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 PROJECT REPORT ON

CASE STUDY OF EXPOSURE OF HAZARDOUS CHEMICAL FUMES IN FIBERGLASS LAMINATING

SECTION IN JERUNG SHIPYARD

BY AINUL SUFIAH, PRODUCTION EXECUTIVE AS A REPRESENTATIVE EMPLOYER IN SAFETY

COMMITTEE

DISEMBER, 2020
 INTRODUCTION

BACKGROUND CASES
The purpose of this research is to investigate the issue involve one of personnel in fiberglass
laminating section caused by prolog exposure of hazardous chemical fumes. Fiberglass
laminating is the process of taking a thin fiberglass sheet and laminating it to another material
in order to provide strength and support to that material. Legislation requires that the person
responsible for the workplace must identify all hazards that a person at the workplace is likely
to be exposed to assess the risk and identify the means by which the risk may be reduced. For
example, explosion risk may happen from mixing different chemicals together without referring
and adhering to manufacturer’s specific instructions. This task is also requiring Task Force
department to produce Hazard Audit Plan and Findings and Proposal to overcome the
problems.
This accident has lead the personnel being suspected for lung infection and warded due to the
exposure of chemical. This situation puts employees in danger if no solution is done because it
is not only affect their health but also the performance of the company, Jerung Shipyard and
employees.

PURPOSE AND SCOPE OF AUDIT

The overall purpose of this audit lead by the Task Force is to develop guidance for Hazard Audit
Plan in minimizing any health risk to workers and others at the company as well as the
fiberglass laminating section and risk to the environment from hazardous materials and
chemical products. The purpose of the audit is also to obtain reasonable findings about the
causes of the incident for improvising the audit plan. The scope of the audit establish the audit
which will be performed to provide details of the applicable regulations where the vulnerable
to risk and the environment of the workplace.
 AUDIT PLAN
Checklist
A safety audit checklist is used to ensure companies comply with safety regulatory
requirements to prevent any work-related incidents, injuries, or fatalities.
 Chemical Storage and Safety
 Compressed Air and Compressed Gases
 Hazardous Waste & Materials Disposal and Recycling
 Manuals, Training, SOPs, MSDSs, Occ. Health
 Safety Equipment and Emergency Preparedness
 Electrical Safety
 Fire Prevention and Protection
 General and Miscellaneous Safety
 General Work Environment & Indoor Air Quality
 Personal Protection Equipment (PPE)
Task and Responsibility
Lead Auditor : Ainul Sufiah , Production Executive as employer representative in safety
commitee as Task Force leader
Auditors : Edmund Tan, Quality Manager, Jerung Shipyard
: S.R. Tanesh Assistant General Manager, Jerung Shipyard
: Azman Hariz, Assistant Manager, Jerung Shipyard

Audit Team Responsibility

Lead Auditor Responsible for leading the audit team.
 Prepare the audit plan,
 Delivers meeting
 Submit audit report at the end of
quarter or year
Auditors Ensures compliance with established internal
control procedures by;
 examining records, reports, operating
practices, and documentation. Verifies
assets and liabilities by comparing items
to documentation. Completes audit
workpapers by documenting audit tests
and findings.
Timelines

Month Audit Type

Feb-16 Health and Safety Plan
Jun-16
Oct-16
January Policies
February Planning:
May Legal requirements
September Objectives/Tragets/ Improvements
December
Every Month Implementation/ Operations:
Site Audits
Hazard Management:
Every Month SOPs
January MSDs
April
July
October

Survey Form

No. Survey Questions No Rare At Yes/

/Not times Always
at all
SCS Element Group: Safety Management SCS Element: Emergency Management
1. Are you aware of your role in Emergency 1 2 3 4
management plan
2. Do you know the nearest assembly point 1 2 3 4
3. Do you feel safe working in this section 1 2 3 4
SCS Element Group: Safety Management SCS Element: Emergency Communication
4. Can you recognize all the hazards at our work place 1 2 3 4
5. Are the accidents investigationreports/ findings 1 2 3 4
circulated amongst employees?
 AUDIT FINDING AND RISK ASSESSMENT
1) Hazard Identification
• From the cases the hazard that can be identified is health hazard which is any
agent that can cause illness to an individual. It may produce serious and
immediate (acute) affects, or may cause long-term (chronic) problems. All or part
of the body may be affected. Someone with an occupational illness may not
recognize the symptoms immediately. In this cases the personnel in fiberglass
laminating section has been warded suspected for lung infection due to prolong
exposure of hazardous chemical fumes.
• This hazard can be identified with a few technique which is;
- any hazardous occurrence investigation reports;
- first aid records and minor injury records;
- work place health protection programs;
- any results of work place inspections;
- any employee complaints and comments;
- any government or employer reports, studies and tests concerning the health
and
safety of employees;
- any reports made under the regulation of Occupational Safety and Health
Act,1994
- the record of hazardous substances; and
- any other relevant information

2) Risk Assessment
As soon as a hazard is identified, the risks must be assessed. To determine the level of risk,
you need to consider;
i. Outcome – If a person came into contact with the hazard which is include chemical,
it can enter the bloodstream through the pores, small cracks, or cuts in people’s
skin. where workers and other personnel are exposed to hazardous
chemicals through inhalation, absorption through the skin, or ingestion and
swallowing. Chemical health hazards can be acute (nausea, vomiting, acid burns,
 asphyxiation which happen immediately) or chronic (dermatitis, asthma, liver
damage, cancer which develop after prolonged exposure). The actual health risk of a
chemical depends on the toxicity and the actual exposure. An assessment of the
chemical's toxicity and the possible routes of entry will help determine what protective
measures should be taken.
ii. Probability – Chemical exposure is estimated to have caused approximately 190,000
illnesses and 50,000 deaths of workers annually.
iii. Exposure - About 32 million workers work with and are potentially exposed to one
or more chemical hazards. There are an estimated 650,000 existing chemical
products, and hundreds of new ones being introduced annually. This poses a serious
problem for exposed workers and their employers.
iv. Existing Control – Use required PPE and the workers follow the established
procedures and work precisely as they've been trained. Elimination is the process of
removing the hazard from the workplace. It is the most effective way to control a
risk because the hazard is no longer present. It is the preferred way
to control a hazard and should be used whenever possible.

PROPOSAL FOR RISK CONTROL

Control is the elimination or inactivation of a hazard in a manner such that the hazard
does not pose a risk to workers who have to enter into an area or work on equipment in
the course of scheduled work. Once the hazardous chemicals identified and assessed
the risks, controls must be put in place to manage health and safety risks.
When controlling the risks of hazardous chemicals, the risk must be minimized by using
the following approaches;

 Substitution
Substitution of hazardous chemicals is a way to transpose into chemical risk management
the general principle of ‘replacing the dangerous by non-dangerous or less dangerous. One
of potential substitute is vapour pressure is an indicator of how easily a chemical
evaporates into the air. Exposure by inhalation is the primary route of exposure for many
products; therefore, the vapour concentration in the air largely influences the potential
degree of exposure. If a solvent is not very volatile (does not evaporate easily), the potential
for exposure by inhalation may be very low.

 Isolation
Isolating or separating the hazard or hazardous work practice from people not involved in
the work or the general work areas. When hazardous chemicals are required by the section
or the workplace can be made safer by minimising the amount of contact workers and other
personnel have with the chemicals. Some effective examples include:
 Placing laboratory chemicals in a fume hood or fume cabinet
 Using closed or sealed systems for chemical dispensing and transfer
 Carrying out certain mixing and experimental works in a glove box or glove bag
 Restricting the amount of chemicals kept in work areas by storing them in safety
cabinets or bulk stores constructed to Australian Safety Standards
 Performing certain tasks in enclosures fitted with exhaust extractors that remove
air-borne contaminants while the operator is working
 Working from a positive pressure room which cannot be penetrated by air-borne
contaminants
 Restricting access to chemical storage and work areas

 engineering controls.
Engineering controls protect workers by removing hazardous conditions or by placing a
barrier between the worker and the hazard. Examples include local exhaust ventilation to
capture and remove airborne emissions or machine guards to shield the worker. If isolation
cannot be achieved, implement a number of engineering controls to reduce the risk
associated with hazardous chemicals. Engineering controls are physical in nature and are
devices or processes that eliminate exposure to hazardous chemicals. Engineering controls
can be used to:
 Minimise the generation of hazardous chemicals
 Suppress or contain chemicals
 Limit the area of contamination in the event of spills
Engineering controls can include devices such as mechanical ventilation systems,
compliant chemical storage containers or the automation of processes involving the use
of hazardous chemicals.
 MONITORING SCHEDULE AND CHECKLIST
Chemical Storage & Safety Y N N/AComments
1 Chemical containers properly labeled, stored, &
closed when not in use.
2 Chemicals segregated and stored by
compatibility.
3 Peroxide formers dated at purchase and again
upon opening.
4 Peroxide formers disposed of within proper time
frames.
5 Secondary containment used where
appropriate.
6 Vacuum equipment trapped and/or filtered.
7 Chemical storage areas free of ignition sources.
8 Refrigerators/Freezers properly labeled.
9 Refrigerators/Freezers properly rated if
flammable liquids are stored within.
10Fume hoods and/or biosafety cabinets not used
for general storage.
11Cryogenic materials stored properly and proper
PPE available.
12Flammable liquids in containers over 4 L are in
approved safety cans.
13Corrosive storage cabinet used if more than 10
gal of corrosives present.

14Chemicals purchased in amounts that can be

used within a reasonable time.

15Chemical stocks purged of old, out-dated, and

unusable chemicals.
16Chemical inventory up to date and copy sent to
EH&S.
Compressed Air and Compressed Gases
1 Air compressors equipped with pressure
gauges and pressure relief valves.
2 Compressed air piping, hoses and fittings in
good condition.
3 Compressed air 30 psi or less for machine/parts
cleaning, 10 psi for clothing.
4 Compressed air cleaning nozzles with
chip/particle deflection device.
5 Gas cylinders w/30 lb or more water capacity
have valve protection capability.
6 Gas cylinders legibly marked as to their
contents.
7 Gas cylinders stored away from high heat,
flames, etc.
8 Gas cylinders stored in secure area and
secured from tipping or falling.
9 Gas cylinders transported on cylinder carts.
10When in use, gas cylinders kept away from
elevators, stairs, and ramps.
11Valve protectors used when cylinders not in use
or when being transported.
12Liquefied gas cylinders (acetylene) always
shipped and stored valve-end up.
13Proper type of regulator used for type of gas
cylinder in use.
14Gas cylinders, valves, couplings, regulators
kept free of oil and grease.
15Gas cylinders lacking obvious defects, leaks,
damage, etc.
16Gas cylinders hydrotested at appropriate
intervals.
17Empty gas cylinders labeled "Empty," valves
closed, and caps on.
18Oxygen and Acetylene in storage are separated
by 5' noncombustible barrier.
Hazardous Waste & Materials Disposal and Recycling
1 Waste storage areas (bins, totes) designated.
2 Waste containers properly labeled (chemical
components, amounts, etc.).
3 Waste containers compatible with waste to be
stored.
4 Only compatible chemical wastes stored in the
same container.
5 Waste containers kept closed except when adding
waste.
6 Waste containers stored compatibly.
7 Fluorescent, HID, Mercury vapor lamps recycled
properly.
8 Used oil collected and recycled properly.
9 Non-alkaline batteries (lead acid, Ni-cad, silver,
etc.) managed for recycling.
10Mercury containing devices (thermostats,
barometers, etc.) properly recycled.
11Electronic devices, (monitors, TVs, circuit boards,
etc.) managed properly.

12Biohazardous materials & animal carcasses

managed & disposed properly.
Manuals, Training, SOPs, MSDSs, Occ. Health
1 Appropriate safety manual(s) available (CHP, ECP,
Bio Safety Rad Safety, etc.).
2 Standard Operating Procedures & Material Safety
Data Sheets readily available.
3 Applicable initial/refresher training completed.
 (LS,HW,BW,BBP, RAD,etc.).
4 Personnel in occ. health program, if required
(blood, etiologic agents, carcin.).
Safety Equipment and Emergency Preparedness
1 Eyewash & safety shower within 100 ft. and 10
second travel time.
2 Eyewash & safety shower unobstructed and
inspected as required.
3 Fume hoods, biosafety cabinets, glove boxes,
properly located and certified.
4 Appropriate spill control kit available and stocked
(Chem, Rad, Bio).
5 Spill & accident reporting procedures understood by
lab personnel.
6 Appropriate first aid kit available and stocked.
7 Emergency contact information posted by entrance
(and by phone if present).
8 Laboratory under negative pressure in relation to
other areas.
Electrical Safety
1 Extension cords are not used as permanent wiring.
2 Extension cords and power strips not daisy-chained one
to another.
3 Electrical cords not under carpets/rugs, through
doorways, or high traffic areas.
4 Multi-outlet power strips are UL listed and have circuit
breakers.
5 Power cords are in good condition with no splices or
broken insulation.
6 Grounding prongs not removed from 3-way plugs.
7 Outlet, switch and junction box covers are in place and
in good repair.
8 Circuit breaker panels and emergency shut offs
unobstructed and labeled.
9 Electrical outlets not overloaded with appliances, i.e.
splitters used.
10 Ground Fault Interrupters installed, labeled and
operating correctly.
11 Energized parts, circuits, and equipment guarded
against accidental contact.
Fire Prevention and Protection
1 Fire extinguishers properly mounted, located, and
identified.

2 Fire extinguishers adequate in number and type.

3 Fire extinguishers inspected, recharged, and maintained

as required.
4 Fire aisles, exitways, stairways, and fire equipment kept
unobstructed.
5 Exit lights properly illuminated and emergency lighting
operable.
6 Fire doors not blocked open or are on magnets
connected to fire alarm system.
7 Flammable liquids stored in approved safety cans.
8 Flammable liquid containers kept closed when not in
use.
9 Flammable liquids of 10 gallons or more stored in
flammable storage cabinet.
10 Flammable storage cabinets labeled "Flammable - Keep
Fire Away."
11 Connections on drums and combustible liquid piping
leak free.
12 Flammable liquid drums grounded and bonded to
containers when dispensing.
13 Proper storage of flammable/combustible materials to
 reduce risk of fire.
14 Oily/greasy rags placed in proper self-closing oily rag
containers.
15 No penetrations through walls or ceilings and all ceiling
tiles are in place.
16 Sprinkler heads clean and no storage within 18 inches.
17 Sprinkler heads protected by metal guards when
exposed to physical damage.
General & Miscellaneous Safety
1 Hand washing sink, soap and towels available & used before
leaving lab.
2 Sink faucets with backflow device or attached hoses above sink
rim.
3 Heavy objects stored below 5 ft. unless secured and stepladder
provided.
4 Stepladder or stepstool available & in good condition for high
storage access.
5 Appropriate signs posted (First aid kit, safety shower, fire
extinguisher, etc.).
6 Proper handling & disposal of broken glass & sharps.
7 Batteries charged in properly ventilated area away from sparks
and flames.
8 Work practices observed during inspection done safety.
9 No food or beverages unless adequately separated from hazard
areas.
10 Benchtops impervious to water and resistant to chemicals.
11 Lab furniture is appropriate for loading and use.
General Work Environment & Indoor Air Quality
1 All areas properly illuminated. Glare and reflections avoided.
2 Noise levels are within acceptable limits or engineering controls
established.
3 Areas with high noise levels posted and hearing protection
required to be used.
4 Work areas clean, sanitary, and orderly. (garbage disposed
properly, etc.)
5 Work area properly ventilated for type of equipment or chemicals
in use.

6 Vacuum systems used when possible instead of blowing or

sweeping dusts.
7 Temperature and humidity seem to be within acceptable ranges.
8 Areas free of visible fungal/mold growth and associated odors.
9 Walls ceilings, floors free of signs of mold or moisture damage.
10 Air intake areas free of odor causing materials or hazardous
chemicals.
Personal Protective Equipment (PPE)
1 Appropriate eye/face protection is available and used if hazard
present.
2 Appropriate hand protection is available and used if hazard
present.
3 Appropriate hearing and foot protection available and used if
hazards present.
4 Protective clothing - coveralls, aprons, gowns, etc. available &
used if needed.
5 Protective clothing and gloves removed before leaving lab.
6 Non-disposable protective clothing laundered on site or by
commercial service.
7 Approved respirators available and used if needed.
8 Respirator users medically certified, properly trained and fit
tested.
9 PPE is properly stored, clean and in good condition.