OSHMP25

Occupational Safety and Health Master Plan 2025 (Malaysia)

    The embarking of Occupational Safety and Health Master Plan 2021 – 2025 (OSHMP25) is a nation’s paradigm to enhance the excellence of OSH performance with the objective to protect human resources. Furthermore, this master plan is in line with the nation’s development programme which is the Shared Prosperity Vision 2030 (SPV2030).

In this particular master plan, the principal strategy is to inculcate a Safety Culture in the workplace which emphasize the characteristic of attitude, internal nature of the organization and individual towards safety aspect. The OSHMP25 transformation and development was based on the investigation results on various occupational accidents and disaster. It is learned that there are loopholes in the local safety and health system. Furthermore, cooperation among involving agencies needs to be strengthened and set a clearer goal in achieving OSH excellence.

The Occupational Safety and Health Master Plan 2021-2025 consists of 6 main strategies and programmes respectively as shown below.

 

Strategy 1 – Empowering OSH in Public Sector

·         Programme 1: Upholding OSH Policies and Laws

·         Programme 2: Empowering NCOSH Functions

·         Programme 3: Government as OSH Catalyst

·         Programme 4: OSH Enforcement Transformation

·         Programme 5: Enhancing OSH Database Management

 

Strategy 2 – Reinforcing Self-Regulation Practices at Workplace

·         Programme 1: OSH Ownership and Leadership

·         Programme 2: Implementation of Systematic Self-Regulation

·         Programme 3: Improvement of OSH Best Practices Through Intervention at  

                        Workplace

·         Programme 4: Workers Self-Regulation Readiness

 

Strategy 3 – Promoting OSH Education and Research

·         Programme 1: Increasing Awareness, Education, and Community

                        Involvement in OSH

·         Programme 2: OSH Competency and Capacity in the Workplace

·         Programme 3: Enculturing OSH Research and Development

 

Strategy 4 – Empowering Occupational Health

·         Programme 1: Providing OSH Competent Occupational Health Practitioners

                       at Workplace to Increase the Performance and Access to

                       Occupational Health Services

·         Programme 2: Comprehensive Occupational Health Risk Management

·         Programme 3: Awareness and Information Sharing Related to Occupational

                        Health and Diseases.

·         Programme 4: Empowering Industrial Hygiene Towards Occupational Quality

                        Improvement.

·         Programme 5: Integrating Occupational Health Risk Assessment

 

Strategy 5 – Enhancing OSH Compliance in SME Sector

·         Programme 1: Special Incentive for SME Sector for OSH Activities

·         Programme 2: Enhancing OSH Management System in SME

·         Programme 3: Enhancement of Support and Cooperation Among Agencies

                        including Special Programme Initiatives.

·         Programme 4: Increase in OSH Knowlegde, Skill and Commitment

 

Strategy 6 – Enhancing OSH Through Technolgy

·         Programme 1: Smart Workplace Development Centered on IR4.0

·         Programme 2: Technological Ecosystem Development in OSH

·         Programme 3: OSH Risk Management System Through Digital Technology

Reference: https://www.dosh.gov.my/index.php/list-of-documents/penerbitan/oshmp2025/4219-occupational-master-plan-2125/file

Chemical Plant Disaster Scenario - Emergency Response Plan

Chemical Plant Disaster Scenario

                        Combinations of drought and flood scenario towards this chemical plant.

Accident Event

 
1^st Event

1.       17 Sept 2016 @ 9.45 am

2.       Ferric acid tank (ferric chloride) collapsed releasing a large amount of ferric chloride.

3.       This collapsed tank fell onto sodium hypochlorite transfer pipe system causing simultaneously mixing of these chemicals which produced a lethal and hazardous chlorine gas.

4.       ERP triggered – Fast response from the Facilities ERT and BOMBA succeeded in neutralizing the chlorine gas; from 3 PPM @ 12 pm to 0.5 PPM @ 1 PM and to 0 PPM @ 3 PM.

5.       However, one factory ERT team member and four firemen were given outpatient treatment.

6.       Stinging odour smelled by the nearby residents causing itchy throats, severe cough and accompanied by burning sensation in their throats.
 
2^nd Event

1.       Flash flood caused by overflooded river nearby, results from heavy rain upstream.

2.       The following day, 18 Sept 2016 @ 2 am, heavy rain pouring down onto the facilities and Bukit Merah area causing sudden flash flood, where the river nearby was overflowed.

3.       The debris from the earlier event caused another disastrous event.

4.       Strong overflow current washed away the debris and hit the nearby ferric acid tank and sodium hypochlorite tank causing sudden mix producing lethal and hazardous chlorine gas.

5.       However, the mixing produced diluted hydrochloric acid which were hazardous and harmful to the facilities, personnel and environment.

Emergency Response Scenario

1^st Event

Date      : 17 Sept 2016

Time      : 9.45 am

 

1.       9.50 am                - Long evacuation alarm sounded

2.       9.50 am                - Emergency Response Plan triggered and evacuation commences.

3.       9.55 am                - ERT mobilize and lead by Facility General Manager which is also the       

                               Incident Commander

- IC check on Emergency Management Team

            - HSE coordinates ERT movement, evacuation, scriber, brief IC

            - Liaison responsible for communications with public, BOMBA, 

                 HAZMAT, POLICE and inter department

-  Operation responsible for facility emergency shutdown sequence.

- HR responsible for headcount, family affairs

- Security responsible for all security matters

4.       9.56 am                - Facility evacuated

5.       9.58 am                - ERT try to contain the release by setting up water curtain.

6.       9.58 am                - IC calls Operation to execute emergency shutdown for the whole facility through designated stages.

7.       9.59 am                - IC contacts BOMBA, HAZMAT and POLICE for further assistance.

8.       10.00 am             - Setting up Incident Command Centre.

9.       10.05 am             - Release of Chlorine Gas escalates.

10.   10.06 am             -BOMBA and HAZMAT to the scene

11.   10.10 am             - Briefing to BOMBA, HAZMAT and Police on the current situation.

12.   10.15 am             - Police starts controlling access and egress

13.   10.15 am             - BOMBA and HAZMAT setting up perimeter water curtain, by using river

                               water and neutralizing the chlorine gas concurrently.

14.   10.20 am             - Large reaction fumes produce whilst in neutralization.

15.   11.00 am             - Still in neutralization mode but it is satisfactorily contained

16.   12.00 pm             - chlorine gas reads at 3 PPM

17.   1.00 pm                - chlorine gas at 0.5 PPM

18.   3.00 pm                - chlorine gas at 0 PPM

19.   4.00 pm                - Debriefing over the operation

20.   4.30 pm                - Further investigation by ERT, BOMBA and HAZMAT.

 

2^nd Event

Date      : 18 Sept 2016

Time      : 2.00 am

 

1.    2.00 am                - Flash flood from overflow river nearby entering facilities premise.

2.       2.10 am                - Alarm not triggered as the power supply have been cut off due to earlier  

                               event.

3.       2.15 am                - Remaining ERT, BOMBA, HAZMAT and Police are still in the facility. They

  had to move to higher ground which is at the operation building. Seeking 

  for help from BOMBA department and Police.

4.       2.20 am                - Strong current washed away collapsed tank debris and yet hit another

  nearby ferric acid tank and sodium hypochlorite tank causing sudden mix  

  producing lethal and hazardous chlorine gas again. However, the mixing

  produced diluted hydrochloric acid which were hazardous and harmful to

  the facilities, personnel and environment.

5.       2.30 am                - Facility bund wall designed was able to slow down the current and 

  eventually enough to dilute chlorine gas and HCL.

6.       3.00 am                - The flash flood starts to diminish.

7.       3.15 am                - Flash flood stop and water with the remaining HCL is still in the premise as

  the bund wall design was to hold overflow river water. However, the  

  bund wall was not quite high enough to stop the water from entering the

  premise.

8.       3.30 am                - ERT, BOMBA, HAZMAT and Police setting up a new command centre at the

   operation building.

9.       3.45 am                - Mitigation plan commences. Checking the water for HCL concentration.

10.   3.50 am                - Pumping out the remaining water in the premise when the specifications of

  hazardous chemical (HCL) concentration are met.

11.   4.50 am                - Helps from another BOMBA fire brigade and Police arrive.

12.   5.00 am                - Operation debriefing

13.   5.30 am                - Continuing investigation of the 1^st event.

Steam Engineer Preparatory Course

Steam Engineer Preparatory Course

Boiler operation requires a competent person to be operated and monitored by a steam engineer and boiler man as prescribed in Malaysian Regulations. Based on the Factory and Machinery Act, every certificated machinery requires a competent person, where process and operation safety are an important element to ensure the machine is in good operating condition.

Steam Engineer Grade 1 must understand the elements below.

Section 1 - Acts, Regulations and Standards

1. Occupational Safety and Health Act 1994 (OSHA 1994) and Regulations
2. OSHA 1994 Amendments
3. Occupational Safety and Health (Use and Standard of Exposure Chemical Hazardous to Health) Regulations 2000 (USECHH Regulations)
4. Industry Code of Practice 
1. The Industry Code of Practice For Safe Working In A Confined Space 2010
2. Industry Code of Practice for Management of Occupational Noise Exposure and Hearing Conservation 2019
5. Guidelines
1. Guidelines On Heat Stress Management At Workplace 2016
2. Guidelines On Ergonomics Risk Assessment At Workplace 2017
6. Other related rules and regulations
7. Steam engineer roles and responsibilities.
8. Plant safety, management and maintenance policy
9. Boiler house management

Section 2 - Boiler Design

1. Applicable codes & standards
2. Steam plant conceptual design
3. Boiler design
4. Boiler component
5. Parts, essentials fittings and safety devices

Section 3 - Boiler Operation

1. Fundamental operational responsibilities
2. Starting cold boiler (Precaution - Furnace explosion, Dust explosion)
3. Connecting of more than one boiler
4. Operating under emergency situations, idling procedure and maintenance (tubes, shell, drums, headers, superheater, economiser, furnace, air heater, pumps, fans, and stacks)
5. Uses of low pressure steam and hot water boiler for process heating
6. Special type of boiler for high pressure and temperature steam
7. Steam management
8. Boiler efficiency and burner efficiency

Section 4 - Inspection, Maintenance, Repair and Alteration

1. Boiler defect & potential root cause
2. Materials, creep and fatigue, corrosion and control
3. Welding and welding mechanical failure
4. Non-destructive examination or non-destructive test

Section 5 - Machine Integrity

1. Fit for services
2. Process safety management elements