safety audit in chemical industry
TRANSCRIPT
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.
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