health and safety risk assessment in palm oil industry

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.


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


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


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


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


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


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


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


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

health and safety risk assessment in palm oil industry

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