A STUDY AND ANALYSIS ON OCCUPATIONAL HEALTH RISK

IN

ABC LIMITED

RASLAFFAN INDUSTRIAL CITY

DOHA, QATAR

Unit 2 Assignment report submitted to

British Safety Council in partial fulfillments of the requirements for award of

International Diploma in Occupational Safety & Health

By

STUDENT NAME

Register No:

Verified By

Mr.R.XXXXXXX

Project Manager, ABC Limited, Doha, Qatar

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 LIST OF CONTENTS

S.NO DETAILS PAGE. NO

1 Executive Summery 4

2 Description of workplace & activity 5-8

3 Identification of Occupational health hazards 9 - 10

4 Background Research 11

5 Assessment of Risks 12

6 Proposed control Measures 13 - 15

7 Conclusion 16

8 Bibliography 17

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 LIST OF APPENDICES

S.NO TITLE NO

1 Foam Glass Insulation MSDS 1

2 PIR insulation - MSDS 2

3 COSHH Risk Assessment 3

4 Job Freeze Audit document 4

5 Tool Box Talk document 5

6 Verification Certificate 6

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 Part - 1

Executive Summery

The study on Occupational health risk carried out at ABC Limited

workshop and warehouse facility located at Raslaffan Industrial City, Doha,
Qatar.

ABC limited one of the largest insulation, painting, scaffolding, fire

proofing, civil contracting organization with excess of 25 years of
experience in Oil & Gas, Power generation sectors in the Gulf region.

The organization has got excellent Safety Management system and

supports for every genuine safety recommendations to prevent ill health of
employees.

The Occupational health risk assessment carried out with a team

members at foam fabrication shop .

During the foam fabrication activity using various machineries, the

particulate matter and a mild odor of acidic gas observed. Even with
operational engineering controls in place, (exhaust ventilation system and
dust collector) it is less effective at the point of actual fabrication.

The necessary recommendations made to replace the dust mask with

NIOSH approved respiratory cartridges to protect from the mild acidic odor
and particulate matter and safety goggle with a mono goggle with side
protection to protect the eyes. Trial carried out for a month and found to be
comfortable and satisfactory from employees. Organization procured the
same for use and implemented in work location.

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 Part – 2

Description of Workplace and Activity

ABC Limited of Qatar associated with XYZ group, one of the largest
insulation, painting, scaffolding, fire proofing, refractory and civil contracting
organization has access to the full financial and technical expertise of the
group.

ABC limited has in excess of twenty five years of experience and

reputation serving clients in the Oil & Gas, Power generation and
Commercial sectors in the Gulf.

The study was undertaken in the ABC workshop and warehouse

facility situated in Grid locator # AB / 32 at west support services area of
Raslaffan Industrial city, Doha, Qatar.

This work area comprises of the following:

1. Office and Administration building

2. Warehouse Building
3. Maintenance Workshop
4. Sheet metal workshop
5. Foam insulation cutting & fabrication shop
6. Grit blasting and coating area
7. Power Room
8. Utility Room
9. Guard House.

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The study was undertaken in the foam glass and PIR prefabrication
workshop.

Scope of work

For thermal insulation of utility systems, Cora foam or PIR rigid foam
is used. The rigid expanded polyurethane modified polyisocyanurate foam
is being manufactured and supplied by Duna – USA Inc in the size of
18cm x 45cm x 60 cm blocks.

The foam blocks are cut, fabricated to the required / relevant size &
shape and fabricated in the workshop to suit the shape and position of the
pipeline / equipment(s) needs to be insulated.

FOAM GLASS / PIR FOAM SHAPED FABRICATED FOAM

BLOCK

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EQUIPMENTS HANDLED:

The following machineries are being used to fabricate foam in the

workshop.

1. Computerized profile cutting equipment

2. Horizontal and vertical band saw
3. Horizontal block splitter
4. Table saw
5. Routing machine
6. Multipurpose Shiplap Machine
7. Large Bend cutting machine
8. Small bend cutting machine

WORK ACTIVITY

1. As per the requirements of the size & shape, the solid rigid foam
block will be cut by CNC machine for automatic operation.
2. The same cutting operation normally done by using horizontal and
vertical band saw machine.
3. On cutting into required piece, it will be shaped to the requirement
with help of growing machine as well as using horizontal band saw
to attain required curvature for the cylindrical sub strates.
4. All the above said work activities are performed after a thorough
risk assessment carried out by a team of members, after the risk
brought to As Low As reasonably practicable level ( ALARP) by
suitable & sufficient control measures and suitable & adequate
personal protective equipments ( PPEs)usage with supervision.

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 FOAM FABRICATION ACTIVITY USING HORIZONTAL / VERTICAL
BAND SAW MACHINES

FOAM GLASS / PIR FOAM BLOCK VERTICAL BAND SAW

18 CM X 45 CM X 60 CM SIZE MACHINE

HORIZONTAL BAND SHAPED FABRICATED

SAW MACHINE FOAM

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 Part – 3

Identification of Occupational Health Hazard

A thorough risk assessment carried out in the foam glass / PIR

workshop forming a team.

The team members were:

1. Mr.Karunaharan - Project Manager

2. Mr. Nagabooshanam - HSE Officer
3. Mr.Cheriyl Mathai babu - Fabrication shop In charge
4. Mr. Ananta Prasty - CNC machine operator
5. Mr.Manian Gopi - Worker Representative
6. Unnikrishnan Jhodiger - Worker Representative

The list of hazards identified at workplace during operation is:

1. Slip, trip and fall

2. Thermal and fire hazard
3. Contact with moving parts/machinery
4. Contact with stationary objects
5. Manual Handling
6. Handling chemical / harmful substances
7. Dust
8. Electrical hazards
9. Environmental hazards

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 All the above hazards are adequately controlled and the risks are
brought below As Low As Reasonably Practicable (ALARP) level and
activities are monitored under continuous supervision.

In addition to routine risk assessment, the organization carries out

Monthly COSHH inspection, Weekly job freeze audit and daily tool box
talks to ensure employees safety and prevention of occupational ill health.

SELECTION OF HAZARD FOR STUDY

The company management suggested having study on the hazards

related to foam glass / PIR fabrication operation as recently they observed
a quarry from an employee regarding the PPE they were using during
fabrication activity.

As in the rest of the activities the risk is within controlled level, as

suggested by the management, foam glass / PIR fabrication work activity is
taken to do a detailed risk assessment specific to respiratory and eye
protection.

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 Part – 4

Background Research

Two types of insulation materials are being used for thermal

insulation purposes. One is foam glass (Glass Oxide chemicals) and the
other one is polyurethane modified polyisocyanurate foam that is called PIR
foam ( MSDS as appendices 1 & 2 ).

During fabrication activity, generally particulate respirator

(dust mask – N95) and safety goggle (spectacle meets ANSI Z-87.1-2010
and CE EN 166 – 2201) were being used in addition to hand protection,
head protection, general body protection and foot protection.

HAZARDS IDENTIFIED

During the process of foam fabrication, it releases quantities of

particulate matter 10 from foam glass and PIR foam blocks.

In addition to particulate release, a suspected negligible odor of acidic

gas found to be present which was the concern for the employee exposed
to the said activity.

It is further observed that the safety goggle used is not giving any
side protection for employee. (COSHH assessment as appendices – 3)

Even though engineering controls like exhaust ventilation, dust

collector is available and in use, still the effectiveness at the point of foam
fabrication, it is less effective.

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 Part – 5

Assessment of Risks

Activity: Foam fabrication in foam glass / PIR workshop

Hazard Who might be harmed Existing Further

Identified & How control necessary action
measures
Release of Employee involved in the Exhaust Identify adequate
particulate activity by breathing Ventilation. respiratory
matter Dust Collector. protection
Use of dust
mask ( N 95 )
( 3M 9010)
Release of Employee involved in the Exhaust Identify adequate
negligible activity by breathing Ventilation respiratory
quantity of Use of dust protection
acidic mask ( N 95 )
fumes ( 3M 9010)
Particulate Employee involved in the Safety goggle Identify adequate
matter activity. Particulate may without side eye protection
(Dust) enter enter through sides of protection
eyes / the goggle
eyebrow

MSDS of both foam material – appendices 1 & 2

COSHH assessment – appendices 3

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 Part – 6

Proposed Control Measures

Case 1 & 2 : Release of particulate matter and odor of acidic gas

during fabrication of foam

Existing control measures : Use of dust mask (N95, 3M 9010)

Disadvantages : Does not protect against any particulate

matter fully and cannot filter acidic fumes

Consequences : Prolonged exposure to particulate matter

and acidic gas may cause respiratory

problem ( Chronic effect)

Key control measures : Instead of dust mask, use of respirator

with filter cartridge (3M – 6000 series &

NIOSH approved) to filter the acidic /

organic vapor and the particulate matter

Projected cost : Present cost of dust mask - Qr 01 /piece

Respirator with cartridge - Qr 135 / piece

Expected benefits : Protection of employees from ill health

Employee satisfaction

High morale due Mgt commitment

Increased production

Reduction in sickness / absenteeism.

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 Proposed Control Measures

Case – 3 : Particulate matter enter eyes during fabrication work

Existing control measure : Use of safety goggle without side protection

Consequence : The particulate matter may enter through

sides of the goggle and create irritation to

eyes and eye problems

Key projected control measure: Instead of safety goggle, use of goggle

with side protection ( BS EN 166 – 2001)

Mono goggle / Splash proof goggle is

recommended for use

Projected cost : Safety goggle – Qr 16 / piece

Goggle with side protection – Qr 60

Benefits : Protection of employee’s eyes

Reduced sickness / absenteeism

Reduced visit to first aid centre

Improved morale / satisfaction

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IMPROVEMENTS POST RISK ASSESSMENT AT FABRICATION SHOP

DUST MASK WITH RESPIRATORY MASK WITH

SAFETY GOGGLE SIDE PROTECTED SAFETY

(PRIOR TO ASSESSMENT) GOGGLE (POST ASSESSMENT)

EXISTING ENGINEERING CONTROLS

DUST COLLECTOR EXHAUST VENTILATION

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 Conclusion

ABC Limited Management, Qatar decided to adhere the said

recommendations and procured few pieces of said personal protective
equipments as a trial basis to check the result from activity area.

Post one month use of recommended respiratory mask instead of

dust mask and side protected mono goggles instead of normal safety
goggles, the employees feel comfortable while using recommended
personal protective equipments.

The effective use of the same is being monitored and recorded.

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 Part – 7

Bibliography

1. www.3M.com / PPE safety – June 2015

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