Report of Hazards

at the Dry Dock

of Boustead Naval Shipyard Sdn. Bhd.

By
Index No: NS13387
IC NO: 921117-14-6289

Safety and Health Officer Examination

Paper IV Part 1: Workplace Assignment
20 November 2017- 21 December 2017
 PERAKUAN TUGASAN TEMPAT KERJA

WORKPLACE ASSIGNMENT VERIFICATION

Adalah dengan ini saya mengaku bahawa dokumen ini disediakan untuk Peperiksaan Pegawai

Keselamatan dan Kesihatan adalah berdasarkan hasil kerja asal saya sendiri kecuali sedutan atau

petikan.

I hereby certify that this document prepared for the Safety and Health Officer Examination is

based on my original work except for citation and quotation made.

Tandatangan :..

Signature

No. Kad. Pengenalan :.

I.C.No.

No. Indeks :

Index. No

Tarikh : 20 November 2017

Date

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Table of Contents

No Title Page
WORKPLACE ASSIGNMENT VERIFICATION 3
1.0 ABSTRACT 4
2.0 INTRODUCTION 5
3.0 OBJECTIVE 8
4.0 METHOD 9
4.1 Hazard Identification 9
4.2 Risk Assessment 10
5.0 RESULT AND DISCUSSION 14
5.1 List of Hazards 14
5.2 Prioritizing Hazard 14
5.3 Impact on the most critical hazard 18
6.0 RECOMMENDATION 19
6.1 Control Measures 19
6.2 Review 22
6.3 Benefits 23
7.0 REFERENCES/RESOURCES 26
8.0 APPENDIX A ORGANIZATION CHART

APPENDIX B SAFETY AND HEALTH COMMITTEE CHART

APPENDIX C PICTURES

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1.0 ABSTRACT

This report attempts to identify all hazards at a chosen workplace that leads to risks and

how safety and health measures could bring about beneficial end results by containing or

preventing these risks from bringing harm to the workers and the organization. The

workplace identified in the assignment that could contribute to high risks and harm at a

Dry Dock. The report sets out to identify the many forms of hazards at the workplace and

a few suitable techniques that were selected to tabulate the risks involved. The risk

assessment process was used as the main technique to access and evaluate the risks of the

hazards identified. Among these, the most critical hazard was seen to be the oxygen

acetylene welding and dust for health hazard. The control measures to eliminate or reduce

this critical hazard are then recommended based on the findings, results and reviews

obtained with appropriate references/sources and appendices.

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2.0 INTRODUCTION

Boustead Naval Shipyard is a one-stop centre for defense and maritime needs.

Covering an area of 46 hectares, it was originally known as the Royal Malaysia Navy

Dockyard became fully operational in 1984. The Company was corporatised in 1991 and

subsequently privatised in 1995 as PSC Naval Dockyard Sdn Bhd.

In 2005, the Company was taken over by Boustead Holdings, a diversified

Malaysian business conglomerate belonging to the Armed Forces Provident Fund, and the

Companys name was changed in August of the same year to Boustead Naval Shipyard

Sdn. Bhd.

Strategically located within the main base of Royal Malaysian Navy, Lumut,

Perak. Boustead Naval Shipyard is part of the Boustead Heavy Industries Corporation or

BHIC, a public listed company on the Main Board of the Kuala Lumpur Stock Exchange,

along with its other associated companies, Boustead Penang Shipyard and Boustead

Langkawi Shipyard.

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Activities

There are a lot of activities done in the dry dock, but for the purpose of this assignment

only repair works are discussed. The activities that are discussed in this report are on

repair works carried out, erection of scaffolding, lifting, cutting, grinding, welding,

testing, sand blasting, and painting.

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Work Environment

The entire process and activities has various hazards. We may observe their existence

from the initial stage of the building works. The hazard identified are working at height

that can cause falling from height, falling object, slip, trip and fall from scaffold, heat

stress, exposed to weather conditions (rain, drizzles etc) and health hazards due to

inhalation of dusts.

Work Process

a. Before the work start safety induction will be given to all supervisors and workers
for the work that involves.

b. Scaffolding erection work is required to work at height for the installation of the
metal plate and other work processes.

c. The material will be transported to site and a 20 tone mobile crane is required to
hoist the material for the metal plate.

d. The metal plate will be processed accordingly to the specific size via cutting and
grinding.

e. The metal plate will be oxygen acetylene welded to the ship and the non-
destructive testing is done.

f. After isolating the workplace by using canvas and tapes, sandblasting is done to
clean the surface for the painting process.

g. Lastly, the surface of the painted is checked for defects and passed by the quality
control officer.

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CUTTING

GRINDING

DRILLING

WELDING

SAND
BLASTING

PAINTING

QUALITY

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3.0 OBJECTIVE

A number of objectives will be fulfilled in this assignment, as follows:

a. Identification of signification safety and health risks posed at the workplace.

b. Identification of workplace safety and health risks and hazards.

c. Estimation of severity of the safety and health risks from each of the safety and
health hazards.

d. Based on their risk rating, determine the likelihood and severity of each safety and
health hazard by the use of Qualitative and Quantitative Risk Table.

e. Discuss control measures to eliminate or reduce the risk of most critical safety and
health hazards.

f. Recommend post analysis of program to ensure continuity of effectively

managing Safety and Health at the work place.

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4.0 METHOD

4.1 Hazard Identification

The first step in the managing risk is through hazard identification at the workplace. All

these hazards can be categorized into 5 categories:

a. Mechanical Hazard

Machinery, its parts, tools, objects and materials processed or used in the work

process are often a source of mechanical hazards leading to injuries.

b. Physical Hazard

Any hazard associated with that could cause physical harm, including but not

limited to corrosives, flammability, or explosion hazards. This hazard can cause

explosions, fires, violent chemical reactions, or other hazardous situations.

c. Chemical Hazard

A chemical hazard is any substance that can cause harm. Chemicals which are

stored in the workplace and at the house and can result in serious injuries if were

not properly handled.

d. Biological Hazard

A biological hazard or biohazard is an organism, or substance derived from an

organism, that poses a threat to (primarily) human health. This can include

medical waste, samples of a microorganism, virus or toxin (from a biological

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 source) that can impact human health. It can also include substances harmful to

animals. The term and its associated symbol are generally used as a warning, so

that those potentially exposed to the substances will know to take precautions.

e. Ergonomic Hazard

Ergonomic Hazards includes workplace hazard which related between man and

machine. Material Handling and Back Injuries provides information on back belts,

lifting, pushing and pulling, and material handling aids. Repetitive Motion Injuries

provides information on musculoskeletal injuries, risk factors, design hazards,

wrist splints, and ergonomic hand tools.

Hazards could be identified through many methods such as identification,

inspection, data analysis, interviews, or hazard reporting system by workers.

4.1.1 Identification Method

Through this method, we can easily identify any hazard exist at the workplace. Every job

performed must be classified into various steps to ensure the hazards could be identified

including the risk.

I. Observation and inspection at workplace

a. This method uses all senses that are sight, hearing, smell, and taste to

identify the hazards involve

II. Question and answer / Interview

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 a. The interview session involves safety and health at workplace, accident

records, and work processes

b. From the information obtained, the hazards involved will be more easily

identified and also to figure out the risk control for each hazard.

III. Revising documents

a. Information is also obtain from reports of accident, articles, rules and

regulations, and statistics.

b. This method helps to identify hazards that were not identified, thus helping

to prevent near misses and accident.

4.1.2 Inspection Method

By doing inspection at the workplace, we could also identify hazards. Inspection should

be done on schedule basis or by ad-hoc.

4.1.2 Data Analysis Method

Through this method, all data such as the accident data could provide us the information

on the existing hazard occurs; it includes also the near miss and the diseases infection

data.

4.2 Risk Assessment

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All hazards identified must be assessed of its risk. Risk assessment will be performed

through risk estimation and risk evaluation. This value is represented by two parameters

that are probability and severity. Every probability and severity is valued accordingly by

high or low of the hazardous event as per Figure 1 and Figure 2.

PROBABILITY DEFINITION

Very likely Can happen frequently

Likely Could happen occasionally

Unlikely Could happen, but not rarely

Highly unlikely Could happen, but probably never will

Figure 1 Valuation on Probability

SEVERITY DEFINITION

Fatality Death

Sick leave for more than 4 days/permanent

Serious Injury
disability

Sick leave maximum of 4 days/permanent

Injury
disability

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 Small Injury Near miss/First Aid

Figure 2 Valuation on Severity

This type of assessment is called Qualitative Risk.

Events or situations assessed as very likely with fatality consequences are the most
serious (HIGH) risk and those assessed as high unlikely with negligible injuries are the
least serious (LOW) risk. This can be seen on Figure 3 below for the Qualitative Risk
Table.

Consequences Likelihood

Very likely Likely Unlikely Highly unlikely

Fatality High High High Medium

Major injuries High High Medium Medium

Minor injuries High Medium Medium Low

Negligible injuries Medium Medium Low Low

Figure 3 Qualitative Risk Table

From definition,

Risk = Consequences X Likelihood

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In real scenario, we could not explain the risk by saying high or low because sometimes

there are existing two types of hazard and with the same level of risk high, but the

question is how high it is. So to differentiate the level of risk, the estimate risks were

represented by numbers. Numbers are given to present the level of likelihood and

severity. This numbers can be multiply, and ranked by value for 4 higher and 1 low.

This type of assessment is then called Quantitative Risk. This can be seen on Figure 4 and

5 below.

VALUE PROBABILITY DEFINITION

4 Very likely Can happen frequently

3 Likely Could happen occasionally

2 Unlikely Could happen, but not rarely

1 Highly unlikely Could happen, but probably never will

Figure 4 Valuation on Probability

VALUE SEVERITY DEFINITION

4 Fatality Death

3 Serious Injury Sick leave for more than 4 days/permanent disability

2 Injury Sick leave maximum of 4 days/permanent disability

1 Small Injury Near miss/First Aid

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 Figure 5 Valuation on Severity

For example:

Likelihood: Very Likely (Daily) =4

Likely (Weekly) =3

Unlikely (Monthly) =2

High Unlikely (Yearly) =1 and

Severity Fatality or Permanent Disability =4

Major Injuries (more than 4 days MC) =3

Minor Injuries (less than 0r 4 days MC) =2

Negligible Injuries (first aid and near miss) =1

Calculation example:

Likelihood of hazard is estimated =2

The severity is estimated =4

Then, the risk will be =2X4=8

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 This risk assessment can be seen on 2 D Matrix Table on Figure 6 below.

Consequences Likelihood

Very likely Likely Unlikely Highly unlikely

(4) (3) (2) (1)

Fatality High High High Medium

(4) (16) (12) (8) (4)

Major injuries High High Medium Medium

(3) (12) (9) (6) (3)

Minor injuries High Medium Medium Low

(2) (8) (6) (4) (2)

Negligible injuries Medium Medium Low Low

(1) (4) (3) (2) (1)

Figure 6 - Risk Assessment on 2 D Matrix Table

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5.0 RESULT AND DISCUSSION

5.1 List of hazards

BIL HAZARD CLASSIFICATION EXPLANATION

The respiratory system can be effected because the

mineral dust can be inhaled into the body via

breathing.
1 Dust Health
Source: workers exposed to mineral dusts during

sand blasting activity to remove rusts on the surface

of metal plates.

The exposure of hazard through welding is exposure

to ultra violet rays, ozone rays, infrared rays, and

2 Ray Health bright lights to the workers.

Source: rays from the ultra violet rays when seeing

the electric arc or bright welding rays.

The noise exposure at the work place exceeds the

permissible exposure limit that is 85dB (A) and can

reach up to 115dB (A). Workers exposed to noise

3 Noise Health when doing work, grinding, drilling, sand blasting,

cutting, and other mechanical works.

Source: noise from the power tools, grinder, cutter,

and air compressor.

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 The risk of workers pierced and penetrated is when

doing grinding and drilling works

Piercing
Source: penetration caused by the grinding disk
4 And Safety
shattering and becomes lethal projectiles when
Penetrating
grinding. The chips produced when drilling can

injure workers.

The risks of electrocution is when workers are

doing welding works.

Source: this hazard caused by the connection of arc

5 Electricution Safety welding equipment to wire currents through faulty

insulators and the usage of damaged welding

equipments. Arc weldings that uses up to 100 volts

The risk of an explosion happens due to leakage of

gas and fuel and explodes when sparks from

welding equipment. Also, empty tanks that are not

6 Explosive Safety
stored properly, exposed to sunlight.

Source: acetylene gas cylinder and liquid petroleum

gas leakage from the regulators and hos.

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 These hazards were categorized on the level of their risk. The higher the risk, the hazard

will be placed on top among them.

a) Safety Hazard

I. Welding

II. Grinding

III. Lifting material

IV. Working at height

b) Health hazard

I. Noise

II. Dust

5.2 Prioritizing Hazard

Prioritization of hazards was conducted by applying risk assessment method. Risk

Assessment Matrix designed for each hazard at the workplace. Through this matrix, all

hazards that were identified through the above methods were weighted by their risk

elements through respective data and tables, their possible occurrences and risks involved.

The combination of all components in each activity was able to provide a comprehensive

tabulation as on Figure 7 below (from descending order):

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 Type of hazard Hazard Severity Likelihood Risk Value

Oxygen acetylene
Safety hazard 4 4 16 High
Welding

Lifting material using

4 3 12 High
crane

Working at height 3 3 9 High

Grinding 2 2 4 Medium

Health hazard Dust 4 4 16 High

Noise 4 3 12 High

Figure 7 Hazard List and Risk Value Table

5.2 Impact on the most critical hazard

I. Safety hazard

Evaluation based on;

Total of workers exposed: 50% of the workers

Time frame: 8 hours per day

Oxygen Acetylene Welding (safety hazard)

Workers a mostly exposed to this hazard when the task involves oxygen acetylene

gas and liquid petroleum gas for welding and cutting steel metal. The risk of

explosion is high caused by the leakage of the hos and the regulators of the gas

cylinders. Explosion happens when sparks from the welding or cutting ignites the

volatile gasses from the leakages. The distant of the gas cylinders is too close to

the workers. There are also empty cylinders that are left out in the open to the

sunlight. The storing method is not according to specification as the LPG and the

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oxygen acetylene cylinders are stored beside each other. This elevates the risk of

explosion.

Risk = Probability X Severity

(16) = 4X4

Hazard Effect

The effects of the explosion hazards are great loss to the company property,

employer and employee. It also causes severe injuries if not death to the workers.

the company may loss experiences and skilled workers. Damages to the materials

that had to be delivered to the customers. Paying a fine to the Department Of

Safety And Health. The company had to pay for the costs of hospital bills of the

injured workers. Lastly, the workers cannot work because of the investigation

being done. The chances or probability of getting involved in an explosion are

very great and be valued as 4 (can happen frequently) and the severity was also

high and valued as 4 (fatality).

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II. Health hazard

Evaluation based on;

Total of workers exposed: 50% of the workers

Time frame: 8 hours per day

Dust (health hazard)

The workers are exposed to the mineral dust garnet in the process of sand blasting

that uses garnet to as a substance to remove rusts. Garnet is a substance that is

listed in the schedule of Factories and Machineries Act (mineral dust) (1989).

Sand blasting is done when garnet is accelerated through the blasting nozzle at

very high speed by using air compressors. From the observations done, there are

workers that are not wearing facemask while sand blasting. Poor housekeeping is

can also be seen as the residual blasting material is not managed properly because

they do not have proper residual management. Workplace is also not isolated, thus

making the residual sand blasting material to be carried up by the wind to other

workplace. This causes the workers to have high risks of getting lung diseases.

Risk = Probability X Severity

(16) = 4X4

Abrasive blasting operations can create high levels of dust and noise. Abrasive

material and the surface being blasted may contain toxic materials (e.g., lead paint,

silica) that are hazardous to workers.

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 Silica sand (crystalline) can cause silicosis, lung cancer, and breathing

problems in exposed workers.

Coal slag and garnet sand may cause lung damage similar to silica sand

(based on preliminary animal testing).

Copper slag, nickel slag, and glass (crushed or beads) also have the

potential to cause lung damage.

Steel grit and shot have less potential to cause lung damage.

Slags can contain trace amounts of toxic metals such as arsenic,

beryllium, and cadmium.

Work production will be slow because the workers get sick, workers

will have to go to medical checkup.

6.0 RECOMMENDATION

6.1 Control measures

The most critical hazard either safety or health must be controlled. The control measures

of these hazards were done in according with means of hierarchy of control. The steps are

as follows:

a. Oxygen Acetylene Welding(Safety Hazard)

i. Elimination

To eliminate this process is to not to any works related to welding. This

method is hereby impossible to adhere because it is a core process, and the

job would not be done.

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ii. Substitution

To substitute this process with a much safer type of connecting the plates

with the ship is also impossible because there are no other method that is

the most suitable other than oxygen acetylene welding.

iii. Isolation

To isolate means to isolate the welder from the metal plates or isolating the

other workers. This is also impossible because the welder needs to be

directly in contact with the metal plate to make welding possible.

iv. Administrative Control

This type of control measure constitutes that no physical changes are to be

done but limits the daily exposure to hazards by adjusting work task or

schedule.

v. Engineering Control

Engineering control method physically changes the work area or the

process that effectively minimize the work exposure of the hazards to the

worker. To avoid the explosions of the tanks, fuel and oxygen, they need to

be far away from the welders, by using long hosts, thus effectively

lowering the possible hazards of explosion.

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 vi. Personal Protective Equipment

This method of control is the last resort on controlling risk. Every worker

must be provided with PPE such as welding shields or welding gloves

whenever they are involved with welding works.

b. Dust(Health Hazard)

i. Elimination

Use a less toxic abrasive blasting material.

Use abrasives that can be delivered with water (slurry) to reduce

dust.

ii. Substitution

Use barriers and curtain walls to isolate the blasting operation.

Use blast rooms or blast cabinets for smaller operations.

Use restricted areas for non-enclosed blasting operations.

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 Keep coworkers away from the blaster.

iv. Engineering Control

Use exhaust ventilation systems in containment structures to

capture dust.

v. Administrative Control

Perform routine cleanup using wet methods or filtered vacuuming

to minimize the accumulation of toxic dusts.

Do not use compressed air to clean as this will create dust in the air.

Clean and decontaminate tarps and other equipment on the

worksite.

Schedule blasting when the least number of workers are at the site.

Avoid blasting in windy conditions to prevent the spread of any

hazardous materials.

Prohibit eating, drinking, or using tobacco products in blasting

areas.

Provide wash stations so workers can wash their hands and face

routinely and before eating, drinking, or smoking.

Vacuum or remove contaminated work clothes before eating,

drinking or smoking.

vi. Personal Protective Equipment

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 Hearing protection

Eye and face protection

Helmet

Leather gloves that protect to full forearm and aprons (or coveralls)

Safety shoes or boots

6.2 Review

Reviewing on the recommendation for improving any lacking and to ensure the

effectiveness of the control measures proposed must be performed. This review process

must be done ongoing in accordance with necessity such as for example if there is a

change in the work process or work procedure. The review process should be done

through:

a. Referring to the accident records for comparison from time to time.

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 b. Getting feedback from workers on the effectiveness of the control measures

through discussion, meeting, questionnaires and reports.

c. Medical records of workers from Occupational Health Doctor.

d. Surveillance and implementation on using of PPE with workers whether they are

suit to them, knows how they are being utilized, taking care and used.

6.3 Benefits

a. To the Company

i. will increase productivity.

ii. will give good reputation to the Company

iii. will reduce the number of accident

iv. will follow all the laws and regulations

a. For Workers

i. will increase awareness and knowledge on the importance of practicing

safety and health at the workplace

ii. will reduce accident to the workers

iii. will produce a good working environment

iv. will ensure the safety and health of workers being taking care of

v. will follow the required laws and regulations of the government

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7.0 REFERENCES/SOURCES

a) ILBS, Occupational Safety and Health Act 1994 (Act 514) & Regulations and Orders,

International Law Book Service

b) ILBS, Factories and Machinery Act 1967 with Regulations, International Law Book

Service

c) NIOSH, Module 1 Occupational Safety and Health Management, NIOSH Publisher,

2004

d) Guidelines on Working at Height by DOSH.

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