safety audit in chemical industry

Safety Audit in Chemical Industry

Contact Detail(for full Report) :

patel_vishal29196@yahoo.com

Introduction

•Safety is the non-desirable the condition of being protected against any non desirable activities.

•Chemical plant safety•Major Problematic Area of chemical industry

•Occupational Exposure Limit (OEL)•PPE(Personal Protective Equipment)

Occupational Health and Safety : Occupational health and safety is about preventing people from being harmed by work or becoming ill from work by taking adequate precautions and providing a safe and healthy work environment.

Need Of Safety

Bhopal Gas Disaster : • 25 to 40 tones Methyl isocyanate (MIC) leaked

• More than 8,000 people were killed• And thousands of people affected by gas.

• Protective systems,Refrigeration system, Scrubbing system and Flare system were out of service

And main reason behind this Disaster is inefficient safety system.

So Safety Audit is the tool to utilize safety system properly and for maintaining distance from hazards.

Union Carbide was aware of the risks as Safety audits as early as 1982 showed major hazards.

Rules, Act, Policy and ISO related Safety

• Environment Protection Act, 1986• Responsible Care; OSHAS 18001• Factories Act, 1948, 1987• Quality policy (ISO-9001),• Environmental policy (ISO-14001)• Occupational Health and Safety policy (ISO-

18001).

Implementation of safety

Safety Week

Safety Calendars

Celebration of National Safety Day

Safety Inspection and Audit Programme

Safety Audit

• Safety auditing is a core safety management activity, providing a means of identifying potential problems before they have an impact on safety.

Auditee•An organization to be audited

Audit Team•Team of auditors who are suitably qualified

Client•An organization which appoints auditing agency

Work site audits also provide an evaluation of compliance to Occupational Safety and Health Administration (OSHA) standards relating to ergonomics, respirator use, hearing conservation and use of personal protective equipment

Objectives of Safety Audit

To identify the

potential hazards

To advise the company the risk involved in plant and measures to be taken to avoid risks

To assess the safety standards

maintained

To recommend measures for improving the effectiveness

of existing organizations

Types of Audit

Safety Audit

External audit

designated State regulatory

authority

consultancy agency

Internal Audit

safety committee of the unit

Statutory Requirement

1.Under section 7(a) and section 68-O,98j(ii) of the Factory Act 1948 (1986) and the Gujarat Factories Rules 1963(1995)

2.Under section 10(1), Schedule 8 of The Manufacture, Storage and Import Hazardous Chemical Rules (MSIHC)-1989

Focus of a Safety Audit

How Institutional responses centralize

attention to safety

Personal Protective

Equipment(PPE)

Environmental impact Process plant

Process of a Safety Audit

Duration of Safety Audit

Depends on- on the scope and focus of the Audit, the available resources, the availability of an Audit coordinator, decisions about how and when to collect data

Confidentiality

• Do not discuss details • Audit team decides with approvals from their

respective agencies• No individual Audit team member speaks on

behalf the Audit without the team’s approval• Audit teams may decide to make their work

public or not

Desired Outcome

Discovering gaps in safety and accountability

New expertise in a process

Suggest safety solutions

Improve the environment and personnel safety

Reduce incidents and injuries

Increase workplace safety pride

Protect your greatest asset…your employees

Auditing Methodology

Initiating the OS&H Audit

Preparing the OS&H Audit

Executing the OS&H Audit

OS&H Audit Documents

Audit Scope

Audit Frequency Initiating

the OS&H Audit

Audit Plan

Audit Team Assignments

Working Documents of the Audit TeamQuestionnaire of Preliminary Information

Preparing the OS&H

Audit

Opening MeetingRepresentation of organization

Examination

Audit Recommendation

Closing Meeting with Auditee

Executing the

OS&H Audit

Audit Report Preparation

Report Content

Report Distribution

OS&H Audit

Document

Phases

• Phase One Safety Audit Preparation• Phase Two Fact Finding• Phase Three Review of Findings of the safety

audit• Phase Four Recommendations from the

safety audit• Phase Five Corrective Actions from the safety

audit• Phase Six Publish the safety audit results

Occupational Health and Safety Administration (OSHA)

OSHA and The Chemical Industry

• OSHA has been particularly concerned about the chemical industry since the mid-1980's.

• Voluntary Protection Program (VPP).• OSHA enforces numerous safety and health

standards.• OSHA's Hazard Communication Standard and

the Standard on Process Safety Management(PSM).

Rights and Responsibilities under OSHA law

• By law, employers must provide their workers with a workplace that does not have serious hazards and must follow all OSHA safety and health standards.

• Employers must find and correct safety and health problems.

Health and Safety standards of OSHA

•limits on hazardous chemical exposure,

•employee access to hazard information,

•requirements for the use of personal protective equipment, and

•requirements to prevent falls and hazards from operating dangerous equipment.

OSHA Inspection

• Inspections are initiated without advance notice

• Performed by highly trained compliance officers, and based on the following priorities:

1. Imminent danger2. Worker complaints and referrals.3. Catastrophes – fatalities or hospitalizations.4. Targeted inspections – particular hazards,

high injury rates

PSM Audit Guidelines

• Audit Guideline for Documentation

• Interrelationship of Elements

Documentation

1. Checklist

2. Report

1. Checklist

• Chemical Hazards1. Transportation of Hazardous Substances2. Handling of Hazardous Substances3. Material Safety Data Sheet (MSDS)4. Spill Control measures5. Bulk Chemical Storages6. Gas Cylinders7. Labeling and Color Coding8. Hazardous Waste management

2.Report

1. Introduction to Audit:2. Executive summary 3. Audit Profile4. Company Profile Detail5. System Element6. Plant / Section wise Observation and

Recommendation7. Judgment of Compliance8. System Ability9. List of Annexures

The Plan-Do-Check-Act (PDCA) cycle

• Corrective action is aiming to correct an existing non-conformity and to avoid reoccurrence of the same non-conformity

• Preventive action is aiming to avoid the initial occurrence of a non-conformity by proactively implementing improvements.

• Form for accident/incident or near miss in next slide:

Advantages and Disadvantages of Safety Audit

Advantages•Quick, effective and accurate assessment of how chemicals are managed•platform to establish and maintain effective chemical management policies•took a fresh look at the areas which needed improvement

Disadvantages•It can be time consuming.•Takes manager away from their day to day work.•Can be misused by unscrupulous managers.

Thank You