48 Challenges in anticipating unfamiliar hazard in technology project venture: a PETRONAS insight from potential respirable dust exposure incident

A series of respiratory health issues occurred among Crude Algae Project’s lab staff, prompting an urgent internal investigation. Three employees experienced symptoms like coughing, shortness of breath, pneumonia, and bronchiolitis after working on the project. These symptoms coincided with the introduction of biomass charcoal activity, which generated respirable dust. Two prominent safety deficiencies were identified: First due to inadequate engineering controls during extraction, drying, and grinding processes. Although chemical exhaust and local exhaust ventilation (LEV) were planned, employees often worked without them due to facility limitations. Secondly, irregular adherence to personal protective equipment (PPE) usage due to staff’s limited awareness also contribute to the accident. A set of recommendations has been proposed in rectifying the identified issues which include to execute Chemical Exposure Monitoring (CEM), enhance Local Exhaust Ventilation (LEV) for specific activities, consider relocating processes to isolated facilities, revise Hazard and Effect Registers and Standard Operating Procedures (SOPs) to accommodate mass production. Staff also should receive training on proper PPE utilization, respiratory fit tests, and awareness programs. This investigation offers valuable insights for bolstering safety standards, particularly in research-based environments characterized by adaptable better work practices. In conclusion, this report underscores crucial areas for refining the safety framework within the Project and will be the baseline strategy poised to fortify safety protocols and safeguard staff well-being, ensuring the project’s continued success