INTERNATIONAL GENERAL

CERTIFICATE
(2011 specification)

Candidates observation
sheet

IGC3 THE HEALTH AND

SAFETY PRACTICAL APPLICATION
Sheet number
Student name xxxxxxxxxxxxxxxxxxxxxxxxxxxxxx
Place inspected

xxxxxxxxxxxxxxxxCompany __________

Observations
Hazards and consequences

Student number

of __4___

xxxxxxxxxxx

Date of inspection xx / xx /xxxx

Control measures

Timescale

Immediate and longer term actions

PLANT
Raw material conveyor has no prior
moving alarm. Risk of contact with
moving parts. Lead to entanglement
and injury of human body or part of it.

-Stop conveyor being used.

-Apply prior moving alarm due to
standard.
-Tool box talk on perception of risk and
guarding to operators.

Immediate
48 hours

Hydraulic steel sheet cutter in tins

moulding unit has no guard on blades.
Risk of contact with moving parts lead
to finger amputation.

-Stop machine being used.

-Set a fix guard to cover exposed blades.
-Tool box talk on safe operation of
hydraulic cutter.
-Competent supervisor to ensure guard is
used correctly.

Immediate
3 days
1 week

-Contact fire fighting company to replace

it.
-Carry out pressure testing to all hose
reel and replace the damage ones.
-To add portable fire extinguishers to use
in case of damage of hose.

Immediate

Poor electrical connection in electrical

panel of absorption unit. Risk of
overheated, lead to fire and explosion.

-Isolate electrical panel.

-Proper connection by competent person.
-Tool box talk on electricity safety to all
staff.

Immediate
24 hours
1 week

Emergency stop on grinding machine

were difficult to access because clutter.
Hazard of not stop machine as quickly
as possible, lead to increase severity of
injury.

-Remove clutter from emergency stop.

-Tool box talk on emergency control
system.
-Reposition emergency stop location.

Immediate
1 week

Boiler unit is too hot. Risk of exposure

to excessive heat, lead to heat stroke
and stress to workers.

-Isolate and shield the hot surfaces.

-Frequent breaks and job rotations.
-Provide appropriate ventilation fans and
coolers.

3 days
Ongoing
2 weeks

Fire fighting hose reel nozzle close to

western gate is damage. Risk of
inability to control fire; lead to spread
fire then increase damage or injury.

1 week

2 weeks

1 month
1 week

1 month

INTERNATIONAL GENERAL
CERTIFICATE
(2011 specification)

Candidates observation
sheet

IGC3 THE HEALTH AND

SAFETY PRACTICAL APPLICATION

Observations

Control measures

Timescale

Hazards and consequences

Immediate and longer term actions

Control rooms seats are hard flat

surface and unadjustable. Risk of back
injury and haemorrhoids.

-Replace seat with proper and adjustable

seat.
-Provide Training and instructions in
correct seat adjustment.
-Carry out DSE assessment for all users.

Immediate

-Ear plugs must be provided.

-Carry out noise survey to ascertain how
over all level can be reduced.
- Job rotation to reduced time of
exposure.

Immediate
1 month

High
dust
level
of
hazardous
substances in packing area. Risk of
inhalation hazardous chemical lead to
respiratory diseases.

-Provide respiratory mask.

-Provide appropriate LEV.
-Frequent breaks and job rotation.

Immediate
1 month
On going

Sanitary, resting and eating facilities are

applied in well standard.

-Good practise.
-continue to provide and maintain.

On going

An electrical socket is close to wash

basin in centrifugal unit. Risk of socket
damped lead to electrical shock to
workers.

-Stop wash basin being used.

-Isolate socket.
-Reposition socket to safer location.

Immediate
Immediate
3 days

Noise levels were excessively high in

crushing unit. Risk of hearing damage
and confusion in an emergency case.

Packing operator were not wearing

hand gloves. Risk of contact with
hazardous substances lead to skin
dermatitis.

1 week
1 month

1 week

-Instruct operator to wear gloves.

Immediate
-Ensure suitable gloves are available 24 hours
close to job.
-Provide training and instructions in hand 1 week
gloves importance and usage to workers.
-Maintain pipe leakage by competent 24 hours
Water pipe leakage on floor close too -Cleaning
person. surface floor.
Immediate
cooling tower entrance. Risk of slip
-Maintain
-Conductpipe
inspection
leakage
to check
by competent
leakage.
241hours
month
Lead to serious injury.
plumber.

INTERNATIONAL GENERAL
CERTIFICATE
(2011 specification)

Candidates observation
sheet

IGC3 THE HEALTH AND

SAFETY PRACTICAL APPLICATION

Observations

Control measures

Timescale

Hazards and consequences

Immediate and longer term actions

The cable of mixing motor had been

exposed. Hazard of contact with worker
lead to electrical shock and death.

-Stop machine being used.

-Replace cable and re-route cable to
keep it away from been damage.
-Ensure all machines and apparatuses
are earthed.

immediate
24 hours

-Remove all flammable substances a way

from oven.
-Training and instructions in safe use and
store of flammable substances to all staff.

Immediate

Chemical substances in lab have been

stored in unresisting fire cabinet and
poor singed. Risk of spread fire. Lead to
increase severity of injury and damage.

-Stop using this cabinet.

-Provide a proper fire resisting cabinet
with lockable door and clearly signed.
-Training and instructions in safe use and
store of chemical substances to all staff.

Immediate
5 days

All fire extinguishers had been tested

and were in date.

-Good practise.
-Continue to provide and maintain.

On going

Lab analyst using chemical agent

without catch spill tray. Risk of spill
contamination which lead to emission
toxic vapour to atmosphere and
inhalation.

-Stop using chemical agent.

-Provide a proper tray to catch spill.
-Provide training and instructions in
chemical hazards to lab operators.

Immediate
3 days
3 weeks

STORE
Fire exit door in products store
completely blocked by stock and bulk of
products. Risk of worker being trapped
in the event of fire then suffering burn or
death.

- Ensure that all escape routes are clear,

provision of adequate light and
emergency signs.
-The store area must be racked to take
excess materials.
- Provide Training and instructions to all
staff in emergency procedures and how
to evacuate in emergency case

Laboratory
The
analyst
Using
flammable
substances close to dryer oven. Risk of
catch fire lead to human burn and
explosion.

2 weeks

3 weeks

3 weeks

3 days
3 weeks
1 month

INTERNATIONAL GENERAL
CERTIFICATE
(2011 specification)

Candidates observation
sheet

IGC3 THE HEALTH AND

SAFETY PRACTICAL APPLICATION

Observations

Control measures

Timescale

Hazards and consequences

Immediate and longer term actions

Storage of acetylene and oxygen

cylinders in same store without any
barrier. Risk of catching fire from any
sources around lead explosion and
property damage.

-The cylinder must be separated.

-provide well ventilated and secure store.

Immediate
1 month

Storage of raw chemical material in

unmarked container. Risk of using
incorrect material. May lead to loss
material and human poisoning.

-Clearly mark and sign container.

-Provide proper container.
-Training
staff on how to storage
chemical materials.

24 hours
3 days
3 weeks

Large heavy and awkward boxes were

being manually handled by store
workers using poor techniques. Risk of
back disorder and shoulder injury.

-Handling of boxes by two persons.

-Tool box talk in safe handling technique
-Provide trolley to make handling safer.

Immediate
2 weeks
1 month

Forklift truck had no sign of daily check

being carried out. Risk of loss control
which lead to accident.

-Daily check list must be drawn up.

-Training in how to complete checklist for
driver.
-Develop checklist to be fitted for future
reference.

Immediate
1 week

Poor lighting at store entrance. Risk of

forklift collision with pedestrian or racks
which could fall on workers lead to
serious injury or death.

-Provide adequate lighting and wearing

high visible clothing.
-Protect racks with guard rail.
-Reposition entrance location so that
forklift cannot collision.

3 days

Rack near walkway had length of wood

protruding into walkway at head height.
Risk of worker struck against protrudes
wood lead to head and eye injury.

-Rack maintained to be in safe condition.

-Clear route must be marked.

Immediate
1 week

1 month

1 week
3 months

INTERNATIONAL GENERAL
CERTIFICATE
(2011 specification)

Candidate report template

Report on an inspection of the petrochemical plant, QC laboratory and store.

Introduction
The inspection was carried out at (Vona Petrochemical Company) it has about 70 employees in three
main sections (Plant, QC Lab and Warehouse). The company produce several materials such as
construction detergents and solvent by reaction raw petroleum products. The QC Lab testing raw
materials and final products, the warehouse divided in to two sections one for raw materials and
another for final products.
th
The inspection was carried out on 02 of Sep 2014 at 10:00 AM to identify hazards, assess risk and
set suitable control measure to eliminate or reduce risks, which lead to maintain health, safety, quality
and productivity.

Executive Summary
The inspection demonstrates there are significant weaknesses in some serious hazards such as:

Fire safety
The fire risk rising from improper storage and using of flammable substances. Should be controlled
through separated flammable substances from ignition sources and develop safe system of work.

Health of workers
The health risk arising from exposure to high dust level of hazardous chemical. Should be control
through improving ventilation.

Machinery guards and safety devices

The risk of injury from the hydraulic sheet cutter. Should be controlled by removing machine from use
immediately and not using until the guard is fixed.

Electricity safety
Electrical risk increase by poor connection in electrical panel. Should be controlled through correct
electrical connections.

Working practices
There were evidences of lack of safety awareness of the staff. Should be controlled through provide
appropriate and adequate training and instructions.
These corrective actions will reduce the risk of accident and ill-health in plant. This will have the effect
of improving efficiency and productivity then increase profits. And will help to reduce cost of
investigation and insurance premiums. Failure to take these actions will lead to decrease productivity,
increase accident, sickness rate, staff turnover and risk of prosecution which it could mean fines,
compensation and loss of goodwill costumers and damage of company reputation.
More detailed coverage is provided in the main body of this report, which includes timescales and
approximate cost.

Main findings of the inspection

Fire safety
There were many fire hazards in the plant, flammable substances were close to source of ignition in
QC lab, acetylene and oxygen stored in the same store, without barrier which could cause fire and
explosion and lead to burning, death and damage in property.
Chemical substances stored in unresisting fire cabinet and poor signed, this increase severity of fire
by spread fire. Fire exit door completely blocked by stock and bulk of product which could prevent an
emergency evacuation
These risks breach of INTERNATIONAL LABOUR ORGANISATION Occupational safety and health,
as state in Article 10(A, B, C), Article 3(M) of R164 Recommendation and Article 16(1) and article 18
of C155 Convention.
The management should:
- Ensure that flammable substances are separated from ignition sources.
- Ensure that fire spread is reduced by provide a proper fire resisting cabinet with lockable door
and clearly signed.
- Ensure that all escape routes are clear, adequately lit and emergency signs.
- Train all staff in emergency procedures and how to evacuate during emergency case.
The estimated cost of these measures is 5000$

Health of workers
The most reasons of ill-health, sickness and stress are exposure to excessive dust and noise, the
noise levels were excessively high that lead to increase stress and depressed then decrease staff
morale.
High dust level of hazardous chemical that increase respiratory diseases then increase absenteeism
rate which effect directly on production rate
These risks breach of INTERNATIONAL LABOUR ORGANISATION Occupational safety and health,
as state in Article 3 (B, E, F, and P), Article 3(E, J) of R164 Recommendation and Article 5 (B), Article
4 of C155 Convention.
The management should:
- Carry out noise survey to ascertain how over all level can be reduced.
- Provide local exhaust Ventilation system.
- Reduced the exposure time by organised job rotations.
- Conduct training to the workers on how to deal with this kind of hazard.
The estimated cost of these measures is 10000$.

Machinery guard and safety devices

A poor standard of guarding around fixed machinery is significant issue, for example there is no guard
around hydraulic steel sheet cutter and this increase likelihood of finger amputation which lead to
absenteeism, cost of first aid treatment and compensation. Emergency stop on grinding machine were
difficult to access and this decrease ability of dealing while something gone wrong.
These risks breach of INTERNATIONAL LABOUR ORGANISATION Occupational safety and health,
as state in Article 3(A,D) of R164 Recommendation and Article 5(A), Article 16(1,2) of C15
Convention.
The management should:
- Set a fix guard to cover exposed blades and adjusting the work place lay out around machine
to adequate space and easy access to control of machine.
- Tool box talk on safe operation and competent supervisor to ensure guard is used correctly.
The estimated cost of these measures is 500$

Electricity safety
Sufficient evidence was seen during the inspection to demonstrate the risk of an electrical incident
causing serious injury, death or property damage and that increase direct and indirect cost. There was
evidence of poor connection in electrical panel which cause overheated.
There was electrical socket close to wash basin, that increase likelihood of electrical shock, as we
know any accident decrease staff morale which lead to poor quality and productivity.
These risks breach of INTERNATIONAL LABOUR ORGANISATION Occupational safety and health,
as state in Article 10(A, C) of R164 Recommendation and Article 16(1) and Article 5(A) of C155
Convention.
The management should:
- Ensure that the correct electrical connections are applied.
- Reposition socket and plugs to safer location.
- Ensure all machines and apparatuses are earthed.
- Conduct awareness session on electrical hazard for all employees.
The estimated cost of these measures is 400$

Working practices
The inspection demonstrates lack of safety awareness by staff in this plant which will cause ill-health
and increase severity of injury, damage and loss. There were number of unsafe practises, including
Using flammable substances close to dryer oven, packing operator were not wearing hand gloves,
Manual handling using poor techniques, Storage of raw chemical material in unmarked container.
These risks breach of INTERNATIONAL LABOUR ORGANISATION Occupational safety and health,
as state in Article 4(D), Article 10(A, B, C) of R164 Recommendation and Article 5(C, E), Article 13
and Article 16(2, 3) of C155 Convention.
The management should:
- Remove all flammable substances a way from ignition sources.
- Instruct operator to wear PPE
- Provide handling aids to make handling safer.
- Training and instructions in safe use and store of chemical substances to all staff.
The estimated cost of these measures is 5000$

Conclusions
The main objective of this report is to identify and explain exactly the weaknesses points at the health
and safety management system of Vona Company and how can be improved. Such problems had
been appeared through this report, like poor storage procedure of flammable and chemical substance,
and the high level of dust of hazardous chemicals, in addition to the poor electrical connection and
lack of safety guard of machineries and there is evidence that the safety awareness of the staff is low.
The improvement of storage procedures of the flammable and chemical substance through
segregation and aggregation from any source of ignition and to put clear warning signs, and as well
the good ventilation by using local exhaust fan to reduce the level of the hazardous dust. All Electrical
cables should be connected properly as per standard procedures, Safety guards to be fixed at the
hazardous machineries and to conduct adequate training and safety awareness session for all
employees of Vona Company.
The Commitment of Vona Company management towards the health and safety principles like the
compliance with the legislations, law and standard to provide a safe place of work, safe plant and
equipments, safe system of work, adequate training and supervision and to hire competent
employees. Also the economic factors should be consider by Vona management, since it has been
related to the accident and ill-health and both of them costed money, because when the accident
occurs there will be direct and indirect costs associated with the events, these costs affected on the
production performance, reputation, compensation and to the total profit of the Vona company. The
importance of the moral obligation and duty of Vona company management towards their employees,

through taking care of their health and safety, to avoid injury, sick and death of the workers and to
ensure that they are safe in their work
Through out of this report I would like to draw attention of Vona top Management Company to the
benefits of the good health and safety practices and it is direct effects on increasing the level of
complaisance to the law and standards, and reducing the number of accident and ill-health in the
company which may lead to improve the efficiency and productivity then increase profits. Also will
help in reducing the cost of incident investigations and insurance premiums, increase the moral,
cultures and motivations of the employees of Vona company, and of course this will reducing the
damage of equipments, staff complains & turnover. As a hall value it increases the company
reputation and encourages good customers.

Recommendations
Recommendation

Likely resource
implications

Priorit
y

Target
date

No external cost it may take

half
an
hour
of
maintenance time

High

Immediatel
y

Ensure that fire spread is reduced by provide a

proper three fire resisting cabinet with lockable
door and clearly signed.

The estimated cost 2000$

High

1 month

Ensure that all escape routes are clear, adequately

light and emergency signs are available.

The estimated cost 300$

High

3 days

No external cost it cost of

internal trainer and
employee time.

Mediu
m

1 month

No external cost it cost of

internal engineers time

Low

1 month

The estimated cost 10000$

No external cost it cost of
internal trainer and
employee time.

High

1 month

Low

1 week

High

3 days

Mediu
m

3 weeks

High

5 days

High

2 weeks

Fire safety
Ensure that flammable substances are separated
from ignition sources.

Train all staff in emergency procedures and how to

evacuate in emergency case

Health of workers
Carry out noise survey to ascertain how over all
level can be reduced.
Provide two local exhaust Ventilation system.
Train all staff on the chemical hazards and it is
effect on their health.

Machinery guard and safety devices

The estimated cost 500$
Set a fix guard to cover exposed blades
Tool box talk on safe operation and Competent
supervisor to ensure guard is used correctly

Electricity safety

No external cost it cost of

internal supervisors time

The estimated cost 100$

Reposition socket and plugs to safer location.

Ensure all machines and apparatuses are earthed

No external cost it may take

half an hour of
maintenance time

Working practices
Provide handling aids to make handling safer.

The estimated cost 5000$

Mediu
m

1 month

Training and instructions on safe handling and store

of chemical substances to all staff

No external cost it cost of

internal trainer and
employee time.

Low

3 weeks

Signed ________________________

Date _________________________