Download to read offline
![concept of safety[1].ppt BSN YEAR 1 SEM1](https://cdn.slidesharecdn.com/ss_thumbnails/conceptofsafety1-240509093204-8977567e-thumbnail.jpg?width=640&height=640&fit=bounds)
Audit : Security : Risk Handling : Response
- 1. Part 2: RiskAssessment Organisation name: Riyadh Ceramics Date of assessment: January 11th , 2025 Scope of risk assessment: Raw Material Storage and Preparation Section, Mixing and Blending Section, Pressing and Molding Section, Drying Section, Glazing Section, Printing and Design Section, Firing Section (Kiln Area), Polishing Section, Cutting and Finishing Section, Quality Control and Testing Section, Packaging Section, Storage and Dispatch Section. Hazard category and hazard Who might be harmed and how? What are you already doing? What further controls/actions are required? Timescales for further actions to be completed (within …) Responsible person’s job title 1.Work, Equipment and Machinery Unguarded pressing machines having rotating flywheels and belts in pressing and molding section. Press Machine Operators, Hydraulic Technicians, Molding Supervisor. In the Pressing and Molding Section, unguarded machinery posed a significant risk to workers. The pressing machines, used to shape ceramic tiles, were found to be inadequately guarded. The machines had exposed moving parts, such as flywheels and belts, which were Medical health facilities were provided to the workers. Workers were provided workers with appropriate PPE such as cut-resistant gloves, safety boots, and eye protection. a. Remove the need for direct worker interaction with moving parts by introducing fully automated pressing. 1-Month Site Engineer mechanical b. Replace mechanical locks with electromagnetic safety locks that disengage only when the machine is completely powered down. 3-Months Site Engineer Instrument c. Implement interlocking safety devices that automatically stop the machine if the guard is opened or tampered. 1-Month Site Engineer I/C d. Establish standard operating procedures (SOPs) for machine 2-Weeks Planning Lead
- 2. Hazard category and hazard Who mightbe harmed and how? What are you already doing? What further controls/actions are required? Timescales for further actions to be completed (within …) Responsible person’s job title accessible to workers during maintenance and operation. The lack of proper guarding mechanisms increased the risk of accidental contact with the moving machinery, which could lead to severe injuries, including amputation, crushing, or entanglement. operation and maintenance. e. Implement a lockout/tagout (LOTO) system for maintenance, ensuring machines are properly de-energized. 1-Month HSE Coordinator f. Conduct regular safety training sessions for all workers in the Pressing and Molding Section. 1-Month Training Coordinator 2.Noise Sharp, repetitive clanging sound from hydraulic cylinder in pressing and moulding section reaching 125 dB. Press Machine Operator, Hydraulic Technician, Molding Supervisor. In the Pressing and Molding Section, workers were exposed to high noise levels from the continuous operation of the tile presses, which generated noise levels exceeding 125 dB(A) during tile formation. The pressing Signage was installed in the area indicating “Use Earmuffs”. Noise monitoring sensors were installed in the area. Toolbox talk was given to workers. a. Source of the high noise levels should be eliminated by replacing the hydraulic presses with quieter, electric-driven presses. 3-Months Site Engineer Mechanical b. The presses should be fitted with noise-dampening mats and soundproof barriers. 2-Months Site Engineer Mechanical c. Acoustic enclosures should be installed around the presses using soundproof materials, such as foam panels. 1-Month Site Engineer Mechanical d. Worker exposure to high noise levels should be minimized through job 2-Weeks Planning Lead
- 3. Hazard category and hazard Who mightbe harmed and how? What are you already doing? What further controls/actions are required? Timescales for further actions to be completed (within …) Responsible person’s job title machines, equipped with large hydraulic cylinders, produced sharp, repetitive clanging sounds when force was applied to mold the tiles. This constant noise exposure could in workers experiencing ear fatigue, tinnitus, and potential long-term hearing damage. rotation. e. Workers should be trained on noise hazards and the proper use of hearing protection. 1-Month Training Coordinator f. All workers should be provided with earplugs or earmuffs with an NRR of 30 dB(A) or higher. 3-Weeks In-charge Storage 3.Fire Malfunction in the gas-fired kiln’s burner assembly and ignition failure due to improper fuel- air mixture causing unburned fuel to accumulate in the combustion Kiln lubricators, Combustion Technicians, Kiln Supervisor and patrol man. In the Firing Section, a fire hazard arose due to a malfunction in the gas-fired kiln’s burner assembly, which is responsible for maintaining the required firing temperature for Fire extinguishers were installed in the area. Marking of fire assembling area was carried out. Fire escape routes were designated in the area. a. Replace the existing burner with advanced systems such as Riello Burners or Weishaupt Burner Systems. 3-Months Site Engineer Mechanical b. Substitute the gas-fired burner with a safer electric heating element. 2-Months Site Engineer Mechanical c. Install flame arrestors in the burner assembly to prevent flashbacks. 3-Months Site Engineer Instrument d. Implement a routine maintenance schedule, 2-Weeks Planning Lead
- 4. Hazard category and hazard Who mightbe harmed and how? What are you already doing? What further controls/actions are required? Timescales for further actions to be completed (within …) Responsible person’s job title chamber of firing section. ceramic tiles. The burner system, which operates at temperatures exceeding 1200°C, experienced an ignition failure due to improper fuel-air mixture regulation. This malfunction caused unburned fuel to accumulate in the combustion chamber, increasing the likelihood of a flashback. During routine operation, a flashback occurred, which could ignite the fuel-air mixture and causing a fire within the combustion chamber. Fire could result in skin pigmentation, third- degree burns, skin lacerations, severe pain etc. In severe case it could lead to ensuring the burner system is inspected regularly e. Workers should be trained on the risks of gas-fired kiln operations, the proper procedures for ignition and shutdown. 1-Week Training Coordinator f. Provide fire-resistant clothing, gloves, and face shields to workers operating in or near the kiln area. 3-Weeks Store In- charge
- 5. Hazard category and hazard Who mightbe harmed and how? What are you already doing? What further controls/actions are required? Timescales for further actions to be completed (within …) Responsible person’s job title fatality and property damage. 4.Hazardous Substances Exposure to silica dust in mixing and blending section in concentration of 150 µg/m³ (micrograms per cubic meter of air). Mixing Operator, Process Technician, Section Supervisor In the Mixing and Blending Section, workers were exposed to hazardous chemicals used in the preparation of ceramic glazes and clay mixtures. The chemicals included silica dust in concentration of 150 µg/m³ (micrograms per cubic meter of air), which was generated during the blending of raw materials, used in some coloured glazes. The process involved mixing large quantities of fine powder, which created significant dust clouds, and the application of lead- Sensors were installed in the area for ambient air monitoring. Workers were provided with PAPR respirators, chemical-resistant gloves, and protective eyewear to prevent exposure. a. Replace lead-based chemicals with non-toxic, water-based ceramic colorants to eliminate lead exposure. 2-Months Site Engineer Process b. Install automated dust extraction systems with HEPA filters to capture airborne silica particles. 1-Month Site Engineer Mechanical c. Enclose mixing equipment to prevent dust dispersion and contain hazardous chemical fumes. 1-Month Site Engineer Mechanical d. Upgrade ventilation systems to provide positive pressure airflow and ensure safe air quality levels. 1-Month Site Engineer Mechanical e. Implement rotation schedules to minimize prolonged exposure and reduce overall health risks. 2-Weeks Planning Lead f. Conduct specialized training on handling hazardous substances and recognizing toxic exposure 2-Weeks Training Coordinator
- 6. Hazard category and hazard Who mightbe harmed and how? What are you already doing? What further controls/actions are required? Timescales for further actions to be completed (within …) Responsible person’s job title based chemicals to achieve specific tile finishes. Silica dust, when inhaled, posed a risk of developing silicosis. Silica dust could lead to long-term respiratory issues, including lung cancer. symptoms. 5.Working at height Inspection and maintenance at platforms located at 10 feet having lack of guardrails in glazing section. Glazing Machine Operator, Spray Technician, Quality Check Assistant. In the Glazing Section, workers were frequently required to perform routine inspections and maintenance on the high-pressure air compressors located on elevated platforms. These platforms, about 10 feet above the ground, lacked proper guardrails. During one maintenance task, a For fall protection, safety net was installed below the work area. Area of working was barricaded. Workers were provided with fall protection equipment, such as full-body harnesses, lanyards, and shock-absorbing devices. a. Eliminate the need for working at height by relocating the air compressors to ground level. 1-Month Design Engineer b. Substitute manual tasks at height with mechanical systems and hoists. 2-Months Site Engineer Mechanical c. Install permanent guardrails with mid-rails around all elevated platforms to prevent accidental falls. 2-Weeks Site Engineer Mechanical d. Use scaffolding systems or mechanical lifts with proper access to enable safe and secure working at heights. 3-Weeks Site Engineer Mechanical e. Implement a strict permit-to- work system for any tasks involving work at height. 1-Month HSE Coordinator
- 7. Hazard category and hazard Who mightbe harmed and how? What are you already doing? What further controls/actions are required? Timescales for further actions to be completed (within …) Responsible person’s job title technicians could fall while accessing the compressor, which could result in severe injuries, including fractures. The absence of fall protection equipment, such as harnesses and safety lanyards, significantly increased the risk of injury when working at height. f. Provide all maintenance personnel with comprehensive training on working safely at height. 2-Weeks Training Coordinator 6.Health, Welfare and Work Environment Scorching temperatures in firing section reaching 45- 50°C due to kiln operation. Kiln Operator, Combustion Technician, Kiln Supervisor In the Firing Section, workers were exposed to extreme temperatures due to the operation of gas- fired kilns, which operate at temperatures exceeding 1200°C. As a result, the ambient Training was provided on recognizing symptoms of heat stress, dehydration, and heat exhaustion. Ambient air temperature monitoring was carried out by using sensors. Workers were provided with heat-resistant clothing, including cooling vests, heat-protective gloves, and safety footwear. a. Replace gas-fired kilns with more energy-efficient and cooler operational technologies. 2-Months Site Engineer Mechanical b. Install high-performance ventilation systems to improve airflow and reduce ambient temperatures. 1-Month Site Engineer Mechanical c. Use air-conditioning or localized cooling units in high-temperature zones to provide relief for workers. 2-Weeks Site Engineer Mechanical d. Install thermal insulation 1-Week Site
- 8. Hazard category and hazard Who mightbe harmed and how? What are you already doing? What further controls/actions are required? Timescales for further actions to be completed (within …) Responsible person’s job title temperature in the surrounding area reached upwards of 45- 50°C, especially near the kilns. This excessive heat exposure could led to several health-related issues, including heat exhaustion, dehydration, and fatigue, cramps, dizziness, and heat stroke. around kilns and heat sources to reduce radiant heat exposure. Engineer Mechanical e. Implement heat shields or barriers between workers and kilns to reduce direct exposure to high temperatures. 1-Month Site Engineer Mechanical f. Limit the duration of exposure to high temperatures through shift rotations to prevent prolonged heat stress. 3-Weeks Planning Lead