health and safety risk assessment in palm oil industry
TRANSCRIPT
HEALTH AND SAFETY RISK ASSESSMENT IN PALM OIL INDUSTRY
AZUAN ABU TALIB
UNIVERSITI MALAYSIA SARAWAK
2001/2002r
TD 1052 A997 2002
Universiti Malaysia Sarawak
Kola Samarahan
RJ3a
BORANG PENYERAHAN' TESIS
ludul: HEALTH AND SAFETY RISK ASSESSMENT IN PALM OIL INDUSTRY
SESI PENGA.JIAN: _.,--_ _ 1999-2002. ___
Saya AZUAN ABU TALIB (HURUF BESAR)
mengaku membenarkan tcsis ini disimpan di Pusat Khidmat Maklumat Akademik, Universiti Malaysia Sarawak dengan syarat-syarat kegunaan seperti berikut:
L Hakmilik kertas projek adalah milik penulis dan UNIMAS. 2. Naskhah salinan di dalam bentuk kertas atau mikro hanya boleh dibuat dengan kebenaran bertulis
daripada UNIMAS atau penulis. 3. Pusat Khidmat Maklumat Akademik, UNIMAS dibenarkan membuat salinan untuk pengajian mereka. 4. Kertas projek hanya boleh diterbitkan dengan kcbenaran penulis atau UNIMAS. Bayaran royalti adalah
mengikut kadar yang dipersetujui kelak. 5 . * Say a membenarkan/tidak membenarkan Perpustakaan membuat salinan kertas projek ini sebagai bahan
pertukaran di antara institusi pengajian tinggi. 6. ., * Sila landakan ( .; ) di mana kotak yang berkenaan
c=J SULIT (Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysia seperti yang termaktub di dalam AKTA RAHSIA RASMI 1972). I
L=:J TERHAD (Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi/ badan di mana penyelidikan dijalankan).
L=:J TIDAK TERHAD
Disahkan oleh
(TANDATANGAN PENULlS) (TANDATANGAN PENYELlA)
Alamat tetap: Lot 669, Kpg Segedup, Jalan
Balu Kawa, 93250 Kuching, Sarawak. ~41~ \ Yt'H Q.l · rts, Nama Penyelia
~lVt--U
Tarikh: Tarikh: .23,1OYXro i ,
CATATAN * Polong yang tidak berkcnaan. ** Jika Kertas Projek ini SULIT alau TERHAD, sila lampirkan surat daripada pihak berkllHsa!
organisasi berkcnaan dengan menyertakan sekali tempoh kerlas projck. Ini perlll dikelaskan sebagai SULIT atall TERHAD.
HEALTH AND SAFETY RISK ASSESSMENT IN PALM OIL INDUSTRY
P.KHIDMAT MAKLUMAT AKADEMIK
11111111111 riimi 11111111111 0000118361
BY
AZUAN ABU TALIB
MATRIC NO. 4078
A project paper presented to the
Faculty of Engineering
In partial fulfillment of the requirements for the Degree in Bachelor of Engineering
with Honours (Mechanical Engineering and Manufacturing System)
UNIVERSITI MALAYSIA SARA WAK
2001/2002
APPROVAL SHEET
This project report entitled "HEALTH AND SAFETY RISK ASSESSMENT IN
PALM OIL INDUSTRY" was prepared by Azuan Abu Talib as a partial fulfillment of
the requirement for the degree of Bachelor of Engineering with Honours (Mechanical and
Manufacturing System) is hereby read and approved by:
23rdCik Rubiyah Haji Baini April, 2003
Faculty of Engineering
Universiti Malaysia Sarawak
ABSTRACT
HEALTH AND SAFETY RISK ASSESSMENT IN PALM OIL INDUSTRY
By
Azuan Abu Talib (4078)
The objective of this report is to carry out health and safety risk assessment on the palm
oil processing plant to identify risk level at each part in a typical palm oil mill that has
been divided to nine (9) main stations. Adoption method for the research was visiting
the selected palm oil mill (Serian Palm Oil Mill) itself and two organizations that are
involved in this industry such as Sarawak Land Development Berhad (SLDB) and
Sarawak Land Consolidation and Rehabilitation Authority (SALCRA). This is
important to get a clear view of what happen in this industry especially in the health
and safety aspect. Other tasks carried out are the study on the process of palm oil mill,
inspection on the operation and observing working culture. Then the risk assessment
conducted at the Serian Palm Oil Mill according to the method that had been chosen.
This report managed to give an overview of what can happen in daily work process and
reduction or prevention measure that can be taken to lowering the risk. Finally, risk
levels at each nine (9) stations are plot in a graph to represent the overall result of
study.
ABSTRAK
HEALTH AND SAFETY RISK ASSESSMENT IN PALM OIL INDUSTRY
Oleh
Azuan Abu Talib (4078)
Kertas kerja ini bertujuan untuk melakukan kajian risiko kesihatan dan keselamatan ke
atas kilang pemprosesan minyak kelapa sawit. Kilang yang telah dipilih dibahagikan
kepada sembilan (9) bahagian utama untuk dilakukan kajian risiko. Kaedah yang
digunakan untuk menjayakan kajian ini ialah dengan melawat kilang (Serian Palm Oil
Mill) yang telah dipilih di samping mendapatkan maklumat tambahan dari dua organisasi
yang terlibat dalam industri ini iaitu Sarawak Land Development Berhad (SLDB) dan
Sarawak Land Consolidation and Rehabilation Authority (SALCRA). Ini adalah penting
untuk mendapatkan pandangan yang lebih jelas mengenai industri kelapa sawit
terutamanya dalam aspek kesihatan dan keselamatan. Antara program kerja lain ialah
memahami proses-proses di kilang kelapa sawit, menganalisa operasi seharian dan
memerhati budaya kerja di kilang tersebut. Selepas itu, barulah kajian risiko dijalankan
ke atas Serian Palm Oil Mill. Kertas kerja ini juga dapat memberi gambaran mengenai.. apa yang mungkin berlaku dalam proses kerja seharian serta langkah-Iangkah untuk
mengurangkan atau mengelakkan kejadian tersebut daripada berlaku seterusnya
menurunkan tahap risiko. Akhir sekali, risiko di setiap sembilan (9) bahagian utama
kilang diplotkan dalam sebuah graf untuk memberi gambaran keseluruhan kajian.
l
I
ACKNOWLEDGEMENT
Fir t of all, I would like to record my greatest gratitude to my supervisor, Cik Rubiyah
Hj . Baini who has been giving priceless supervision and advice in leading all the way
through to complete this project paper. Without her ever-present patience and
understanding, this project would not have taken off successfully.
Special thanks also to the Management of Serian Palm Oil Mill Sdn Bhd for the
opportunity given to carry out the research and their staff for the assistance rendered.
Besides, I would like to express my heartiest thanks to all my friend especially Siti
Zaharah for their assistance and guidance towards the completion of this project paper
with success.
Last but not least, my beloved father, mother, brothers and sisters for their loving support
throughout the years.
I
I:
TABLE OF CONTENT
LIST OF TABLES
LIST OF FIGURES
CHAPTER 1: INTRODUCTION
1.1 Overview of Palm Oil Industry
1.2 Palm Oil Processing
1.3 Risk Assessment - An Overview
1.4 Objective of this Report
1.5 Rational/Justification of this Report
1.6 Definition of Term Used in this Report
CHAPTER 2: LITERATURE REVIEW
2.1 Occupational Safety Hea1th in Malaysia
2.2 Palm Oil Milling Industry Acts
CHAPTER 3: METHODOLOGY
3.1 Introduction to the Approach
3.2 Data Collection
3.3 Data Analysis
CHAPTER 4: RESULT OF ASSESSMENT
4.1 Risk Assessment Result From ~"-stations
CHAPTER 5: DISCUSSION & CONCLUSION
5.1 Analysis of the Result
5.2 Conclusion
CHAPTER 6: RECOMMENDATION
BI LIOGRAPHY
IX
X
1-13
1-4
5-7
8-10
11
11-12
12-13
14-26
14-15
16-26
27-31
27
28
29-31
32-38
32-38
39-45
39-41
42-45
46
LIST OF TABLES
Tabl 1.1 Performance of The Malaysian Palm Oil Industry-2DD1 4
Table 3.1 Complete risk analysis table 28
Table 4.1.1 Fresh fruit bunches reception 32
Table 4.1.2 Steriliser station 33
Table 4.1.3 Threshing station 34
Table 4.1.4 Press station 35
Table 4.1.5 Depericarper station 35
Table 4.1.6 Kernel recovery plant 35
Table 4.1.7 Clarification station 36
Table 4.1.8 Boiler Station 37
Table 4.1.9 Power House 38
IX
LIST OF FIGURES
Figure 1.1 Export of Palm Oil to Major Destination 1
Figure 1.2 Schematic Flow Diagram of Palm Oil Mill Process 7
Figure 2.1 Malaysia: Number of Industrial and Fatal Accident, 15
1994-1998
Figure 3.1 Exposure Rating 29
Figure 3.2 Hazard Rating 30
Figure 3.3 The Risk Matrix 31
Figure 5.1 Graph of risk matrix at 9 stations 39
x
CHAPTER ONE: INTRODUCTION
Chapter 1 Introduction
1.1 Overview of Palm Oil Industry
Malaysia is the world's largest producer and exporter of palm oil, accounting for
49.7% of world palm oil output and 66.7% of world exports of palm oil l. Malaysian
palm oil is exported to more than 80 countries worldwide. The major markets are
India, European Union countries, Pakistan, People's Republic of China, Japan and
Egypt. (See Figure 1.1)
Figure 1.1: Export of Palm Oil To Major Destination
Japan
Egypt
'. Pakistan
India
o 500 1000 t500
'000 Tonnes
2000 2500
1999 .2000
Source: Review Of The Malaysian Oil Palm Industry 2000
ru reported by MPOB (Berita Sawil, 1 Seplember 2001)
1
I
CHAPTER ONE: INTRODUCTION
From its pioneering efforts in the early part of this century, the oil palm industry
in Malaysia has grown to become a dominant and dynamic industry in the country.
Contribu ting not only to growth but also to the attainment of socio-economic objectives
of the rural population. Going by the available plans set out for it, Malaysia oil palm
industry will continue to be a vibrant industry and contribute to national growth and
development.
The Malaysian palm oil industry can be categorized into the following main
activities:
• Milling of fresh fruit bunches
• Crushing of palm kernel
• Refining of palm and palm kernel oil
• Manufacturing of specialty fat products
• Manufacturing of oleochemicals
Advances in processing technology have widened the potential usage of palm
oil. The ability to separate palm and palm kernel oil into distinct fractions has made it
possible to expand the range of pro~ts available to the consumers and to meet the
customers tailor-made requirements.
Malaysia will continue to be a main actor in world palm oil production in the
next century. This is because Malaysia has highly efficient managerial skills, large
amounts of accumulated capital and advanced technologies to refine crude palm oil,
ne of which is available in other major palm oi] producing countries. However, there
is a ed for Malaysia to further increase its productivity and managerial efficiency
2
CHAPTER ONE: INTRODUCTION
through continuous research and development in order to compete with other
producers. Although the efficiency in those countries does not match Malaysia's for the
time being, each country has its own advantages, for instance, cheap labor and vast
land. Efficiency can be upgraded over time. Therefore, it is estimated that in the next
couple of years; the Malaysian palm oil industry will face tremendous competition from
other producers, especially from neighboring countries.
In addition, the position of palm oil in the world's oils and fats market is still
volatile since it is easily threatened not only by supply-demand changes but also
international affairs. For the purpose of developing the palm oil industry in Malaysia,
therefore, further research and development efforts in downstream ventures should be
encouraged to develop more value-added end products, especially non-food application
of the oil, thereby increasing the utilization of palm oil.
3
CHA.PTER ONE: INTRODUCTION
Table 1.1: Perfonnance ofThe Malaysian Palm Oil Industry - 2000
Crude Palm Oil 10,553,918 10,842,095 2.73
Palm Kernel 3,025,690 3,162,760 4.53
Palm Kernel Oil 1,338,905 1,384,685 3.42
Palm Kernel Cake 1,624,134 1,639,227 0.93
Palm Oil
Palm Kernel Oil
Palm Kernel Cake
Oleochemical Products
Finished Products
Others
Peninsula
14,418.1
1,494.1
230.7
2,833.0
226.5
8.5
18.12
10,217.1
1,066.1
196.4
3,032.3
401.5
15.2
18.31
(29.1)
(28.6)
(14.9)
7.1
77.3
78.4
1.05
Sabah 19.76 20.10 1.72
Sarawak 20.83 20.52 (1.49)
FFB Yield (Tonnes IHectare) 19.26 18.33 (4:83)
Oil Yield ctare) 3.58 3.46 (3.35)
Source: Review OfThe Malaysian Oil Palm Industry 2000 .
4
CHAPTF.R ONE: INTRODUCTION
1.2 Palm Oil Processing
The main stages of processing Fresh Fruit Bunches ( FFBs) are:
(i) Sterilization
Fruit bunches are sterilized by steam at about 140°C for a period of 75
90 minutes. The main objectives are to deactivate hydrolytic enzymes
responsible for the breakdown of oil to free fatty acids; to loosen the
fruits from bunches; to coagulate mucilage to facilitate breaking of oil
cells and aid recovery of oil; and precondition nuts to minimize kernel
breakage.
(ii) Bunch Stripping
The fruits are stripped and separated from the bunch in a rotary drum
stripper. Fruits are knocked out of the bunch by the lifting and dropping
of bunches as they pass through the stripper. The detached fruits fall
through the spaces between the bars on the stripper and are collected in a .'conveyor, which then feeds them into the digester.
(iii) Digestion
Digestion involves the mashing up of the fruits under steam heated
conditions. The digester is a vertical cylindrical vessel fitted with a
rotating shaft carrying a number of stirring arms. The action of the
5
CHAPTER ONE: INTRODUC71ON
stirring arms breaks up the oil-bearing cells of the mesocarp to form a
digested mash.
(iv) Oil Extraction
Twin-screw presses are generally used to press out the oil from the
digested mash. Hot water may be added to enhance the oil flow and the
crude oil slurry is collected in the crude oil tank for purification. The
fibre and nut (press cake) are conveyed to depericarper for separation.
(v) Clarification and Purification
The crude palm oil (CPO) mixture from the screw press consists of a
mixture of crude oil (35-45%), water (45-55%) and fibrous materials
and other solids in varying proportions. The mixture is pumped into a
continuous clarification tank. The oil is maintained at about 90°C to
enhance oil separation. The oil is continuously skimmed off the top of
the tank while the denser impurities settle at the tank bottom. The oil is
..... passed through a high-speed centrifuge and a vacuum dryer to moisture
content of below 0.1 % before being sent to the storage tank.
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TER ONE: INTRODUCTION
Risk Assessment - An Overview
1.3.1 What is Risk Assessment?
Ri k assessment is the process of identifying hazards or examining what
in a particular situation could cause harm or damage and then assessing the
likelihood that specified populations would actually experience that harm and
what con equences would be. The main objective is to obtain a view on how to
manage the risk or to compare the risk with other risks.
At a conceptual level it is useful to make a distinction between an
asses ment of the risks (the evaluation of the likelihood of harm and its
consequences for populations or individuals) and risk control (the prioritization
of ri ks and the introduction of measures that might be put in place to reduce, if
not prevented, the harm from occurring). Risk assessments by and large are
scientific and objective, but risk control is less so because it integrates the
results of an assessment of risks with other critical inputs such as economic
analysis, perception of risks, need for and availability of alternative
technologies, concerns about equity, consistency across a range of risks and .....<
other matters which involve subjective elements. [University of Sheffield, 1999]
It also a tool to assist with making decisions on the safety of process
plant. Risk assessment when used to assess or analyze the hazards in process
plant and storage (palm oil mill which is the area of study) is sets out to answer
three questions:
o What can go wrong? (Hazard identification)
8
CHAPTER ONE: INTRODUCTION
o What are the consequences and effects and are these acceptable?
o Are the safeguards and controls adequate to render the risk
acceptable?
Actually risk assessment, has three major components:
1. hazard identification
2. risk analysis
3. risk evaluation
Hazard identification consists of a qualitative revIew of possible accidents,
which may occur, based on previous accident experience or judgment where
necessary [University of Sheffield, 1999]. While risk analysis will give the
rating for the possible accidents using risk matrix. Risk evaluation is a stage
where we introduce criteria, which are yardsticks to indicate whether the risks
are "intolerable" or "negligible" or to make some other value judgment about
their significant. But the author only performs the first two components due to
time constraint and the complexity of the task if that entire component is .~
conduct.
1.3.2 Purpose of Risk Assessment
The main purpose of risk assessment is to develop a comprehensive
qualitative assessment of the workplace, the processes, materials used and the
employee's exposure, and the risk presented by these to the employees.
9
CHAPTER 0 E: INTRODUCTION
It also enable the risk to be determined and for appropriate measures to
be implemented to quantify the risk (via monitoring) and to reduce or control
the risk.
Therefore it enables management or an organization to comply with the
existing legislation and implement successful environmental, health and safety
programs.
1.3.3 Benefits of Assessing Risks
The primary benefit of conducting a risk assessment is to evaluate the
hazards of a situation prior to the occurrence of an incident or accident. Having
this knowledge, the organization or the affected person can then make an
infonned decision on whether or not to accept that risk. A risk assessment
program is one of many necessary elements for a successful risk management
program if it looks in a broader aspect.
Once identified and evaluated, the risks can then be prioritized in an
'k' informed way. Recognizing that risks can never be zero, the assessment process
provides organizations with the information so that resources can be applied
most productively so as to provide the most added values . Virtually every
organization that has excellent safety and health performance also conducts risk
assessments. These organizations see reduced injury rates, improved operating
profits, lowered property loss insurance rates, and greater productivity
improvements.
10
CHAPTER ONE: INTRODUCTION
1.4 Objective of this Report
The objective of this study is to carry out risk assessment on the palm oil
processing plant. This will involves some tasks such as :
I. Collecting information from palm oil processing plants.
II. Analyze the working environment and safety culture In the palm oil
processing plants.
m. Finally to prioritize the level of risk.
1.5 Rational/Justification of this Report
Palm oil industry has become an important activity that contributes to the
economic growth of Malaysia. The technology involved in the processing plant may
introduce hazards, which could not be significant to the plant workers. The operation
may handle toxic or flammable materials and heavy machineries, which require strict
handling procedures.
Accidents in the process industry may delay operation, effect production, cause
considerable loss of business, damage the industrial plants and the environment, and in
the worst cases it involves human fatalities . Inadequate awareness about the hazards in
workplace can be one of the factors that lead to a series of accidents or disaster.
These accidents must be prevented in order to protect the workers as well as the
business. Therefore, to prevent accidents is to understand the nature of the hazards and
e appropriate actions.
11
CHAPTIm ONE: INTRODUCTION
Risk Assessment is a tool to translate the hidden potential accidents into
foresight to the workers, showing ways and means for better planning, procedures and
supervision to prevent accidents from happening. This will definitely increase the level
of safety in the organization.
1.6 Definition of Term Used in this Report
An understanding of basic terms related to risk assessment is necessary in order
to apply these techniques and, more importantly, to determine where such techniques
are worth of application on a particular organization. Below are several terms used in
risk analysis (University of Sheffield, 1999):
1.6.1 Definition by University of Sheffield.
Consequences: A measure of the expected effects of an incident outcome case.
Frequency: Number of occurrences of an event per unit of time.
Hazard: A chemical or physical condition that has the potential for causing.... damage to people, property, or the environment or some combination of these.
Risk: The likelihood of a specified undesired event occurring within a specified
period or in specified circumstances. It may be either a frequency (the number
of specified events occurring in unit time) or a probability (the probability of a
specified event following a prior event), depending on the circumstances.
12
CHAPTER ONE: INTRODUCTION
Risk analysis: The development of a quantitative estimate of risk based on
engineering evaluation and mathematical techniques for combining estimates of
incident consequences and frequencies.
Risk assessment: The process by which the results of a risk analysis (i.e., risk
estimates) are used to make decisions, either through relative ranking of risk
reduction strategies or through comparison with risk target.
Risk management: The systematic application of management policies,
pr cedures, and practices to the tasks of analyzing, assessing, and controlling
ri k in order to protect employees, the general public, and the environment as
well as company assets while avoiding business interruptions.
13
CHAPTER TWO: UTERATlIRE REVIEW
Chapter 2 Literature Review
2.1 Occupational Safety Health in Malaysia
Occupational Safety Health (OSH) in Malaysia has come to the stage where
more and more employers and employees understand their roles and responsibilities in
order to ensure hazards at the work places are identified, assessed and controlled. These
responsibilities, if correctly discharged, will definitely contribute to the prevention of
untoward incidents causing injury, illness, death and property damage at the workplace.
If all these destructive incidents can be kept at bay, employees will be more focused at
work and will find greater commitment to work and produce goods or services
efficiently and productively. More recently, protection of the safety and health of
workers has been restated as an essential element in the achievement of decent working
conditions for all, more so in the current context of globalization of the world's
economies. OSH is therefore at the heart of not only the requirements to achieve decent ....., work, but it is also a major and positive factor in favor of economic growth and
productivi ty.
In Malaysia, laws and regulations related to OSH are quite extensive. Strategic
enforcement of the laws and regulations by the regulator and willingness to attain
higher OSH standards by the employer and the employee will give tremendous
ovement in OSH performance throughout the country. The Government is always
••Dring the OSH performances of undertakings and will formulate workable plans
14