Unit IG2: Risk assessment

Part 1: Background
Learners Number:00520202 Learners Name: Abdul Majeed Ghanim al-Farsi

Include in here the organisation’s name* and location* and number of workers. You must then go on to give a
description of the main activities/products/services carried out. You must also describe the area to be risk
assessed eg, whole site, and anything else that you consider relevant (approximately 150 to 200 words.
The name of company which it takes a part for doing the risk assessments is Sohar Aluminum. This company has specialization i n
Aluminum product such as producing panels, raw materials and beams which is formed in the factory with high temperature to melt the
materials in order to sell it as a row materials or form it to other products.
it is in Industrial Estate, Sohar, Sultanate of Oman. It appears in 2004. It is owned by Abu Dhabi national energy company, Oman oil
company, TAQA and Rio Tinto.

It has many achievements, which are,

In 2009: Obtaining the ISO 9001 certification in the field of primary aluminum manufacturing
In 2012: Obtaining the company's power plant ISO 9001 certification
In 2016: Obtaining the ISO 14001 certification and the Occupational Health and Safety management certificate 18001

It is production of aluminum is 375000 per year. This company has many sections for example (Cast house, reduction, carbon, port,
power plant, stores, furnace, parking and central maintenance)
This company is unique because they believe it is better to be safe than sorry.

This company is controlled by approximately 1000 employees, which are divided to work in several departments. The factory is
operating for 24 hours, which needs to have different shifts for the workers. Each shift works for 8 hours with additional time for
emergency and shut down of the factory for maintenance. The area of the company is 8 km square including cast house, reductio n,
carbon, power plant, furnace, parking and central maintenance

The second part of this company is separated from the main buildings of the company and it is located in the port in order to transport
the materials abroad.

The company has several rules for placing the factories, Warehouses, parking and main building according to the safety of the company
and employees.

Learner number: 00520202 Learner name: Abdul Majeed Ghanim al-Farsi

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 For safety requirements, it is not allowed for the normal vehicles to enter the sites for safety reasons.

There are several activities which are necessary to operate the factory. Starting with the power plant, which is needed to provide the
electricity for the factory by using suitable generators.
The second activity is to melt the material and separate them according to their density. Following activity is to form the materials as
several product to be ready to export them by using the special line to deliver them to the port and distributed them abroad.

You must now give a brief outline on how you completed the risk assessment (approximately 200 words):

Before starting to achieve my risk assessment, I have taken a deep look at all sections in the company. I did that in accordance with
the information I got it from Mustafa Alfarsi who is an engineer. He gave me many ideas about the environment of the work in every
section, process, machine, system of work and the time for work to be done completely.

I had a meeting with Mr. Ali Almamari to give me some additional information, he is working as HSE SUPERVISOR. I talked with
him about the safety and he told me about the general risks and incident happened previously. He showed me some reports about
accident happened and then I noted the department where the most accident happened.

I got the external information from the ILO OSH 2001 for the risk assessment, and also I consulted the HSE website UK
www.hse.org.uk to get the information how to do the risk assessment and got the guidance from the safety law “health and
safety at work regulation 1974” that highlight the importance of the risk assessment. At that company they have 5 steps to do the
risk assessment (Identify the hazard, identify the people who might be harmed, find the likelihood and controls, recording and
reviewing the document), I used the same steps and advised the control based on the ILO OSH 2001 article 3.10.1 as described in
the hierarchy of controls.

Learner number: 00520202 Learner name: Abdul Majeed Ghanim al-Farsi

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 Part 2: Risk Assessment
Organisation name: Sohar aluminium
Date of assessment: 25 -10-2020
Scope of risk assessment: furnace, power plant, stores, Cast house, reduction.

Hazard Who might be harmed and What are you already What further controls/actions Timescales for
category and how? doing? are required? further actions to Responsible
hazard be completed person’s job title
(within …)
Confined Who is working inside pit, 1-Mostly avoid 1-Fire rescue team 1 month High management
area (Hot supervisor and People working the
work inside near the pit hot work inside pit ………………………………… ……………….. ……………………….
pit) This work will cause:
Fire explosion, toxic fumes 2-System of 2 months HSE managers
and hot surface. extraction fumes
………………………
2- Cooling …………………………………..
the heat may cause burns for fan ……………………. ….
workers. if Explosion (ventilations) Immediately, take it Supervisors
3- Thermal
happens, Explosion from stores.
protectively Gloves
fragments will Affects people
near the site of the
explosion, when doing hot
work this work causes
Spread toxic gases.
Inhaling this gas causes
difficulty breathing and
Over time, it may cause
respiratory diseases.

Learner number: 00520202 Learner name: Abdul Majeed Ghanim al-Farsi

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Hazard Who might be harmed and What are you already What further controls/actions Timescales for
category and how? doing? are required? further actions to Responsible
hazard be completed person’s job title
(within …)
Electrical 1-Warnings signage
Hazard Who will be near the
(Over socket. 1- Add more socket 2 months Supervisor and
loading (Over loading socket maybe inside Office . electrical technical
socket) cause fire or damage in office 2-Safety device
or both and electric shock) . if like (fuse)
the socket has over current
inside it and Bearing cannot
Emptied electricity and this 2-Use the good quality of Inspection team
emptied will cause electricity 1 month
socket and mast this socket
shock for users and have guarantee ………………………
sometimes cause Power …
outages or fire in place ………………………… HSE supervisor
……
When a person is hit by an …………………………………..
electric shock, he may cause Immediately
3-More supervisions and
health problems, for example raise the inspection rate.
(burns, fainting and at some
time causing
death) It depends on the
strength of the electricity

Machine Workers (welder) People 1- PPE 1- permit to work Immediately Supervisor

hazard inside workplace and
visitors. they will be 2-welding tool ……………………………. ……………………. ………………………..
(Welding the affected by dust, radiation
3- fire 2- daily Immediately Workers
rail) and naked flames. These extinguishers housekeeping …………………
- reasons may cause health (water, foam, CO2) ……………………….
…………………………… …….
Welding problems, especially HSE managers
…..
machine- breathing and eye problems. 1 month
When eyes are 3- LEV

Learner number: 00520202 Learner name: Abdul Majeed Ghanim al-Farsi

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Hazard Who might be harmed and What are you already What further controls/actions Timescales for
category and how? doing? are required? further actions to Responsible
hazard be completed person’s job title
(within …)
always exposed to welding
rays, it may cause weakening
of the
retina. And inhalation of dust
may cause asthma

physical 1-Used ear 1- Soundproof room 6 months HSE managers

hazard Workers/supervisor/visitors.
(noise
protection. 2- ……………………………………. ………………………… …………………..
) …
Silencers 2- Automatic HSE managers
Noise effectiveness will
engine cause several problems activities inside this
noise relating for hearing as a room 3 months
3- Isolation of engine
(generator of result of high frequency). the ………………………..
power) high noise Affect the ……………………………… ………………………. Supervisor
eardrum and caused …….. Immediately
permanent damage of the 3- Reduced exposure time
hearing.

physical 1-PPE 1- Job rotation Immediately Supervisor

hazard ( Who is used this machine.
2- Limited time ………………………………….. …………………….. ………………………
vibrations) When the human body
2- Monthly health check 1 month HSE supervisor
receiving to continuous
(Earth digging vibration for a long time Will 3- Hand books
drilling …………………………………. ………………………… ………………………
cause (muscle, nerve and Disc
machine) disease), Over the time, the 3- Maintenance for machine to be Immediately
Technical
sequences will be dangerous more safety department
to humans, and may need
surgery operations. The
surgery will be expensive and
.dangerous

Learner number: 00520202 Learner name: Abdul Majeed Ghanim al-Farsi

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 Hazard Who might be harmed and What are you already What further controls/actions Timescales for
category and how? doing? are required? further actions to Responsible
hazard be completed person’s job title
(within …)
Confined area . Workers who work inside pit . 1-stayed away from 1-filled half bag only 1-immediately 1-workers
Removing the Workers who drive forklift . suspending loading and 2-only one signals man 2-immediately 2-workers
bags from pit . Tipping of forklift and snapping forklift 3-trining forklift driver 3-2 months 3-HSE supervisors
load 2-pre-inspection of loading
carrying bags straps /
slings

physical 1- Cooling system 1- Insulated heat source. 3 months HSE manager

hazard (hot Workers inside this location or
environment) nearby 2- Temperature ………………………………… ………………………. ………………………
monitor device
Workin when the body is exposed to 2- Availability of Immediately Supervisor
3- Frequent breaks
g inside high temperatures it will cause drinking water/fluids and manager
and near health problems (cause nearby
furnace ………………………… ………………………
dehydration, heat stroke and …………………………………
… Supervisor
muscle cramps) The human 3- Job rotations
body should be kept at Immediately
temperatures between 36 and
37,2.
When the human body
temperature rises, the body
may lose a lot of fluids and
Mineral salts.

Learner number: 00520202 Learner name: Abdul Majeed Ghanim al-Farsi

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Hazard Who might be harmed and What are you already What further controls/actions Timescales for
category and how? doing? are required? further actions to Responsible
hazard be completed person’s job title
(within …)
fire hazard 1- Fire extinguishers
Who is used this machine,
Cutting Workers in place, supervisor,
machin visitors.
e
1- Gas detectors Immediately HSE supervisor
(Gas cylinders) Leaking of gas from
2- PPE ………………………..
cylinders will cause fire …………………………………. ……………………….
explosions, because 1 month
everything inside workplace 2- Fire drills (training) HSE manager
helps for fire heat, flammable 3- Monthly
inspection for
material and oxygen.
equipment and gas
cylinders

This hazard causes the

destruction of all property.
And all people may suffer
first-degree burns or gas
suffocation. People nearby
the gas cylinders may die
because Explosion fragments 1 month HSE supervisor
3- Give the workers how
and be difficult to help. deals with emergency
………………………….. ………………………..
……………………………………
Immediately Workers
4- Daily inspection

fire hazard 1- Fire detectors 1- Heat detectors 1 month HSE supervisor

Workers inside store /
(Generator people near to store 2- Fire ……………………………. …………………. ………………………..
or socket extinguishers and
near 2- Warning signage 3 weeks HSE supervisor
Because of the heat of the best choice
strong electricity with flammable
flammable (carbon dioxide ………………………………… …………………… ………………………
liquid) and foam)
3 - Monitoring devices 3- firefighting and rescue team. 1 month High manager

Learner number: 00520202 Learner name: Abdul Majeed Ghanim al-Farsi

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Hazard Who might be harmed and What are you already What further controls/actions Timescales for
category and how? doing? are required? further actions to Responsible
hazard be completed person’s job title
(within …)
materials they will cause
)explosion ……………………………… ………………….. …………………
Like this hazard will cause of 1 month
4- Shelves and Workers
mass destruction, it's this specific place for inside store
means deaths and injuries, flammable and HSE
and loss of all property supervisor
because Explosion fragments
and caused spread of toxic
gas.
7chemical 1- LEV 1 month Manager
s hazard Workers inside workplace
(Reduction) ……………………………. ……………………… ………………….
(The place 1-Cooling
2- Coverall 2 weeks Manager
for melted melting process Produce a
aluminium) group of gases and all of them system 2-PPE thermal
resistance ……………………….. ……………………….
are harmful and toxic. This 3- Warning signs
toxic gas causes Breathing Immediately HSE manager
difficulty. 4-Warning ……………………………….

system 3- Respiratory
Melt processes are required protective equipment
high temperatures, and 5- Not allowed (RPE)
because of them, the surfaces lighters 6 - Cannot
visitors come inside
are hot, and human cannot
during work
bear that hot.

Learner number: 00520202 Learner name: Abdul Majeed Ghanim al-Farsi

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 Part 3: Prioritise three actions and justification for the selection

You must pick the three highest priority/most urgent actions and justify your choice. Your justification must include moral, legal and
financial arguments (500 to 700 words); consideration of likelihood and probable severity of injury, ill-health and/or harm (150 to 250 words);
description of how effective each action is likely to be in controlling the risk (250 to 350 words).

Three action as priority:

1- Hazard category (confined space entry) Provide the force system for the extraction fumes from the confined space.
2- Hazard category (fire). Advise to set up firefighting and rescue team to mitigate the risk from fire.
3- Hazard category (hazardous substances- chemical). Provide an effective local exhaust ventilation system (LEV) to reduce
the fumes and extract the vapors.

Justification for the above actions.

Moral:
The aluminium company has lot of hazardous working conditions where person can get sickness and injury, for example the above
highlighted hazards has a potential that workers can get serious and long term sickness which can affect the life of the workers
negatively. The organization must provide health and safety to the workers, and this is a moral duty that the organization provides
to its workers. Workers work within the organization to get salary and support themselves and their families, not to get diseases,
because these diseases affect workers, and effects their families and friends. Long term sickness, hospitalization due to unexpected
injuries, and other work-related calamities, or disabilities will affect the whole operation of the life of the workers. They may become
jobless, unable to perform their normal working capacity and they will be undergoing emotional and physical trauma. The
consequence will be lifetime suffering for themselves and their families. This way society will be facing a lot of upsets and it will be
bad reputation for the company also. To avoid and save the workers from these type of problems the the organization is responsible
to take care of safety of the workers and the company shall treat the workers as their precious assets to get the progress in the
work and meet the production targets. It will place the company at high respect in the society.

Legal:
All countries have law to workers and organizations. When organizations want start should this organization follow all laws. The
laws different organizations because every organization has different material and process. For example, can’t not compare

Learner number: 00520202 Learner name: Abdul Majeed Ghanim al-Farsi

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between Al Aluminium Factory and cloth Factory, Because of the different degrees of risk. the degrees of risk are due to the tools,
materials and processes that use in the two places. But the goals are always the same. the goals will be how makes safe
Environment and how apply laws. we have 2 Sources for that rules first one is international law’s such as (Employers responsibilities
and workers responsibilities) and another Source is local. the international laws come from international labour organization (ILO)
and local law comes from government for country. Laws differ from one country to another due to the different terrain, weather and
number of working people. in all countries the government is seeking to make laws to reduce damage in the working area and
nearby areas. And the laws not only to the damage for place, that law includes workers and people who are located close to the
area, the environment, all devices, tools and Products. these laws are beneficial to everyone. And it always come with positi ve
results. finally, before starting work in an organization, you must know the rights that the employer must provide for you and know
your duties towards your organization.

Financial reason.
The organization cannot get the money without providing the health and safety conditions. The organization must provide health,
safety and suitable environment to work. For not losing its money in treatment the injured or getting a fine. So, all organizations try
to apply health and safety standards to avoid losing money and property.

When an accident happens, the organization will face 2 kinds of costs. this cost will be:
A-direct costs- the lost will be directed after accidents such as:
1-first aids treatment.
2-damage products.
3-lost time.

B-indirect costs-the losses will be in future such as:

1-reduces in staff morale.
2- losses some customers.
3- damage the business reputation.

The consequences are such as layoffs and closure of the organization, workers may get long term sicknesses and company must
pay these losses that will make the loss of their profit. Company may have to pay fines and penalties which will also reduce the part
of their profit. There might be unexpectedly high cost of accident that may lead very high impact on the financial resources of the
company and the organization will not be able to continue the business. For example, if fire happen and they have not fire team to
control the emergency I, the factor may suffer the losses beyond its tolerance and the organization's business may end due to huge
losses.

Learner number: 00520202 Learner name: Abdul Majeed Ghanim al-Farsi

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Likelihood and consequences.
1- Working inside a confined area is dangerous, so hot work inside the pit is more dangerous. Hot work is producing too
many fumes and vapours, and workers are exposed to these fumes inside the confined space. They can have the high
likelihood of getting adverse health issues, such as eye irritation, breathing problems, long working will affect kidney and
lungs

2- Power generators around flammable liquids was a big issue, which may lead to a huge fire and explosion. There is a lot of
flammable liquid around generator and any spark from the generator can start the fire and the likelihood of incident is high.
The severity of the consequence is severe property damage or multiple casualties.

3- There are fumes of the melted aluminium, and fumes are produced by the process of preparing the aluminium, the workers
are exposed to the fumes of melted aluminium and other mixed chemicals. The likelihood of getting the sickness is high,
and exposure chemical fumes will be causing the kidney and liver damages in the long term.

Effectiveness of controls.
1- Provide the force system for the extraction fumes from the confined space. This control will extract the fumes and vapours
from the confined space and person can work with safety, it will reduce the risk from the confined space to the safe level.
This control I have advised to complete in 2 months because it may need some approval, but I am sure this is enough time
to complete. Once completed the workers can have a good equipment to work safety.

2- Advise to set up firefighting and rescue team to mitigate the risk from fire. I am giving this control beaus there is no
firefighting team can control the fire and mitigate the consequence. The firefighting ream will also check the area and they
will reduce the likelihood of the fire to ignite. I am giving one-month time to fix this control because it is urgent and needed
badly. I hope the safety officer and supervisor will request in time, and they will get the approval from management.

3- Provide an effective local exhaust ventilation system (LEV) to reduce the fumes and extract the vapours. This location is
producing the vapour at the point of operation and operator and other helpers are exposed to that. The best option is to
provide the appropriate extraction system as I advised. This will reduce the vapours and the workers will be working safely.
I have given the time to fix this control for 1 month because it is needed urgent and it is available also from the local
market.

Learner number: 00520202 Learner name: Abdul Majeed Ghanim al-Farsi

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Part 4: Review, communicate and check

You must now give a review date for your risk assessment and say why you have chosen this date (10 to 50 words).

The plant management already reviewing the risk assessment every 6 months there for I will give the review date 25-4-2021

You must now indicate how the risk assessment findings will be communicated (including who needs to know the information) (100
to 150 words).

The risk assessment will be taken to the supervisor, after that the supervisor will disrepute the risk assessments for each section
for example some report will be given for safety manager, manager of the section and director. The safety manager will check
if there is any shortage in material s like PPE and RPE in order to make them available to the workers, while the manager of
the section will inspect the pl ace to check if it required any maintenance and adjustment and the director will make any order
for the materials which should be bring form the outside.

You must now indicate how you will follow-up on the risk assessment to check that the actions have been carried out (100 to 150
words).

For follow up, will communicate with the responsible person regularly to check work completion, also I will try to be identified if
there is any obstacle or problem that hinder the work completion to solve them. Moreover, I will set the reminder to remind
myself and the responsible person about the work, present for the manager the consequences of not completing the work at
the identified time, if the work did not completed at the identified time I will try to give the workers more advices and encourage
them to work as save as possible with the available equipment, if the work did not taken at if I do not get any response from the
manager, director, I will speak to managing director.

Learner number: 00520202 Learner name: Abdul Majeed Ghanim al-Farsi

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