used in the work environment

Part 3

EMAL De artment: Site name: EMAL ALMUNIUM

l. Uneven floor Engineers 01 [jYes ONO2. Insufficient lighting Vehicles Operators 03

Fork lifter 3. Overloading Workers 224. Speeding Operators 045. Collision

"0 0 Total 30 0 0Engineers 02 [jYes ONO

l. Chemical hazards Coke Dust Vehicles Operators 03Carbon during loading and unloading Workers 22

2. Exposure Operators 103. Inhalation of carbon

0 4. Crane moving hazard of workU Total 37 0 0collision

l. The crane collapsing or toppling Engineers 01 c:JYes ONOover Vehicles Operators 03

Crane 2. The load falling overloading Workers 153. Live services like cables Operators 024. Blind spot during work

0 0 Total 21 0 0Please sign to confirm that this is your own work: MS Project

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lash Hazard Checklist: activitiesActivities carried out within your work environment

Part 4

o

: EMAL Deoartment: Site name: EMAL ALMUNIUM

Note: For the purpose of this exercise, all three activity hazards must require a risk assessment.

Description Of,the I De~cri~tion Of,the h~zard I Number and occupat, ion ofWork activity (m relation to the work activity) ,I people affected' .

'(in relation to the wor,k,acl:iliiM""'A

1. Chemical hazards Coke Dust Engineers 00Unloading Coke and potting on I during loading and unloading Vehicles Operators 10the conveyer Exposure Workers 15

2. Inhalation of carbon Operators 093. Crane moving hazard of worker

0 collision o I Total 34

1. During erection of bus bar Engineers 07Setting the new bus bars by

Imoving of crane boom Vehicles Operators 01

crane in pot rooms 2. Blind spot for crane operator Workers 123. Collision with workers Operators 03

01 o I Total 23

o

o oEngineersVehicles OperatorsWorkersOperators

1. Noise of generators2. Fire hazard during welding3. Current hazard due to sparking4. Tools using in workshop5. Fume

00051405

Maintenance shop is formaintenance, repairing andwelding equipment

o ooo Total 24

Please sign to confirm that this is your own work:__ ~+-,t.b...£....-I-__

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~Risk assessmentrecommended?

~Yes ONO

rJYes ONo

~Yes ONo

MS ProjectPack version 3.1

iosh Risk assessment form Part 5

Site name: EMAL ALMUNIUMCompany: EMAL Department: Field Engineering

Note: For the purpose of this exercise, all three activity hazards must require risk contro s.Workactivity

Hazard, hazardous event and People Assessment of risk(m relation to the work activity)expected consequence affected Likelihood X Consequence = Risk

(in relation to the work activity) (in relation to the work level level levelactivity)

Are risk controls'required?

l. Chemical hazards Coke Dust during Occupation:

Unloading loading & unloadingVehicle operator,

Coke and May cause respiratory problem Workers & operators2. Crane moving hazard of worker

putting on the collision Injury Number: 22 4 5 20conveyer 0 5. Crane moving hazard of worker C 0 0 0 0collision

l. During erection of bus bar Occupation:~Yes ONoSetting the moving of crane boom Injury Engineer, Vehicle

operator, Workersnew bus bars 2. Blind spot for crane operator- & operators

by crane in Can cause collision workers 4 5 20potroomsc 3. Collision with workers 0 Number: 25 0 0 0 0May cause serious injury

l. Noise of generators hearing loss Occupation:~Yes ONOMaintenance 2. Fire hazard during welding Workers & operators

shop is for 3. Current hazard due to sparking cancause borne

maintenance 4. Tools using in workshop Injury [ Number: 15 4 4 16repairing 'E] 5. Fume ] 0 0 0 0welding

Date: 18-11-13 Time: 04:30 pm Review period: One Month Date of next review: 20-12-13

Assessor's name: Hamid Ali Position: Road Safety Officer Signature:

Please sign to confirm that this is your own work:_----"'""'"""i'-T9r---o--t- _MS Project

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iosh Risk control form Part 6

Company: EMAL Department: Field Engineering Site name: EMAL ALMUNIUM

Work activity Existing Further risk . Resid~alri~k .. Description of(In relation to t e wor activity)and risk level risk controls controls required Probable X Potential = New risk monitoring requiredj!\l{from risk (in relation to the work ,(in relation to tlie'Wotk activity) >Likelihood, '"Consequence level (in relation to the residual 'risk)

. ,as'sessmenUorm)"

' activity), '~ Ii " Ij '!iI!~

"$F'!

Unloading Coke 1. ProvideProper 2 3 6 Supervisionand putting on PPE's likedust 1. Job rotationthe conveyer mask 2. Installation of LEV

2. Instruction& " Barricade the area Frequency: After StartingJ.informationabout & Completing shift

Risk level: 200 safe systems0 0 0 0 0 QSetting the new 3. Proper 1. Permanent hard Engineerbus bars by Barricade barricading until workcrane in pot 4. Awareness by finish 3 2 6rooms training worker 2. Arrange training of Frequency: AfterRisk level: 200 0 workers for working in 0 0 0 Starting & Completing

~blind spot n shift

Maintenance Permanent monitoring duringshop is for 1. Provide ear 1. Workers training to wear working hoursmaintenance, plugs and use ear plugs 2 2 6repairing and C 2. Don't use 2. Provide fire Frequency: After Startingwelding handmade tools extinguishers & fire watch 0 0 0 & Completing shift 121I man 0Risk level: 16

Assessor's name: Hamid Ali Position: Road Safety Officer Signature:

MS ProjectPack version 3.1

Date: 18-11-13 Review period: One Month Date of next review:

Please sign to confirm that this is your own work: ..... In, I

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