assessing safety analysis at fkm's laboratory - Universiti Malaysia ...

CHAPTER 4POLICY AND LEGAL OPTIONS AND RECOMMENDATIONS …………………………………............………… 49Measures to Promote Transparency and Accountability …………………………………………………............... 49Constitutional Reforms ………………………………………………………………………………………………………………........ 49Joining the Extractive Industry Transparency Initiative (EITI) ……………………………………………………....... 50Role of Parliament ……………………………………………………………………………………………………………………............. 51Voluntary Reporting by Mining Companies ……………………………………………………………………………........... 52Mining Rights and Contracts …………………………………………………………………………………………....................... 52Awarding Mining Rights to Investors …………………………………………………………………………………………........ 52Review of Existing Mining Contracts …………………………………………………………………………………………......... 52Mining Contract Negotiation ……………………………………………………………………………………………………......... 53Revenue Generation and Community Participation in Mining ……………………………………………......... 54Mining Taxation Regime …………………………………………………………………………………………………….................... 54Creation of Inter-Generational Fund …………………………………………………………………………………………....... 55Community Participation in Mining and Indigenisation ………………………………………………………………. 55Corporate Social Responsibility …………………………………………………………………………………………………....... 57Position of Relocated/Displaced Communities ……………………………………………………………………............. 58Legal Reforms in the Mining Sector ………………………………………………………………………………....................... 58Proposed Diamond Law ……………………………………………………………………………………………………….................. 58Amending the Mines and Minerals Act ………………………………………………………………………………………...... 59etablihment of an Environmental Court ……………………………………………………………………………………........ 60Compliance with International Standards ………………………………………………………………………................... 60Compliance with the Kimberly Process Certification Scheme Requirements ………………………………. 60Working with Civil Society and Communities …………………………………………………………………................... 61REFERENCES ……………………………………………………………………………………………………………...............................… 62

“To my beloved mother and father. You are everything to me and always be therewhenever I need you”

ABSTRAKAnalisis keselamatan dengan menggunakan cara menganalisis tenaga telahdigunakan ke atas makmal Fakulti Kejuruteraan Mekanikal (FKM) UniversitiMalaysia Pahang. Analisis ini di aplikasikan dalam makmal FKM 3A yangmerangkumi mesin umum seperti mesin kisar (milling) dan mesin larikkonvensional. Tujuan analisis ini adalah untuk mengenalpasti dan menilai bahayaberlaku di makmal FKM menggunakan kaedah analisis tenaga. Pendekatan untukkajian ini berdasarkan konsep tenaga dan kaedah langsung yang bernama AnalisisTenaga. Cara ini adalah sesuai untuk mendapat satu gambaran keseluruhan dengancepat tentang bahaya yang sedia atau telah wujud dalam bentuk tenaga. Proses yangteratur dan sistematik dilakukan untuk menunjukkan bagaimana analisis ini bolehdijalankan. Analisis tenaga merupakan kaedah yang efisen dalam mengenal pastibahaya yang wujud di makmal FKM 3A. Bahaya telah dikenalpasti melalui kajiselidik, permerhatiah dan temu ramah yang telah dilakukan. Dengan menganalisissemua bahaya yang telah dikenalpasti, pelbagai langkah-langkah keselamatandicadangkan. Cadangan ini juga adalah untuk meningkatkan keselamatan di tempatkerja.

TABLE OF CONTENTSUPERVISOR’S DECLARATIONSTUDENT’S DECLARATIONACKNOWLEDGEMENTSABSTRACTABSTRAKTABLE OF CONTENTSLIST OF TABLESLIST OF FIGURESPageiiiiiivvviviixixiiCHAPTER 1INTRODUCTION1.1 Background of Study 11.3 Problem Statement 21.3 The Objectives of the Research 21.4 Scope of Study 2CHAPTER 2LITERATURE REVIEW2.1 General 32.1.1 Definition of safety analysis 42.1.2 Definition of risk analysis 42.1.3 The systematic approach 52.2 Classification of Hazard 52.2.1 Respiratory Hazard 52.2.2 Corrosive Hazard 62.2.3 Energy Hazard 62.2.4 Engulfment (contents) Hazard 62.2.5 Fire and Explosive Hazard 7

2.2.6 Mechanical Equipment Hazard 72.2.7 Fall hazard 72.2.8 Environmental Condition Hazard 72.3 Selection Method 82.4 Energy Analysis 92.4.1 Principles 92.5 Example of Application Analysis 12CHAPTER 3METHODOLOGY3.1 Introduction 133.2 Flow Chart3.2.1 Final Year Project 1 163.2.2 Final Year Project 2 173.3 Flow Chart Explanation 183.4 Data Collection 193.4.1 Survey (questionnaire) 193.4.2 Observation 193.4.3 Interview 203.5 Analysis Procedure3.5.1 Preparation 203.5.2 Structure 203.5.2.1 Conventional Lathe Machine 213.5.2.2 Milling Machine 223.5.3 Identify Energies 233.5.4 Assess Risk 243.5.5 Propose Safety Measure 24CHAPTER 4RESULTS AND DISCUSSION4.1 Introduction 254.2 Survey Analysis 254.2.1 Question 1 264.2.2 Question 2 274.2.3 Question 3 284.2.4 Question 4 294.2.5 Question 5 304.2.6 Question 6 314.2.7 Question 7 324.2.8 Question 8 334.2.9 Question 9 34

4.2.10 Question 10 354.2.11 Question 11 364.3 Observation 374.3.1 Conventional lathe machine (former) and Conventional 38lathe machine (new)4.3.1.1 Potential Energy 394.3.1.2 Kinetic Energy 394.3.1.3 Rotational Movement 404.3.1.4 Hot and Cold 404.3.1.5 Miscellaneous 404.3.2 Milling Machine 414.3.2.1 Potential Energy 414.3.2.2 Kinetic Energy 424.3.2.3 Rotational Movement 424.3.2.4 Hot and Cold 434.3.2.5 Miscellaneous 434.3.2 Observation Picture 434.4 Interview 464.5 Analysis Procedure 474.5.1 Volume of Conventional Lathe Machine 474.5.2 Volume of Milling Machine 494.6 Propose improvement on safety 514.6.1 Employer safety obligation (FKM laboratory51management)4.6.2 Employee safety obligations (Students) 52CHAPTER 5CONCLUSION AND RECOMMENDATIONS5.1 Conclusion 545.2 Recommendation 55REFERENCES 56APPENDICES 58A Checklist of questions to survey for machine guarding problems 58from Reference OSHA Standards 1910.211-2.19B Questionnaire 64C Finding safety measure using Energy Analysis 66D Gantt Chart for FYP 1 67E Gantt Chart for FYP 2 68F Example of Questionnaires Answer from respondent 69

G Standard from OSHA 71

LIST OF TABLESTable No.2.1 Example of a direct risk acceptance scaleapplied in Energy Analysis3.1 Direct risk acceptance scale applied inEnergy AnalysisPage11153.2 Checklist for Energy Analysis 233.3 Record sheet from energy analysis 244.1 Evaluation and proposed measure forconventional lathe machine4.2 Evaluation and proposed measure formilling machine4749

LIST OF FIGURESFigure No.Page3.1 Main stages of procedure in energy Analysis 133.2 Flow chart for FYP I 163.3 Flow chart for FYP 2 173.4 Conventional Lathe Machine (formal) 213.5 Conventional Lathe Machine (new) 213.6 Milling Machine (formal) 223.7 Milling Machine (new) 224.1 Pie Chart 1 264.2 Pie Chart 2 274.3 Pie Chart 3 284.4 Histogram 4 294.5 Pie Chart 5 304.6 Pie Chart 6 314.7 Pie Chart 7 324.8 Pie Chart 8 334.9 Pie Chart 9 344.10 Pie Chart 10 354.11 Pie Chart 11 364.12 Conventional lathe machine (former) 384.13 Conventional lathe machine (new) 39

4.14 Milling machine (former) 414.15 Milling machine (new) 414.16-4.174.18-4.234.24-4.29Observation Picture 43Observation Picture 44Observation Picture 45

CHAPTER 1INTRODUCTION1.1 BACKGROUND OF STUDYFaculty of Mechanical Engineering (FKM) at Universiti Malaysia Pahang hasa laboratory for students. The laboratory consist various kind of machines for studentpurpose. Some of the machine can be found in FKM’s laboratory such as punchingmachine, conventional lathe machine, conventional milling machine, grindingmachine, conventional drilling machine, CNC lathe machine, CNC milling machineand EDM machine. Hazard and accident could be occurred while conducting themachine if the safety precaution was neglected since many students and staffs wereusing the machines everyday.Hazard can be defined as anything that has potential to cause harm. Mosthazards are dormant or potential, with only a theoretical risk of harm, however, oncea hazard becomes 'active', it can create an emergency situation [1]. This present paperpurposed to identify hazard at FKM laboratory, analysis the hazard and suggest theidea in improving hazard control.The data was collected and analyzed to trace where the hazard or accidentpotentially and was occur. Then, then possible solution to control or avoid the hazardsuggested to FKM’s laboratory management. This paper is concerned on how thehazard at FKM’s laboratory was identified, analyzed to control the hazard. Themethod called Energy Analysis was applied.

1.2 PROBLEM STATEMENT(i)(ii)To identify hazard occurs at FKM’s Laboratory (General Machine Lab, FKM3A) by applying energy analysisTo improve safety at FKM’s Laboratory by proposes the suggestions tocontrol and reduce hazard.1.3 OBJECTIVEObjectives of this research are as follows:(i)(ii)(iii)To assess whether it is possible or not to identify hazard by using energyanalysis method at FKM’s Laboratory (General Machine lab, FKM 3A).To analyze the hazard occur using energy analysis method.To propose improvements on safety at FKM’s laboratory (General Machinelab, FKM 3A).1.4 SCOPE(i)(ii)Identify hazard occur at workplace in FKM’s laboratory (General Machinelab, FKM 3A).Propose the suggestions to control and reduce hazard.

CHAPTER 2LITERATURE REVIEW2.1 GENERALThe safety analysis is tools that can be apply in safety work. By utilizingappropriate methods, the knowledge that is available in a workplace can besupplemented and applied more systematically. Good result can be obtained fromthe suitable designed analysis. Systematic safety work has economic benefits andrisks can be reduced. Safety analysis has become methodology that is applied to agrowing extent, often providing the basis for safety activities at plan level [2].The implementation of the risk analysis regulations gives rise to a number ofquestions concerning the consistency between risk acceptance criteria and theavailable risk analysis methods and the feasibility of estimating the risk of accidentson a theoretical basis. There is a long tradition in the area of major accidents inaddressing these questions (Versteeg, 1991; Allen et al., 1992; Niehaus, 1989). In thearea of occupational accidents, questions concerning measures of risk, primarilybased on historical data, have been thorough studied (Tarrants, 1980).Comprehensive literature exists on risk analysis methods and their application duringdesign in this area (Harms-Ringdahl, 1987; Harms-Ringdahl, 1993; Kjellen, 1990;Reunanen, 1993; Soukas and Rouhiainen, 1993). However, there is a general lack ofintegration of these fields concerning the application of risk analysis in conjunctionwith risk acceptance criteria based on measures of risk as input to the decisionmaking process. The paper addresses this integration.

2.1.1 Definition of safety analysisSafety analysis is analysis of risk that is conducted within a variety ofprofessional area and in various ways. There are standard that define part of theterminology for certain application area. One attempt at definition refers to a “safesystem” as one that is free form obvious factors that might lead to injury of a personor damage to property or surroundings (SCRATCH, 1984). In sense, safety is theopposite of risk and can be regarded as inversely proportional to the risk (Kumamotoand Henley, 1996). Safety analysis is a systematic procedure for analyzing systemsto identify and evaluate hazards and safety characteristics [2]. This definition is wide.The analyses are conducted within variety of professional area and in various ways.There are standards that define parts of the terminology for certain application area.Safety analysis usually has three main elements which is identification of hazards,assessment of the risk that arises and the generation of measures that can increase thelevel of safety [2].2.1.2 Definition of risk analysisDefinition of Within the area of dependability and reliability there is aninternational standard ( IEC, 1995) that defines “ risk analysis” and a number ofrelated terms. According this standard,Risk analysis is the systematic use of available information to identifyhazards and to estimate the risk to individual or population, propertyor environment.Risk analysis is also sometimes referred to as probability safety analysis(PSA), probability risk analysis (PRA), quantitative safety analysis and quantitativerisk analysis (QRA).

2.1.3 The systematic approachThe analysis might apply to an existing installation or to production facilitiesthat are still at planning stage. According to Lars Harms-Ringdahl, 2001 [2], thereare several different aspects to a systematic approach:Gathering of information on the system provides the basis for the analysisand must be carried out systematically.The entire system and the activities within it should be included in theanalysis. The analysis need to be designed so those important elementsare not overlooked. A main thread must be identified and followed.A systematic specified methodology is required for the identification ofhazards.The risk to which these hazards give rise need to be assessed in aconsistent manner.A systematic approach is required when safety proposals are to begenerated and evaluated.A method for safety analysis can also be seen as a compressed account ofprevious experiences. The developments of analysis and safety activities are much“accident-driven”. Or, as Reason (1990) put it, “events drive fashions”. People havebeen forced to rethink, in one way or another, by their own experiences. Perspectiveson accidents and strategies for the analysis of risks have been governed to aconsiderable extent by accidents that have already occurred.2.2 CLASSIFICATION OF HAZARDS2.2.1 Respiratory HazardOSHA does not permit anyone to enter or occupy a space containing less than95% oxygen. Even though human may be able to hold their breath for a couple ofminutes, a single breath of an atmosphere without oxygen will result immediateunconsciousness and death if the victim is not removed to fresh air within minutes.

OSHA standard 29 C.F.R 1910.146 requires monitoring of these space to ensure thatat least 19.5% oxygen is available prior to and during any confined space entry.2.2.2 Corrosive HazardCorrosive atmosphere have the ability to cause damage to the skin or anyother human tissue they contact. Strong acids and alkali materials are used in manyindustrial processes and are by-products generated in others. These atmospheres alsohave the ability to damage or destroy personal protective equipment (PPE). All PPEselected for use in corrosive atmosphere should be compatible with the materials inspace.2.2.3 Energy HazardThese same hazards often conceal other deadly hazards such as energizedelectrical components, high pressure gas, and liquid transmission lines, andpneumatic or hydraulic equipment and component. The only way to protect entrantsfrom these hazards is to educate them about the entire hazard in the workplace byisolating and de-energizing every component in the space before allowing them toenter.2.2.4 Engulfment (contents) HazardFailure to isolate valves that direct contents into vessels is one of theproblems. Unauthorized entry into open-top container with sloping sides andcontaining grain or other similar materials has also results in fatalities. One of theprimary ways to guard against unauthorized entry and improperly compensated riskis trough effective education. Every employee must be taught to appreciate thedangers and they must understand the company policies that will not tolerateunauthorized entry.

2.2.5 Fire and Explosive HazardFlammable atmosphere pose serious fire and explosion threats to workplace.The permit system requires the space to be monitored before entry and continually toensure that flammable vapors do not accumulate whole while the entrants inside thespace. If reading of 10% or greater of the lower flammable limit of the gas is reachedaccording to the combustible–gas monitoring instrument, the entrants must exit thespace. The probe of the monitoring instrument should be located in the space wherethe vapor is most likely to be located.2.2.6 Mechanical Equipment HazardMechanical devices are design to mix, chop, and stir products. If primaryenergy to derive the devices is not properly locked out, according to 29 C.F.R1910.147, and if energy stored in devices such as accumulators, capacitors,compressed air tanks, etc. is not bled off, equipment may activate and injure or killthe entrance. It is worth nothing that a single machine may have several differentenergy sources.2.2.7 Fall HazardThe OSHA requires all employees to be protected from falling from anysurface 4 feet (29 C.F.R. 1910.23) to 6 feet (29 C.F.R. 1926.501) above adjacentsurface. Each employee o walking or working (horizontal or vertical surface) with anunprotected side or edge that is 6 feet (1.8 meters) or more above a lower level mustbe protected from falling by the use of guardrail systems, safety net system, orpersonal fall arrest systems.2.2.8 Environmental Condition HazardOther factors such as extreme temperature may compound the hazard topresent. Any condition that has the potential to distract the entrant from focusing onthe other safety hazards could contribute to an accident or injury. The workplaces are

dark, tiny space, encountering reptiles, rodent, or insects are another potential hazard.In such situation thermal imagers could possibly be used, as any living animal willgive off heat and be visible even in low or no light condition. Noise and vibration areenvironmental conditions that complicate work to rescue. The machinery near theworkplace should be stopped to reduce noise and vibration when ever possible.Psychological hazard of working in restricted space can adversely affect worker.Individuals who are susceptible to claustrophobia could have problems before orduring entry into confined spaces. Employers should attempt to uncover thistendency through training prior to working in actual hazardous condition. Peoplewith minor or moderate claustrophobia anxiety in these working condition can oftenslowly acclimated through training and can learn to overcome the anxiety.Individuals who cannot do so should not be forced to work because they could createdangerous conditions for all the entrants.2.3 SELECTION METHODThere are many method are referred to safety analysis, each with differentfield of application [3]. In general that any one specific method will only cover alimited part of the risk panorama. Extensive descriptions, references and evaluationsof the methods are given by CCPS (1989) Harms-Ringdahl (1993), Lees (1980)Rausand (1991), Suokas (1985) and Suokas and Rouhiainen (1993). The Energyanalysis method is relatively simple and risk analysis expert participation is notrequired (Harms-Ringdahl, 1993). Energy analysis is also called Preliminary HazardAnalysis. A further advantage of Energy analysis is that it is linked to a philosophyfor the development of safety measures (Haddon, 1980). Often an Energy/Coarseanalysis is the first step in a risk analysis process. Job safety analysis is primarilyintended for analyses of well structured activities. Also this method is straightforward and relatively easy to apply. According to Suokas (1985) the quality of theresults (validity and reliability) obtained by Job safety analysis can be impaired bysuch factors as inadequate boundary definition, work steps unintentionally omitted,and variety in the analysis object (e.g. different working methods or auxiliaryequipment may be applied). Some of the criteria that might be used in choice ofmethod are:

The code number three is safety measure is essential for this energy evaluation.This is because of the serious consequences and inadequate barriers.Based on evaluation hazard that has been determined, the next stage ismade to propose to reducing hazard. The safety measure proposed on the table4.1 and table 4.2 are based on the energy hazard that has been identified duringobservation, questionnaire and interview. The safety measure proposed hasbeen guided by finding safety measure using energy analysis (table 5.3) by LarsHarms-Ringdahl [2] as shown in appendix A3. There are some suggestion onsafety measure proposed such as wear safety shoes and safety glass that alreadybeen practical at FKM 3A laboratory but still not 100% successful. Therefore,the safety measure requires proposing again until it achieves the target.4.6 PROPOSE IMPROVEMENT ON SAFETYIn order to have safety environment, laboratory should have future aim & mission tohave zero injury/accident. Based on survey, observation and interview that has beendone at workplace area at FKM 3A, suggestion on improvement safety and to controlhazard occur are divided to two responsible sides. First side is employers whichmean FKM lab management and the other side is employees which mean thestudents or the user of the machines. To develop these safety obligations intocontract of safety measure, a refinement process was carried out as looking foroverall safety measure from this study. This is because the data collection found thatto control and reduce hazard on the workplace, all factor must be consider such asethics or psychology and the managements besides the hazardous energies occur.4.6.1 Employer safety obligation (FKM laboratory management)(i)(ii)(iii)(iv)(v)Provide personal protective equipmentHave visible safety documentationMaintain a safe workplaceConduct regular safety training with all studentSupply proper work equipment