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

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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 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
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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 6 are for the markers use only.

MS Project
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 Marks
allocated
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
Managers Administration Visitors
I 05 06 I 20 I

Total 270
I I I

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

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 Marks

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

responsibility
allocated

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. Dump Trucks 09 01
4. Mobile Elevator 10 01
5. 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 Aluminium

Using Alumina and coke first of all Coke will processed in Anode Baking Shop
After baking in Carbone area after processed its shape would be rectangle
Than it will go through in Pot Lines there giving high voltage electricity it will melt
And would be refined. After that it will move into Cathode Baking Furnace building
There also it will 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 and also for housekeeping

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

MS Project
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 Hazard Checklist: locatlonsts) Part 2
iosh The location(s) you manage

De artment: Field En Site name: EMAL ALMUNIUM

Description of the Description of the hazard Number and occupation of Risk assessment
(in relation to the location)
location people affected recommended?
(in relation to the location) (If no, please explain)

5. Heavy Vehicles movement Engineers 01 LlYes ONa

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

0 0 Total 21
0 0
1. Vehicle collision Engineers 03 LlYes ONa
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 0
Total 33
0
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 Hazard Checklist: equipment and substances Part 3
Permanent and temporary pieces of equipment and substances used in the work environment

EMAL De artment: Site name: EMAL ALMUNIUM

l. Uneven floor Engineers 01 [jYes ONO

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 ONO
l. Chemical hazards Coke Dust Vehicles Operators 03
Carbon during loading and unloading Workers 22
2. Exposure Operators 10
3. Inhalation of carbon
4. Crane moving hazard of workU Total 37
0 collision 0 0
l. The crane collapsing or toppling Engineers 01 c:JYes ONO
over Vehicles Operators 03
Crane 2. The load falling overloading Workers 15
3. Live services like cables Operators 02
4. Blind spot during work
Total 21
0 0 0 0
MS Project
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 Hazard Checklist: activities Part 4
lash Activities carried out within your work environment
: 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
Work activity
I De~cri~tion Of,the h~zard
(m relation to the work activity)
I
,I
Number and occupat, ion of
people affected' .
Risk assessment
recommended?
'(in relation to the wor,k,acl:iliiM
""'A

1. Chemical hazards Coke Dust Engineers 00 ~Yes ONO

Unloading Coke and potting on I during loading and unloading Vehicles Operators 10
the conveyer Exposure Workers 15
2. Inhalation of carbon Operators 09

0
3. Crane moving hazard of worker
collision o I Total 34
o o
1. During erection of bus bar Engineers 07 rJYes ONo
Setting the new bus bars by moving of crane boom Vehicles Operators 01
crane in pot rooms I 2. Blind spot for crane operator
3. Collision with workers
Workers
Operators
12
03

01 o I Total 23
o o
~Yes ONo
Maintenance shop is for 1. Noise of generators Engineers 00
maintenance, repairing and 2. Fire hazard during welding Vehicles Operators 05
welding equipment 3. Current hazard due to sparking Workers 14
4. Tools using in workshop Operators 05

o 5. Fume
o Total 24 o o
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iosh Risk assessment form Part 5
Company: EMAL Department: Field Engineering Site name: EMAL ALMUNIUM

Note: For the purpose of this exercise, all three activity hazards must require risk contro s.
Work Hazard, hazardous event and People Assessment of risk
(m relation to the work activity)
Are risk controls'
activity expected consequence affected Likelihood X Consequence = Risk required?
(in relation to the work activity) (in relation to the work level level level
activity)
l. Chemical hazards Coke Dust during Occupation:
loading & unloading
Unloading Vehicle operator,
May cause respiratory problem
Coke and Workers & operators
2. Crane moving hazard of worker
putting on the collision Injury 4 5 20
conveyer 0 5. Crane moving hazard of worker
collision C
Number: 22
0 0 0 0
l. During erection of bus bar Occupation:
Setting the moving of crane boom Injury
Engineer, Vehicle ~Yes ONo
operator, Workers
new bus bars 2. Blind spot for crane operator- & operators
by crane in Can cause collision workers 4 5 20
3. Collision with workers Number: 25
potroomsc
May cause serious injury 0 0 0 0 0
l. Noise of generators hearing loss Occupation:
Maintenance 2. Fire hazard during welding Workers & operators ~Yes ONO
3. Current hazard due to sparking can
shop is for cause borne
maintenance Number: 15 4 4 16
repairing
welding
'E] 4. Tools using in workshop
5. Fume
Injury [
] 0 0 0 0

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:

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 Part 6
iosh Risk control form
Company: EMAL Department: Field Engineering Site name: EMAL ALMUNIUM

Work activity Existing Further risk . Resid~alri~k ..

(In relation to t e wor
activity)
Description of
and risk level risk controls controls required Probable X Potential = New risk monitoring required
j!\l{from risk (in relation to the work ,(in relation to tlie'Wotk activity) (in relation to the residual 'risk)
. ,as'sessmenUorm)
>Likelihood, '"Consequence level
' activity) Ii " Ij
'!iI!~
" , '~ "
$F'!

Unloading Coke 1. ProvideProper 2 3 6 Supervision

PPE's like dust 1. Job rotation
and putting on
mask 2. Installation of LEV
the conveyer 2. Instruction& " Barricade the area
J. Frequency: After Starting
Risk level: 200 informationabout
safe systems 0 0 0 0 0
& Completing shift

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. Arrange training 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 and use ear plugs 2 2 6
repairing and C 2. Don't use
handmade tools
2. Provide fire
extinguishers & fire watch
Frequency: After Starting
welding
Risk level: 16 I man 0 0 0 0 & Completing shift
121
Date: 18-11-13 Review period: One Month Date of next review:

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

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

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