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Diesel Generator Risk Assessment

This document discusses occupational hazards and their control. It defines hazards as unsafe conditions or practices that can cause injury or illness. Hazards are classified as health hazards, which cause diseases, or safety hazards, which cause physical harm. Hazards can arise from processes, equipment, tools, or unsafe work practices. The most effective control methods are engineering controls, work practice controls, administrative controls, and personal protective equipment. The hierarchy of control prioritizes elimination, substitution, isolation, ventilation, and PPE. The document then analyzes hazards involved in installing, operating, and maintaining diesel generators.

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2K views

Diesel Generator Risk Assessment

This document discusses occupational hazards and their control. It defines hazards as unsafe conditions or practices that can cause injury or illness. Hazards are classified as health hazards, which cause diseases, or safety hazards, which cause physical harm. Hazards can arise from processes, equipment, tools, or unsafe work practices. The most effective control methods are engineering controls, work practice controls, administrative controls, and personal protective equipment. The hierarchy of control prioritizes elimination, substitution, isolation, ventilation, and PPE. The document then analyzes hazards involved in installing, operating, and maintaining diesel generators.

Uploaded by

Alvin
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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1.

2 Concepts of Hazards

A hazard is an existing (or potential) hazards or unsafe condition or work practice that, by itself or in
combination with other conditions, could cause injury, illness, or death to workers, as well as cause
property damage. Occupational hazard may be classified into two broad categories: (i) health hazards
and (ii) safety hazards. Generally, health hazards cause occupational illnesses, such as noise induced
hearing loss (NIHL), skin infections or impairment to any of the human body organ. Safety hazards cause
physical harm, such as cuts, broken bones or fall from a height and so on. Hazards may exist from:

(i) Processes or procedures-any series of actions or operations (manufacturing, equipment,


product flow, etc., and handling) that convert raw material into a product.
(ii) Unsafe equipment, machinery, or tools-for example damaged tools, unguarded blades or
unguarded moving parts, etc.
(iii) Unsafe work practices – allowing untrained workers to perform hazardous tasks, taking
unsafe shortcuts, being distracted, working long shifts etc.
(iv) It takes both a hazardous condition of some kind and exposure to that condition to cause an
injury/illness. Therefore, the hazardous condition and/ or the exposure can be eliminated or
reduced and an accident can be prevented.

1.2.1 Control of Occupational Hazards

The most effective methods of occupational hazards control involve either elimination or reduction of
hazard and finally putting barrier between worker and hazard if require, though this is lease method.
The hierarchy of hazards control includes:

(i) Engineering control


(ii) work practice control
(iii) administrative control and
(iv) Personal protective equipment (PPE).

The Workplace Health and Safety Acts of 1995 imposes obligations on people at workplaces to ensure
workplace health and safety. Workplace health and safety is ensured when persons are free from death,
injury or harm created by workplaces, relevant workplace areas, work activities or plant/substances for
use at workplace.

Ensuring workplace health and safety involved identifying and managing exposure to the risks. Risk
assessment provides a process that help to meet desired goal. The most effective methods of
occupational hazards control involve elimination or reduction of the risks using primary control, work
practice control, administrative control and personal protective equipment.

Engineering control is the first line of defense against injury, work practice control reduces explosive to
hazards by changing or redesigning safe work place. The administrative control limits employees
exposure thought scheduling breaks and personal protective equipment is a supplementary method by
placing barriers between the workers and the hazard; the PPE devices include safety glasses, hand
gloves, welding shields/helmets ergonomic equipment etc. This paper investigated the hazards and the
risks involved in the installation operation and maintenance of 40kva Wilson Model P40P3 diesel
generator.
2. METHODOLOGY

Job hazard analysis (JHA) assessment was used for this investigation. This comprises of JHA form and
chart. These tools were used to break the job down into tasks for hazard/identification. Rating of
probability and severity of risk was used to determine risk factors; risk priory coding was used to
determine what action to be taken.

Motion observational and record was used to monitor every steps involved in installation, operation and
maintenance of the generator within the study area. Interview was conducted with the operating
technician on the job.

The study and method were solely focused on the hazards identification and consequent risk
assessment there from.

This was complemented by interview with the operating technicians on the job. The study was also
supported with information from Manufacturer Association, trade unions and legislations from relevant
government agencies.

3. Results

Job Hazard Analysis result and Matrix Chart for Risk Assessment in Installation, Operation and
Maintenance of P40P3 FG. Wilson Standby Generator

4. Discussion

The result in reveals that five major jobs or tasks were associated in the study samples. Hazards of
varying degrees were identified with every section and jobbing of the whole activities. The associated
risk classification is about 60 percent high risk to 40 percent medium risk. The most hazardous tasks in
the study in order of risk levels include:

(i) Engine operation


(ii)Electrical wiring and connection to the generator
(iii)
Receipt and installation of the generator
(iv)Preparation foundation
(v) Engine maintenance. The high risk involved in the engine operation and electrical wiring and
connection to the generator tasks were due to high probability of exposure of workers and
critical severity of hazard, if happened. These are indeed, the most hazardous aspect of the job
as hazards involve fire, shocks and electrocution, heat, hot, metal, hazardous gasses, impact,
sprain and many more handlings.
The study however, found out that there is less risk involved in the maintenance activities and
preparation of foundation. The hazards of these sections are predominantly cut, pinch, crush, fall,
impact, and sprain and contaminant dust.

It is important to note that major cause of injuries and fatalities are shocks and electrocution from
improper use of power or accidentally energizing other electrical systems; carbon monoxide from a
generator’s exhaust and fires from improperly refueling the generator or inappropriately storing fuel
and some others. All these have high potential for serious occupational illness.

Major Hazards Identified in the Study and their Control


The various major hazards identified in the study are:

 working In Heat
 hot metal
 airborne contaminants
 dangerous items
 manual tasks
 Hazardous Substance
 Vibration
 Electricity and
 Plant and machinery.

4.1.1 Working in Heat

The engine, when working creates a hot working environment. The human body is able to function
normally within 10C to 1.50C of a 370C core body temperature. The body maintains this temperature by
balancing heat generated within the body and heat loss with the environment. Working in hot
environments causes’ strength to decline, and fatigue occur sooner than it would otherwise. Alertness
and mental capacity may be affected also. Available controls include:

a. Elimination control: this involves eliminating unnecessary sources of radiant heat and water
vapour in the workplace (i.e. leaks from steam valves)
b. Altering the work environment
 Modifying the air temperature, relative humidity and air movement using general or
local ventilation, spot coolers, fans, air conditioning.
 Using ventilation
c. Administrative Control
 Encouraging workers to take short breaks
 Decreasing heat exposure duration e.g. rotation of workers
 Screen workers for heat intolerance (e.g. those with heart and blood pressure problems
or previous heat illness)
 Rescheduling hot work to cooler parts of the day and maintenance to cooler seasons.
d. Use of PPE Devices: this includes ultra violet glasses, non – flammable and heat reflective
clothing and equipment, water cooled suits/vests and other equipment and protective gloves
and footwear.

4.1.2 Airborne contaminants

Significant concentrations of airborne contaminants may be encountered in installation, operation and


maintenance of any typical industrial standby generator. Dust from wood, and silica constitutes serious
occupational hazards.

a. Use of PPE Device: such as eye and face protectors and respirators with organic filter for organic
vapors
4.1.3. Dangerous items
These are materials that have ability to cause or accelerate (i) fire (ii) acute toxic effects and (iii)
corrosion of skin and other materials. Control measures involve elimination, isolation, classification and
the use of PPE devices.

4.1.4 Manual Tasks

Manual tasks are part of nearly all work done by workers. They include any activity where workers
grasp, manipulate, carry, and move (lift, lower, push, pull), bold or restrain a load. Available controls are
stated below:

a) Design Control: This involves job design and redesign control. It requires the arrangement, or
alteration of the work process or physical aspects of the workplace such as equipment or worker
stations.
b) Provision of mechanical aids: some devices that may reduce the manual handling are conveyor
systems, cranes, hoists, forklift trucks and roller systems.
c) Administrative Control
 Task – specific training
 Work organization
 Preventative maintenance programs
 Personal protection equipment (PPE)

4.2 Hazardous Substances

Carbon Monoxide Poisoning: Carbon monoxide (CO) is a colorless, odorless toxic gas. Many people have
died from CO poisoning because their generator was not adequately ventilated.

 Never use a generator indoors.


 Never place a generator outdoors near doors, windows, or vents.
 If you or others show symptoms of CO poisoning – dizziness, headaches, nausea, and
tiredness – get to fresh air immediately and seek medical attention.
Health effects of prolong exposure include: headaches, fatigue, asthma, chemical burns, and damage to
lungs, liver and kidneys. Controls are almost as discussed in airborne contaminants and dangerous
items.

4.2.2 Vibration
Exposure to noise is always accompanied by exposure to vibration. Vibration could be (i) whole body
vibration (1 to 80 Hz) or (ii) hand-arm or segmental vibration (8 Hz to 1 kHz). Vibration is common during
when generator engine is running. Health effects include blood pressure, heart problem disorders, and
joint and spine damage.

4.2.3 Electrical Hazards


All power voltage supplies should be turned off at the source while installing or servicing the generator.
All electrical connections, such as wires, cables and terminals must be properly insulated and covered,
and should not be touched with bare hands or while in contact with water, this is essential to prevent
the occurrence of an electric shock. The frame of the generator and any external conducting parts
should have proper grounding/earthling wiring. This should never be disconnected. 4. Wiring, cable and
cord sets must be of the recommended capacity.

4.2.4 Fire and Explosion Hazards


Smoking in the vicinity of the equipment can be fatal. Fuel or oil spills around the generator, leakages
from the unit’s fuel system and fuel supply lines, and presence of combustible materials around the
generator will pose a risk of an explosion. A fire extinguisher should be readily available. Use of
extinguisher that operate on carbon tetra-chloride is strictly prohibited since the fumes are toxic and
can deteriorate the insulation on the wiring of generators.

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