Chapter IX

Safety Management

An integral part in plant designs is safety considerations to protect both workers and plant

equipment. In improving plant safety, engineering safety management are employed that aimed

to get rid of hazards or to reduce their likelihood, to contain the risk of hazards and to have

contingency measure that could reduce harm if there is an accident. Identification of possible

hazards to reduce risks and eliminate unsafe working conditions that can improve safety is a

continuous process that should be done on the onset of the design, throughout the life of the plant

and eve until it will be decommissioned. The Occupational Safety and Health (OSH) Standards

are provided under the Labour Code of the Philippines to protect workers from work hazards and

other unsafe working conditions.

9.1 Workplace Classification

The OSH Standards Rule 1013 provides criteria for workplaces that are considered to be

hazardous. Some of these classified hazardous workplaces are when the nature of the work

exposes the worker to dangerous elements, contaminants and biologic agents. However, none of

the hazardous conditions mentioned in the standards are present in the plant processes. In case of

the Organosolv Pretreatment section and liquefaction section, the operator is exposed to some

toxic substances since those processes are carried out in batch reaction. With all these

considered, the plant is classified to have hazardous workplaces.

9.2 Training of Personnel in Occupational Safety and Health

Personnel of the plant will undergo the necessary training and attend programs that will

be conducted by the Bureau of Working Conditions as mandated by OSH Standard Rule 1030. A

specified number of supervisors or technical personnel that have undergone the conducted

training and attended the programs of the Bureau will be appointed as safety officer. As indicated

in OSH Standards Rule 1033.a, the plant classified as hazardous workplace and employs more

than 50 workers will have one full-time safety officer.

9.3 Health and Safety Committee

A Health and Safety Committee shall be organized in every place of employment as

mandated by OSH Standards Rule 1041. The type and composition of the Health and Safety

Committee for the plant was determined by the number of workers it employed. Employing more

than 100, the plant falls under Type D and shall have a Health and Safety Committee composed

of:

Chairman: Manager

Members: One foreman

Three workers (must be union members, if organized)

The nurse/first-aider

Secretary: The part-time safety man

9.4 Premises of Establishments

Adequate fire, emergency or danger sign and safety instructions of standard colors and

sizes are installed in the plant premises which are visible at all times. Sufficient comfort rooms,

lavatories and locker rooms are also provided for the workers. The buildings within the plant

premises are constructed structurally to be safe and sound with roofing and foundations that has

sufficient strength to withstand loads they are designed for.

The space requirements for workrooms that are stated in OSH Standard Rule 1062 are

followed. The workroom heights are observed to be not smaller than 2.7 meters and the

maximum worker density not to exceed 11.5m3/person. Enough spaces are also observed

between the equipment and machinery as to allow normal operations and to provide passageway

for maintenance and repair personnel.

9.5 Occupational Health and Environmental Control

It is necessary to maintain and control the working environment in comfortable and

healthy conditions for the purpose of promoting and maintaining the health of the workers. The

indoor and other workplaces environment conditions which include temperature, humidity,

pressure, illumination, ventilation and concentration of noise is measured periodically and will

be made available for the enforcing authority.

9.6 Personal Protective Equipment and Devices

The necessary personal protective equipment (PPE) for the eyes, face, hands and feet,

protective shields and barriers are furnished to the workers. PPEs are necessary to protect the

workers from different industrial hazards that might be present in the plant.
9.6.1 Eye and Face Protection

The grinding and packaging operators who are exposed to dusts and possible impacts

from flying objects are provided with goggles and dust masks. The pretreatment and liquefaction

reactors and dryer who might be exposed to intense concentrations of heat are provided with heat

resistant face masks. Also, a full face shield and safety goggles are provided for workers

assigned to sulfuric acid storage tanks. Other workers who are not directly exposed to any eye

and face hazards are provided with safety spectacles and face mask.

9.6.2 Respiratory Protection

The plant does not utilize and produce any harmful dusts, fogs, fumes, mists, gases,

smokes, sprays or vapors so issuance of respirators to workers are not necessary. However, the

face masks issued under the face protection are already sufficient to prevent inhalation of any

possible dust generated during the processes.

9.6.3 Head Protection

Protecting workers from potential head injuries which can impair or can be fatal is a key

element of any safety program. Top prevent head injuries, all workers are provided with Class A

hard hats that provide impact and penetration resistance along with limited voltage protection

(upp to 2,200 V). Fitting caps made up materials not easily combusted and have sufficient

durability to withstand regular laundering, disinfection and cleaning can be issued to employees

with long hair upon request.

9.6.4 Hand and Arm Protection

The selection of type of gloves issued should depend on the hazards to which the wearer

may be exposed to and the ease and free movement of the fingers. Leather or aluminized gloves

which offer good protection against heat are issued for the dryer, pretreatment, and liquefaction

operators. Mittens and sleeves made up of heat resisting materials are also provided for them.

Coated fabric gloves that are general-purpose hand protection offering slip-resistant qualities are

provided to the rest of the workers.

9.6.5 Foot and Leg Protection

Safety shoes are provided as standard safety footwear issue for all the workers. These

shoes have impact-resistant toes, heat-resistant soles, acid-resistant soles and metal insoles that

protect against punctures. Heat resistant leggings are also provided to workers exposed to high

temperatures to protect their lower legs and feet from heat hazards.

9.7 Hazardous Materials

The plant will be producing polyurethane sandwich panels by utilizing rice straw as the

primary raw material. There are several chemicals used throughout the entire production process

that can be classified as hazardous or corrosive. The control of processes is mandated under OSH

Standards Rule 1093.02. Hazardous processes shall be carried in a separate rooms or building

with a minimum number of workers equipped with suitable protective equipment and trained

thoroughly in safety practices for daily operations and for emergencies. Harmful dusts, fumes,

gases or vapors shall be removed at or near their point or origin by means of fume chambers or

suction hoods properly connected to efficient exhaust system.

 Proper labelling and markings, safety data sheets and safe storage and handling will be

used and provided to materials. Moreover, major hazard facilities are defined as locations where

large quantities of hazardous materials are stored, handled or processed.

9.8 Materials Handling and Storage

The following general provisions are observed as stated in OSH Standards Rule 1150 for

the materials handling and storage:

9.8.1 Use of Mechanical Equipment

Where mechanical handling equipment is used, sufficient safe clearance shall be

allowed for aisles, at loading docks, through doorways and wherever turns or passage

must be made. Aisles and passageways shall be kept clear and in good repair, with no

obstruction across or in aisles that could create a hazard. Permanent aisles and

passageways shall be appropriately marked.

9.8.2 Secure Storage

Storage of material shall not create a hazard. Bag containers, bundle, etc., stored

in tiers shall be stacked, blocked, interlocked and limited in height so that they are stable

and secure against sliding or collapse.

9.8.3 Housekeeping

Storage areas shall be kept free from accumulations of materials that constitute

hazards from tripping, fire, explosion, or pest harborage. Vegetation control shall be

exercised when necessary.

9.8.4 Clearance Limits

 Clearance signs to warn of clearance limits shall be provided.

9.8.5 Guarding

Covers and/or guardrails shall be provided to protect personnel from the hazards

of open pits, tanks, vats, ditches, etc.

9.9 Machine Guarding

The general provision of machine guarding under OSH Standards Rule 1200 requires that

all moving parts of prime movers, transmission equipment and all dangerous parts driven

machinery shall be effective guarded, unless so constructed or located to prevent any person or

object from coming or brought into contact with them. Upon installation, all equipment and

machinery described under this rule are properly guarded in conformity with existing safety

standards.

The machine guards are installed in a way that will not interfere unnecessarily to the

operation or production and are securely fastened and kept in place whenever the machine is in

operation.

The following are machine guards installed in the plant with the minimum standards and

materials for construction as specified in OSH Standards Rule 1203.02:

9.9.1 Small Guards

Minimum dimensions of materials of the framework of metal guards 75 cm (30

in.) or less in height and width, a surface area not exceeding 1 sq. meter (11 sq. ft.) shall
be 1 cm. (3/8 in.) for solid rod, 20 mm x 10 mm x 3 mm (3/4 by 3/8 by 1/ 8) for angle

iron.

9.9.2 Braced Guards

Minimum dimensions of materials of the framework of guards more than 75 cm.

(30 in.) in height and with a surface area exceeding 1 sq. meter (11 sq. ft.) shall be 25

mm. x 25 mm. x 3 mm. (1 x 1 x 1/8) for angle iron or 20 mm. (3/4 in.) diameter for

metal pipe.

9.9.3 Unbraced Guards

When a machinery guard is fastened to the floor or working platform without any

other support or bracing, the framework shall be:

Pipe Railings: The top rail and post shall be 30 mm in diameters and

intermediate rail shall be 25 mm in diameter.

Structural Metal Railings: Top rails and posts of angle iron shall be 38 mm x

38 mm x 5 mm and the intermediate rails of angle iron shall be 32 mm x 32

mm x 3 mm.

All structural metal railings shall be of sound materials free from defects and

all sharp corners shall be rounded and smooth.

9.9.4 Horizontal Overhead Belt Guards

Framework of guards for the horizontal overhead belts, ropes, or chains, more

than 2.6 m. (8 1/2 ft.) above the floor or platform of angle iron, shall be at least:

25 x 25 x 5 mm. (1 by 1 by 3/16 in.) for belts up to 25 cm. (10 in.) in width;

 38 x 38 x 6 mm. (1 1/2 by 1 1/2 by 1/4 in) for belts over 25 up to 35 cm (10 to 14

in.) in width;

50 x 50 x 8 mm. (2 by 2 by 5 /16 in.) for belts over 35 up to 60 cm. (14 to 24 in.)

in width; and

80 x 80 x 10 mm. (3 by 3 by 3/8 in.) for belts over 60 cm. (24 in.) in width;

Horizontal overhead belt more than 2100 mm. above a floor, platform or other

working level shall be guarded for their entire length if located over passageways

of working places.

9.10 Electric Safety

The general provisions of the OSH Standards Rule 1210 or the Electrical Safety states

that all electrical installations must be approved by the Bureau and necessary final inspections

must be conducted necessary for the issuance of safety certificate/permit by the Regional Labor

Office. Furthermore, the safety engineers of the Regional Labor Office or other authorized

representative shall conduct an annual safety inspection on all electrical installations.

Electrical plans are prepared that contains the location plans, electrical layout, and

outdoor and indoor substations. These electrical plans are required for the applications and

approval for the electrical wiring installation.

9.11 Identification of Piping System

The OSH Standard Rule 1230 provides a common code to assist in the proper

identification conveyed in piping systems in industrial plants that are not buried underground.

The identification by color or by colored bands as method of identification of contents of the

piping system is used.

9.12 Fire Protection and Control

The building within the plant premises used specific standards in design and onstruction

for fire protection. Fire protection equipment is installed that follows the provisions of the Fire

Code of the Philippines. Two exits with fire doors that are easily opned from either side are

provided in the factory building that is expected to have the capability of clearing the work area

in five minutes.

Aside from fire protection equipment, firefighting facilities are also installed in the plant.

These facilities include sufficient water supply for the firefighting system, hydrants and hoses

that are the same type and sizes used by the local fire department and portable extinguishers. The

portable extinguishers are distributed in the different key areas in the plant. The class of the

extinguisher is also considered in the selection and distribution. The different classes of

extinguishers that depend on the materials involved in the fire are:

a. Extinguishers for Class A hazards, such as wood, cloth, paper, rubber, and other

similar ordinary materials, shall be selected from foam, loaded stream, multipurpose dry

chemical and water types.

b. Extinguishers for Class B hazards, fire in flammable liquids, gases, and greases, shall

be selected from carbon dioxide, dry chemical, foam, loaded stream and multipurpose dry

chemical.

c. Extinguishers for Class C hazards, fires which involve energized electrical equipment

where the electrical non-conductivity of the extinguishing media is of importance, shall

be selected from carbon dioxide, dry chemical, foam, loaded stream and multipurpose dry

chemical.
 d. Extinguishers for Class D hazards, fire in combustible metals, such as magnesium,

titanium, zirconium, sodium and potassium, shall be of types approved for use on the

specific combustible metal hazard. Only suitable dry powder extinguishers shall be used

for metals.

9.13 Occupational Health Services

The provisions of the OSH Standards Rule 1960 requires the establishment of

occupational health services where the employer, the workers and their representatives shall

cooperate and participate in the implementation of the organizational and other measure relating

to the established services.

The occupational health services without prejudice will have the responsibility to the

safety of the workers and with due regard to the necessity for the workers to participate in

matters of occupational health and safety. The following are the functions of the occupational

health services as enumerated in Rule 1961.03:

Identification and assessment of the risks from health hazards in the workplace;

Surveillance of the factors in the working environment and working practices

which may affect the workers health, including sanitary installations, canteens,

and housing where these facilities are provided by the employer;

Advice on planning and organization of work, including the design of the

workplace, on the choice, maintenance, and condition of machinery and other

equipment, and on substances used in work;

Participation in the development of programs for the improvement of working

practices as well as testing and evaluation of health aspects of new equipment;

 Advice on occupational health, safety and hygiene, and on ergonomics and

individual and collective protective equipment;

Surveillance of workers health in relation to work;

Promoting the adaptation of work to the workers;

Collaboration in providing information, training and education in the fields of

occupational health and hygiene and ergonomics;

Organizing of first-aid and emergency treatment; and

Participation in analysis of occupational accidents and occupational diseases.

Occupational health services organized as a service for a single, hazardous small-scale

establishment employing 51 to 99 workers shall have an occupational health practitioner as one

of its personnel, who shall conduct an inspection of the workplace at least once every month as

provided for under Rule 1961.04.

9.13.1 Medicines and Facilities

As covered by OSH Standards Rule 1963, the workers will be provided in his

workplace at least minimum quantity of medicines, medical supplies and equipment and

medical faculties listed in Table 47 in the Occupational Safety and Health Standard

(1989) of the Department of Labor.

9.13.2 Emergency Medical Services

In small-scale industries where the number of workers is from 51 to 99, the

employer shall provide the services of a part-time occupational health nurse who shall

stay in the premises of the workplace at least four (4) hours a day, six (3) times a week.

Where there are more than one work shift in a day, the nurse shall stay in the workplace
during the shift which has the biggest number of workers. The employer shall also

provide the services of a full time first-aider and shall maintain in his place of

employment an emergency treatment room for his workers.

9.13.3 Emergency Hospital

The plant is a small-scale industry and as permitted in OSH Standards Rule

1963.03, an emergency hospital and dental clinic in the workplace is established for this

plant size. Establishing the emergency hospital and dental clinic is a must since hospitals

and dental clinics in Gimba, Nueva Ecija is more than 5 kilometres away from the plant.