iosh

Managing safely v3.1 - project

Introduction
As part of the Managing safely course, you have to complete a project and have it
assessed. You will be expected to carry out a risk assessment based on your own work
environment. You need to record the results on the attached sheets and submit them for
marking. Do not submit any additional material in support of your project work as only the
six parts of the A4 project will be assessed. The project can be word processed or hand
written.
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 completed
and 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 as
detailed 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 they
may be there.)
permanent and temporary items of equipment and substances
activities carried out within your work environment
MS Project
Pack version 3.1
. .
Part 2 - a hazard checklist of the location(s)
Record a brief description of three location hazards that may arise in your work
environment. For example, car park, stairs, uneven floor. For each of these hazards
please 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 and
substances used in your work environment
Record a brief description of three hazards that may arise from equipment or substances
used. For each of these hazards please include:
a description of permanent and/or temporary items of equipment and substances
used
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 work
environment. 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 are
assessing 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 on
part 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 are
assessing on part 5 must require risk controls.
MS Project
Pack version 3. 1
Part 6 - risk control recommendations
Please complete the risk control form for all three activity hazards you have listed on part
5. 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 not
have space to record them all. In these circumstances, select a representative sample of
hazards for the purposes of this project and record only these. Remember that only three
hazards are required for parts 2, 3, and 4.
Each part has a maximum number of marks which can be awarded and details are given
in 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, the
name of your company, the site name and the name of your training provider are recorded
on the first sheet. '
Please also ensure that you sign each sheet to confirm that the work you submit is your
own.
Please note: the small square boxes in the bottom right hand corner of each section
on parts 2 to 6are for the markers use only.
MS Project
Pack version 3.1
Part 1 - description of the work tasks that are your
responsibility (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 areas
1. Pot line in one pot line 4 Pot rooms
2. Cathode sealing
3. Anode sealing
4. Casting facilities
A description of the people who work in or visit the area on a regular basis
or from time to time and how often they're there
People on regular basis
1. Civil Engineers Supervisor Operator Workers
12 10 20 55
2. Mechanical Engineers Supervisor Operator Workers
10 12 18 30
3. Electrical Engineers Supervisor Operator Workers
11 11 22 40
4. Construction Engineers Supervisor Operator Workers
10 10 05 20
5. Safety Manager Supervisor Officer
01
;
4 08
People on Visit
I
Managers Administration
I
Visitors
I
05 06 20
I
Total
I
270
I
Please sign to confirm that this is your own work: 9W
Marks
allocated

MS Project
Pack version 3.1
iosh
Part 1- description of thework tasks that areyour
responsibility
A description of permanent and temporary pieces of equipment and
substances used in your work environment
Permanent Equipment Temporary Equipment
1. Cranes 06 02
2. Bobcat 08 03
3. DumpTrucks 09 01
4. Mobile Elevator 10 01
5. Worker Vehicle 07 02
Substances
RawMaterials :
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 acontinuous process plant that will produceAluminium
UsingAlumina andcoke first of all Coke will processed inAnode Baking Shop
After baking inCarbone area after processed its shape would be rectangle
Than itwill go through inPot Lines there giving highvoltage electricity itwill melt
And would be refined. After that itwill move into Cathode Baking Furnace building
There also itwill refine after melting process and shaped as required. After this
process Aluminium blocks will be moving into cast house facilities for casting
All Equipment are using to moving the aluminium andalso for housekeeping
~
Please signto confirmthat this is your ownwork:_-""---I-"'1"F'----t-+__
MS Project
Pack version 3.1
Marks
allocated
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 assessment
location
(in relation to the location)
people affected recommended?
(in relation to the location) (If no, please explain)
5. Heavy Vehicles movement Engineers 01
L lY es O N a
Coke raw materials carbon 6. Carbon dust Vehicles Operators 04
plant area 7. Ground uneven Workers 18
8. Vehicle collision Operators 03
0
n
Total 26
0 0
1.
Inclement weather sun, rain, Sand Engineers 02
L lY es O N a
storm Vehicles Operators 03
Installing Bus Bars in Pot 2. Noise of generator Workers 12
rooms 3. L ive services like electrical cables Operators 04
4. Manual material handling
0 0
Total 21
0 0
1.
Vehicle collision Engineers 03
L lY es O N a
2. Insufficient lighting Vehicles Operators 06
Anode rod shop in 3. Ergonomic hazard Workers 19
maintenance area 4. Fire hazard during melting Operators 05
alumina
0 0
Total 33
0 0
Please sign to confirm that this is your own work: ~#
MS Project
Pack version 3.1
Hazard Checklist: equipment and substances
Permanent 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 O N O
2. Insufficient lighting Vehicles Operators 03
Fork lifter 3. Overloading Workers 22
4. Speeding Operators 04
5. Collision
"0 0
Total 30
0 0
Engineers 02
[jYes O N O
l.
Chemical hazards Coke Dust Vehicles Operators 03
Carbon during loading and unloading Workers 22
2. Exposure Operators 10
3. Inhalation of carbon
0
4. Crane moving hazard of workU Total 37
0 0
collision
l.
The crane collapsing or toppling Engineers 01
c:J Yes O N O
over Vehicles Operators 03
Crane 2. The load falling overloading Workers 15
3. Live services like cables Operators 02
4. Blind spot during work
0 0
Total 21
0 0
Please sign to confirmthat this is your own work:
MS Project
Pack version 3.1
lash
Hazard Checklist: activities
Activities 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 of
Work activity (m relation to the work activity) ,I people affected' .
'(inrelation to the wor,k,acl:iliiM
""'A
1.
Chemical hazards CokeDust Engineers 00
Unloading Cokeandpottingon I duringloading andunloading Vehicles Operators 10
theconveyer Exposure Workers 15
2. Inhalation of carbon Operators 09
3. Cranemovinghazard of worker
0
collision oI Total 34
1. During erection of bus bar Engineers 07
Settingthenewbusbars by
I
moving of craneboom Vehicles Operators 01
craneinpot rooms 2. Blind spot for craneoperator Workers 12
3. Collisionwithworkers Operators 03
01
oI Total 23
o
o o
Engineers
Vehicles Operators
Workers
Operators
1. Noise of generators
2. Firehazardduringwelding
3. Current hazard duetosparking
4. Tools usinginworkshop
5. Fume
00
05
14
05
Maintenance shop isfor
maintenance, repairing and
welding equipment
o o o o
Total 24
Please sign to confirmthat this is your own work:__ ~+-,t.b.......-I -__
..
~
Risk assessment
recommended?
~Yes ONO
rJ Yes ONo
~Yes ONo
MS Project
Pack version 3.1
iosh
Risk assessment form
Part 5
Site name: EMAL ALMUNIUM Company: EMAL Department: Field Engineering
Note: Forthe purpose of this exercise, all three activity hazards must require riskcontros.
Work
activity
Hazard, hazardous event and People Assessment of risk
(mrelation to the work activity)
expected consequence affected Likelihood X Consequence = Risk
(in relation to the work activity) (in relation to the work level level level
activity)
Are risk controls'
required?
l.
Chemical hazards Coke Dust during
Occupation:
Unloading
loading &unloading
Vehicle operator,
Coke and
May cause respiratory problem
Workers &operators
2. Crane moving hazard of worker
putting on the
collision Injury
Number: 22
4 5 20
conveyer 05. Crane moving hazard of worker
C 0 0 0 0 collision
l.
During erection of bus bar
Occupation:
~Yes ONo
Setting the moving of crane boom Injury
Engineer, Vehicle
operator, Workers
new bus bars 2. Blind spot for crane operator- &operators
by crane in Can cause collision workers 4 5 20
potroomsc 3 . Collision with workers
0
Number: 25
0 0 0 0
May cause serious injury
l.
Noise of generators hearing loss Occupation:
~Yes ONO
Maintenance
2. Fire hazard during welding
Workers &operators
shop is for
3. Current hazard due to sparking can
cause borne
maintenance
4. Tools using in workshop Injury [
Number: 15
4 4 16
repairing 'E
]
5. Fume
]
0 0 0 0
welding
Date: 18-11-13 Time: 04:30pm Review period: One Month Date of next review: 20-12-13
Assessor's name: Hamid Ali Position: Road Safety Officer Signature:
Please signto confirmthat this is your ownwork:_----"'""'"""i'-T9r---o--t- _
MS Project
Pack version 3.1
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 =Newrisk
monitoring required
j!\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 Supervision
and putting on
PPE's likedust
1.
J obrotation
the conveyer
mask
2. Installation of LEV
2. Instruction&
" Barricade the area
Frequency: After Starting
J .
informationabout
&Completing shift
Risk level: 200
safesystems 0
0 0 0 0 Q
Setting the new 3. Proper 1.Permanent hard Engineer
bus bars by
Barricade barricading until work
crane in pot
4. Awareness by finish
3 2 6
rooms
training worker 2. Arrangetraining of
Frequency: After
Risk level: 200
0
workers for working in
0 0 0
Starting &Completing
~
blind spot
n
shift
Maintenance Permanent monitoring during
shop is for
1. Provide ear 1. Workers training to wear
working hours
maintenance,
plugs anduseear plugs
2 2 6
repairing and C
2. Don't use 2. Provide fire
Frequency: After Starting
welding
handmadetools extinguishers &firewatch
0 0 0
&Completing shift
121
I
man 0
Risk level: 16
Assessor's name: Hamid Ali Position: RoadSafety Officer Signature:
MS Project
Pack version 3.1
Date: 18-11-13 Reviewperiod: One Month Dateof next review:
Please sign to confirm that this is your own work: ..... In, I
..