Candidate Report

UNITIGC3THEHEALTHAND
SheetNumber1of5
SAFETYPRACTICAL
APPLICAITONINTERNATIO
NALGENERAL
Candidatereporttemplate
CERTIFICATE
(2011specification)
Studentnumber:00268752
Location:FAZALSteel(Pvt.)LimitedIslamabad,Pakistan
Date
of
review:
26/January/2015
_______________________________________________________________________________
_
INTERNATIONALGENERAL
CERTIFICATE
(2011specification)
SAFETYPRACTICALAPPLICATION
Sheetnumber1of
26/January/2015
Date
of
review:
1.Introduction
The report is based on the good and bad practices related tooccupationalhealth andsafety
carried out in FAZAL Steel (Pvt.) Limited situated in Islamabad, Pakistan.FAZAL Steel(Pvt.)Limited
deals in productionofreinforcementsteelbarsASTM615AGrade40andGrade60. FAZALSteel(Pvt.)
Limited is situated on the service road connected to main highway.The number of workerspresent in
the Steelmill is 170.Mostoftheprocessiscarriedoutbyautomaticmachinesbutsomeprocesses may
involvemanualoperation.
FAZALSteel(Pvt.)Limitedconsistsoffollowingunits:
PhysicalTestingLab
SteelRerollingmill
o PreheatingFurnace
o RoughStand
o IntermediateStand
o PinchRoll
o TMT
o TailBreaker
o ShearMachine
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(2011specification)
NALGENERAL
Date
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26/January/2015
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WaterTurbineunit
CoalGasProductionunit
SalesServicesDepartment
LogisticsParkingArea
There is a road connecting Physical Testing Lab, Steel Rerolling Mill, water Turbine Unit, Coal gas
productionUnit,SalesServicesDepartmentandLogisticsParkingAreawitheachother.
Physical Testing Lab monitors the Standards and Grading of Steel, Coal gas production unit
provides burning gas to produce fire and heat to meltthebillets inHeatingFurnaceat atemperatureof
about 1100C,Water TurbineUnit supplywatertothemillforthe coolingandquenchingprocessaswell
asdrainouthotwater from themill andallowittocoolinopenairinlargetanks.LogisticsParkingArea
is for theparking of loading trucksforthemovementof raw materiali.e. billets aswell as productsi.e.
Steelbars.
2.ExecutiveSummary
The overall housekeeping of the mill was very convincing for me, therewasno contamination orany
kindofspillageofoilwaspresent in the mill, noobstruction onthefloor.The structureoftheSteelMill
was well maintained and ventilated. Adequately maintainedfirstaidboxeswerepresent in the control
room. Emergency alarms were properly fitted ondifferentprominent places toalert the workersabout
emergencysituation.
But on further inspection unfortunately Inoticedthat anumberofareas were open to the risk of injury
andcanevencause death,besideequipmentdamage.Mostoftheoperationswereautomaticbutsome
aremanuallyoperated both typeofoperations werecreatingsignificantrisks fortheworkerswhichwere
present there due to mismanagement and lack of maintenance. Some machines were without safety
guardswhichmay result in entrapment andentanglementof the worker. On some areasworkerswere
not using proper Personal Protective Equipments and they were unaware of safety practises. There
were no sign boards present in the working area which was very alarming situation. There were no
appropriatewelfarefacilitieslike clean drinking waterand toilets presentfortheworkers.Noprohibition
ofSmoking in the working area. Nodesignated fire exit, for the evacuationofthepeopleincaseoffire,
was present. There were noproper anddefined pathways forpedestrian and loading truck which may
causecollisionandsevereaccidents.
All these conditions were showing that a review of the procedures and bad practises and health and
safety lags by the employeris verynecessary. Information, instruction and trainingforthe workers are
necessary to promote health and safety culture inthemill andtoavoidrisks and hazards to minimum
possiblelevel.
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SAFETYPRACTICAL
CERTIFICATE
(2011specification)
NALGENERAL
Date
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26/January/2015
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3.Mainfindingsoftheinspection
3.1RiskofCollisionofloadingtruckandpedestrian:
For the supply ofrawmateriali.e. Billetsaswellasforproduct i.e.Steel bars,thereisatrafficofloading
trucksinthemill and alsothere ismovement of different workersandvulnerable peopleinthemill,but
there is no separate anddefined paths for the loading trucks andpedestrian whichcancause serious
accidentandcollision.
There should be designated and separatepathways forthepedestrian and loading trucks, thiscan be
donebypainting the path withdifferentcolours. In this way segregationofpedestrianand loadingtruck
will be done whichmay lessentheaccident andcollision risk.Banksmanshouldalsobepresentforthe
safemovementofloadingtrucks
3.2Riskoffireandfirespread:
As different tasks carried out in the Steel mill involve the flameandalso there aresomemaintenance
works also done in the mill which involve hot work i.e. hydrogen welding using hydrogen cylinders.
Hydrogen gas isavery inflammable gas andimproper handlingof cylindermaycause explosion aswell
asfireby completing fire triangle.Workers were not using cylindersproperlyinupright directionduring
welding and also they were moving here and there by revolving the cylinder instead of using moving
cradlewhichwasarisktoexplosionandfire.
Therewas onlyonefireextinguisherpresent in suchalargeareaofthemill,whichwasinsufficientand
cannotstopthefirespread.
To minimise the riskof firefromthehydrogencylinders,always use the cylinderin uprightpositionand
use moving cradle for the movement of cylinder, the number of fire extinguisher shouldbe increased
accordingtotheareaofthesteelrerollingmillandproperlychecked.
Fire drillexercises shouldalsobeorganisedperiodicallytomaketheworkerawareofemergency planin
caseoffireemergency.
3.3Absenceofsignboardsandsafetyguards:
Sign boardsi.e. prohibition signboards,mandatory signboards, fireexitsignboard etc are oneofthe
best and simple way of informing the people,it also shows the management commitmenttowards the
developmenthealthandsafetycultureintheorganisation.
But unfortunately in the whole area oftheSteel Millthere wasno signboard present whichmay bea
causeofaccident.
Thereshould beanerected signboardbesidesthe road,connectingdifferentUnitsofSteelmill,showing
the speed limit of the moving vehicle, also thereshould beNoParking boardsbesidesthegates.No
Smoking boards should be present where ignition can cause fire risk similarly high voltage danger
signboard should also be present where the high voltages electricity is present. Out of Bound for
irrelevant people note mayalso be pasted on the doors ofcontrolroom. There should bepictograms
showingthecorrectandsafetechniquesofmanualhandlingofload.
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Date
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I strongly recommend installation of signboards on their appropriate places which may reduce the
probabilityofanyaccidentoranyillhealth.
It was also noticed thatthere were no safetyguards ondifferentequipmentslikeshearcuttingmachine
andside guards onintermediaterollstandwhichwasoneofthemost commonreasonofaccidentin the
mill, because the red hot barcomingoutofthepreheatingfurnaceslips down and slides towards the
workerandthemachinecausingdamage.
Safetyguards shouldbeadjusted whereitisnecessaryandalwayscheckthe presenceofsafety guards
beforestartingthemill/machines.
3.4Riskofmanualhandling:
During the inspectionit was observed thattheworkswereunloadingbillets from the loading truckto the
conveyorbeltof preheatingfurnace,thecontinuousloadingofbilletswithnobreaksleadstotheserious
injury. This poor manual handling technique could quickly leadtobackache,MSDs orother injuriesto
worker and long term absence from the workdueto ill health. Also the workers were not seems to be
fully trained for the manual handling. Manual handling risks should be avoided where reasonably
practicable and where risks remain they are minimised by proper protection measures, training and
supervision.Workersshouldbe remindedof themanualhandlingriskbyinstallingpictogramboards.Itis
the duty of the employer to provide proper refresh training to the workers about the manualhandling
techniques.Thetrainingshouldbeshortandcanbedoneattheirmonthlymeetings.
Also use the over head crane for loading the billets instead of manual handling. The work practices
should bemonitored foraperiodaftertraininganditisrecommendedthatawarenesstrainingisdoneas
partoftheannualdepartmentmeetingstominimisetheaccidentrate.
3.5WelfarefacilitiesandPersonalProtectiveEquipment:
Drinkingcleanwater isan essentialneedof every humansimilarly provision of clean drinkingwaterto
worker is one the basic need of the worker,afterthattoilet is also a basicneedforaworkerworkingin
theworkplace.
The condition of water cooler present in the mill was very bad the coolers tap and glass was
contaminated by the oil and greasy material which may cause severe illness with acute and chronic
illness effects. Therewas no toilet present in the millthetoilet which the workers wereusingwasvery
far away from the workplace which maybe a sourceof wastageoftime as well as mental fatigue and
stress for the workers. According to ILO occupational Health and safety convention CI55, its the
responsibilityoftheemployertoprovidewelfarefacilitiestoitsemployees.
Another observation wasthat some PPE were presentbutmost ofthe PPE were not presenti.e. hard
helmets, hard shoes etc. According ILO occupational Health and safety convention CI55 and
recommendationR164,itstheresponsibilityoftheemployertoprovidePPEtoworkersfreeofcost.
SoproperPPEsshouldalsobeprovidedtotheworkerssoastominimisetherisks
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SAFETYPRACTICAL
NALGENERAL
CERTIFICATE
(2011specification)
Date
of
review:
26/January/2015
_______________________________________________________________________________
_
4.Conclusions
TheoverallhousekeepingoftheMillwasverygoodandimpressive,therewasinsurancepolicyforthe
workersbutthereweresomebasicandessentialthingsregardinghealthandsafetypresentcreating
risk.
ThemostsignificanthazardsandtheircausesandconsequencesaremainlyrelatedtoFire,absenceof
signboard,vehicleandworkerscollisionhazards,poormaintenance,unsafeworkingpractises,absence
ofPPE,machinerysafetyguardsandpoorwelfarefacilities.Alltheproblems,whichwereidentifiedin
themainfindingsofthereport,cancausesevereinjuryorfatality,whichwouldcausesufferingtovictims
andtheirfamilies.
Under the ILO Occupational Safety andHealth convention C155, article16(1) it istheduty ofemployer
to ensure the safe working environment and equipment, including carrying out the maintenances to
protectworkers,visitorsandallotherswhomaybeintheworkplaceorintheworkingenvironment.
Besides other aspects the consequences of these hazards are financially very huge, as failure to
managerisk can also lead to prosecutions andpenaltieswhich aretheindirectcoston the factoryand
effectsthereputationandfinancialpositionofthefactoryaswell.
The total cost of the recommendations are very less than the consequences of the safety issues
discussedandweightedagainstthelossinaccidentorthepenaltiesandfines.
I suggested that by considering and implementing my recommendations the mill can decrease its
accident rateand can improveitshealthandsafety culture,whichalsosavetheindirectcostsrelatingto
these risks whichare sometimes veryhuge. Beside all these it will also improves the reputation ofthe
millinacompetitivemarket.
5.Recommendationsincludeasatableinthefollowingformat:
Recommendation
Likelyresourceimplications
Priority
Targetdate
3.1 Traffic movement in

the mill should be
segregated
from
pedestrian. This can be
done by designating
separate pathways by
painting floorwithdifferent
colours.
Using different paints colour the

floor, making two different paths
forloadingtrucksandpedestrian.
Estimatedcostisaround550.
High
High
30January2015
28January2015
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SAFETYPRACTICAL
NALGENERAL
CERTIFICATE
(2011specification)
Date
of
review:
26/January/2015
_______________________________________________________________________________
_
3.2 Increase the number
of fire extinguisher in the
mill.
Provide at least 4 to 5 fire

extinguishers,estimated cost115
.
Annually inspected the tags by

the relevantpersons.Noexternal
cost.
Low
3.2 Inspection of fire

extinguishers.
26January2015
Carried out by the safety

personnel,noexternalcost.
Low
3.2 Organize Fire safety

drillexercises.
Estimatedcostis150
3.3 Erect Speed limit

board on the road
connecting different units
ofmill,No Smokingboard
fire exit signboards and
other signage stickers for
theirappropriateplaces.
7April2015
Immediately
High
Estimatedcostis3540
High
Estimatedcostis170
High
3.3 Install fence around

thewatertanks
3.3 Insert safety guard on

the shear machine and
intermediatestand.
3.4 Give the appropriate

manual handling training
toworkers.
No externalcostinvolves. Just a
fewtimeofsupervisor.
3.4 Installing overhead

crane to eliminate therisk
ofmanualhandling.
Around 1500 may berequired

for the installation of overhead
crane.
Immediately within
23hrs
14Feb2015
Immediately
High
Medium
1March2015
SheetNumber7of5
SAFETYPRACTICAL
NALGENERAL
CERTIFICATE
(2011specification)
Date
of
review:
26/January/2015
_______________________________________________________________________________
_
High
Estimatedcosttobe200
Estimatedcostis370
High
3.5 Construction of toilet

near/inthererollingmill.
Estimatedcostis350360

3.5ProvideElectriccooler
with filters and keep it
clean.
3.5 Provide PPE i.e. Hard

shoes, ear plugs, hard
helmets
and
safety
goggles.
High
Immediately
20Feb2015
Immediately

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UNITIGC3THEHEALTHAND

3.1 Traffic movement in

Using different paints colour the

Provide at least 4 to 5 fire

Annually inspected the tags by

3.2 Inspection of fire

Carried out by the safety

3.2 Organize Fire safety

3.3 Erect Speed limit

3.3 Install fence around

3.3 Insert safety guard on

3.4 Give the appropriate

3.4 Installing overhead

Around 1500 may berequired

3.5 Construction of toilet

3.5 Provide PPE i.e. Hard

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