APPENDIX 4

UNIT GC3 – THE HEALTH AND Candidate report template

SAFETY PRACTICAL APPLICATION

Student number 00398965

Location Beni Suef Power Plant 4800 mw Date of review 28 /08 /2017

Structure report under the following headings:

Introduction including overview of area inspected and activities taking place

The project is a power plant construction site in Beni Suef which happens to be the biggest power plants ever being
constructed worldwide in one go. Its capacity is 4800MW. It comprises of 8 gas turbines, 4 steam turbines, 4 wet
cooling towers and water treatment plants (Balance of Plants-BoPs). The site is spread in an area of 10000 square
meters with a permanent source of water from the river Nile. The average manpower as of now is 5800. The Civil
construction part is almost complete. Mechanical, Electrical & Commissioning activities are going on in full swing.
Work at height is one of the most important concerns in this site. There have been few incidents in the past related to
this particular hazard. Few other issues which can be observed here are confined space non-compliances, sub-
standard electrical panels in some places, hot work non-compliances, unsafe lifting practices, etc. In addition to this
handling of hazardous substances, poor material management, improper usage & maintenance of personal protective
equipment’s can also be seen in few work locations.

There are also few good practices in this site such as traffic management at site, pedestrian walkways, access systems,
welfare facilities, communication system followed during high risk activities, etc.

Despites of so many EHS issues, the best part which can be very clearly observed here is the close coordination
between the construction and EHS team to minimize the risk of every activity to the lowest possible level.

Executive Summary

The company management is highly committed towards the wellbeing of all employees, visitors,
Contractors and all people working for the project. They take care of everyone who has any issues from any hazards
arising out of the daily operations. This responsibility is clearly dedicated to competent personnel. Risk
assessment of all the activities done and is reviewed periodically. Resources have been allocated for mitigation of
significant hazards through effective control measures. PPE programs is in place and requirements are
communicated to workforce through trainings, posters and signs. Overall compliance with health
and safety management system is observed satisfactory.
There are some potential hazards and conditions are evaluated at this facility completion of the
following items will help lower both the frequency and severity of losses in terms of personnel
injury, illness, asset damage and business reputation.
Main findings of the inspection
As a company EL SEWEDY / PSP is performing well despite the decline in the construction business in Egypt over the
last few years. But from last year or so they have acquired much larger and considerably more complex projects. The
business appears to be struggling to keep up with this level of expansion. As a result of this it would appear that the
management of health and safety have been compromised which is quite clear from my inspection which shows that
a number of issues and concerns are visible in the management system itself. The main areas of concern are:
1- Management of Work at Height
There are numerous issues surrounding the carrying out of work at height and these need to be addressed. It is not
enough to simply rely on the local subcontractor management to ensure that work at height is being carried out
safely. An electrician tied off his harness to an inappropriate anchorage point (Cable Tray 15 m height) might fall from
height as the anchorage point is not that strong enough to take the load of the electrician if at all he falls. Fall from
height of approximately 15 meters may cause multiple fractures of upper and/or lower Limb or even fatality. Non-
complying with safe working at height procedure will be considered as breaching of legislation of ILOC155
Occupational Health and safety convention 1981 and Work at height regulation-2005(WAHR). Failure to comply is also
breach of ‘The Work at Height Regulations Egyptian labour law 12/2003 book5’.

Recommendations:

Provision of working at height (external) training to all the workers involved in working at height activity within 1
month. It would cost 4000 LE

2- Electrical Issue:
It has been observed that in many places there is no GFCI (Ground Fault Circuit Interrupter) provided in the
electrical panels. Because of the unavailability of GFCI’s could cause electrical shock, burns and even death.
There might be some secondary effects like fall from height due to throw off which could cause serious injury
like bone fractures and head injury. Non usage of GFCI breaches the ILO legislation of C155 Occupational Health
and safety convention 1981 and Electricity at work regulations Egyptian labour law 12/2003 book5’ .

Recommendations:

Buying 50 GFCI & Isolation transformer for confined space activity would cost 10000 LE which can prevent
electrocution, burns, even death .Secondary hazards such as fall from height of victim due to throw off because
of electrocution or serious personal injury can also be prevented.

3- Excavation Cave- In/Trenching:

Workers were observed working in excavations 2 m deep with incomplete hard Barrication. Cracks developed on the
east side of the excavation wall could cause fall of people and fall of vehicles into the trench. Collapse of the
excavation, injury to personnel due to cave-in, damage to vehicles is also possible. Not taking necessary safety
measures during excavation is breach of ILO legislation of Convention C167-Safety and Health in construction
convention, 1988(No.167 Excavation Regulations Egyptian labour law 12/2003 book5’ .

Recommendations:
Competent person to design the type of excavation (shore/bench/slope) & Effective which would prevent workers
and vehicles from falling into excavation and cave-in. Its approximate cost would be around 10000 LE.
 4- Hot Work and Fire Hazard:
Welding activity was being carried out at height and there was not enough spark/splatter containment. Falling of
these sparks or splatters on to the ground on some combustible or flammable materials could cause fire and thereby
property damage. Losses due to fire may vary from of Material damage/ People Injures (Burns& Suffocation) which
breaches the international legislation of Convention C167-Safety and Health in construction convention, 1988(No.167)

Recommendations:
Deploy fire watcher for each hot work activity, use of sufficient number of fire blankets and external firefighting
training can exceedingly minimize the risk of fire during hot work.

5- Hazard Substances & CGC (Compressed Gas Cylinders)

It has also been observed that handling, storing and transporting of hazardous substances is not done as per the
safety requirement. A small mistake can cause a major incident if hazardous substances are not taken care of properly.
Serious injuries to personnel, environmental hazards are the major issues in any hazardous substances incidents.

Similarly, compressed gas cylinders also aren’t taken care with utmost safety. CGC’s can cause severe mishaps
anytime if not handled properly. It may cause major fires, personnel injury, etc.

Recommendations:

Strictly follow MSDS (material safety data sheet) for every hazardous substance. It depicts complete transportation,
handling and storage procedure. It also provides the first aid measures to be taken in case of any emergency.MSDS
and handling instructions to briefed to the workers before using it.

Conclusions

As deliberated earlier, EL SEWEDY / PSP are clearly having a successful business but management of health and safety
appears to have weakened. The company’s awareness and understanding of their duties and responsibilities, though
laudable, needs to be translated into action. However, the effort required to rectify matters is minimal when
compared to the costs of potential fines, compensation, lost time and productivity, and the adverse profile-raising
that would come as a result of serious accidents and incidents. The recommendations set out below a proactive
supervisory approach will address the issues in the report and set a benchmark for future performance and
continuous improvement, hopefully creating a more positive atmosphere and culture on the site. Although there are
costs attached to the recommendations they are relativity small when one looks at the unlimited fines against the
company or significant imprisonment awarded to senior managers and directors in court cases involving negligence
and poor practice.

Recommendations – include as a table in the following format:

Recommendation Likely resource implications Priority Target date

Buying 50 GFCI for
Approximate cost 10000 LE High 2 weeks
electrical panels
10 Isolation transformer
for confined space
Approximate cost 10000 LE High 2 Weeks
activity

shoring system Approximate cost 50000 LE High 2 weeks

Competent designer Approximate cost 80000 LE Medium 1 Month

working at height
external training to 100 %
Approximate cost 4000 LE Medium 1 month
of the workers carry out
working at height activity