Safety Audit Ppt Representation (2)

8/3/2019 Safety Audit Ppt Representation (2)

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SAFETY AUDIT

IS 14489 : 1998

DO INSPECTION AUDIT YOURSELF

GROUP 5


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INTRODUCTION

Safety Audit is management tool comprisingof a systematic ,periodic and objectiveevaluation of how well the safety

organization, management and equipmentare performing, with the aim of helps tosafeguard a companys assets by facilitatingmanagement control of safety, health and

environmental practices and assessingcompliance with established standards


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TYPES OF AUDITS

External : These are conducted by a thirdparty

Internal : Corporate : By headquartersor

personnel from other units of

the same company.

Self :Inhouseby the plant personnelthemselves.


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AUDITS OBJECTIVES

Verify compliance with established standards(regulations, internal policies and industry wisestandards of practice )

Identify deviation from designed and plannedoperating and maintenance procedure andstandards

Identify plant condition or operating procedures

that could lead to an accident and significantlosses to life or property

Ensure that the plan and operating andmaintenance procedures match the design intent

and standards


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Keep the operating personnel alert to the process

hazards Review operating procedures for necessary

revisions

Seek to identify equipment or process changes

that could have introduced new hazards

Ultimate application of new technology to existing

hazards

Review adequacy of safety inspections Look for major risk situations recommend

measures to improve overall safety performance

of the plant


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Methodology in Conducting a Safety Audits

The following activities are carried out in conducting a

safety audit and implementing the audit recommendation

Pre-audit activities

Key on-sites activities

Post-audit activities


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Pre-audit Activities

The safety audit process being with the following activities

before the actual onsite audit takes place :

Request by management / identification of industry according to highhazards/high rate of accidents

Scheduling of the audits

Selection of the audit team

Development of an audit plan which includes-Defining the scope of the audit

-Selecting priority topics-Modifying the audit protocols-Allocating audit team resources

Advance visit to the factory to gather background information and data,administering a questionnaire.


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Background information to be gathered :

1. List of products2. Brief description of the manufacturing process with

process flow diagram/block diagram

3. Built-up area and site plan/names of departments

4. Number of company employees ( managers, supervisorsand workmen ) and contractors employees

5. Organization structure, including SHE function

6. List of chemicals handled:

- Raw materials- Products

- Intermediates

- By-products


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Date to be gathered :

1 Brief description of major accidents in the pastten years

2 Accident statistics for the last five yearstypes/ cause of accidents and analysis

3 Details of fires / explosions / toxic releases inthe last five years


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Key On-site Activities

Understanding Management Systems:

First of all a working understanding of the industrys

internal safety management system, i.e. the set of

formal and normal actions taken by the industry is

required to be developed. This step usually includes

developing a understanding of :

Factory processes

Internal controls ( both management and engineering)


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Plant organization and responsibilities

Compliance parameters and other applicable requirements

Any current or past problems The picture of internal management systems is usually drawn

from the following sources:

Discussions with management personnel, supervisors andworks

Specially designed internal controls questionnaire Plant visits

In some cases, a limited amount of verification testingconducted to help confirm the auditors initial understanding

The auditor records his or her understanding in a flow chart-

narrative, description, or some combination of the two-inorder to have a written description against which audit is to bedone.


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Assessing Strengths and Weaknesses :

In assessing strengths of internal controls,

auditors look for the following indications.

Whether factory personnel are trained andexperienced

Whether responsibilities at various levels are clearlydefined and carefully assigned


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Whether duties are so divided that these minimize conflicts ofinterest

Whether authorization systems are in existence

Whether internal verification procedures are in place Whether protective measures-security systems and alarms are

taken

Whether procedures and compliance / exception results are inplace

For each of the areas assigned, the auditor should ask himselfthe following questions :

* If the facility is doing everything the way they say ithappens, is that acceptable ?* Is the facility incompliance with applicable requirementsand is the factory adequately protected ?


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Collecting Audit Evidence :

Audit evidence forms the basis on which the teamdetermines compliance with laws, regulations,corporate policies and / or other standards.

Suspected weaknesses in the management system areconfirmed in this step. Also management systemsthat appear sound are tested to verify that they workas planned and are consistently effective. Variouswork such as record reviews, examination of

available data, observation and interviews withfactory personnel are used to gather audit evidence.


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Completeness and authenticity of records

Purpose and effectiveness of the format and theirsatisfactory filling-up.

Checking of records and show-up action by neverauthorities.

Method of maintaining records

Interview with factory personnel :

The auditor asks questions, both formally andinformally. The following points should be kept inmind while interviewing a person.


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Interviewing persons is a difficult matter and should behandled properly.

Sometimes due to various reasons, the person is reluctant to

provide the required information. During interviews, unnecessary / irrelevant questions should

be avoided.

The person being interviewed should be kept at ease

The interviewer should create a feeling of trust in the person

being interviewed. Information should be collected by interviewing, persons at

the appropriate level.

Verify statements by interviewing persons of the same /different levels.

The person should be interviewed at his normal workinglocation.

Proper judgments should be used to select a sample of thework force for the interview.


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Observation :

Plant visit, observation is a significant aspect of safety

audit. The auditor collect evidence through what can be

seen, heard, touched or smell. The following points

should be kept in mind during a plant visit :

Visit to the plant must be during the normal working

condition.

Observation on relevant audit elements should berecorded on the spot.

The auditor should develop skills ( keep eyes open ) to

make observation of several elements at each location.


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Once sufficient deficiencies relating to a particularitem are detected, checking of that item at other

locations may be stopped. When sufficient observations ( particularly about

acceptable systems ) are made on a particularelement during plant visit the auditor should spent

less time in document verification of that item. Safe operating procedures should also be checked.

The auditor should try to visit some locations undershut down maintenance, construction, etc.

The auditor must make one visit during second shift/ holiday to assess conditions and functioning ofsystems apart from in the general shift.

The auditor must check the availability of operatingprocedures in the plant.


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Evaluating audit evidence :

After the evidence is gathered, the audit findings

and observations are evaluated. The audit team

sets aside a few hours at the end of the audit to

discuss, evaluate and finalize the tentative audit

findings. The team confirms if there is sufficient

evidence to support all findings. Findings that

may be more significant than individualdeficiencies are identified and each finding is

summarized in a way that most clearly conveys

its significance.


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Post-audit Activities

The final audit report is issued to the chiefexecutive of the company. Some companies also

distribute the report to various levels of the operatingand line management communication and distributedto those with a need to know. A formal procedure forresponding to the audit report is established. Theaction planning process is initiated as audit findingsare identified. If assigns responsibilities for correctiveaction, determines potential solutions and preparesrecommendations to correct any deficienciesmentioned in the audit report, and establishes time

tables. Companies may also incorporates the actionplan in the final report. Action plans are monitoredand followed either by the operating management,the safety department. Or the auditors. The follow-upinvolves a written or oral inquiry to the status of the

planned action.


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Audit ElementsThe detailed scope of the audit is listed as a series of

audit elements in two broad categories :

1 Management Systems , and

2 Technical / Hardware Aspects .

Under each element a number of sub- elements have

been listed. There may be many instances,particularly in small or medium sized plants, whereall elements need not be used. Further, for eachtype of industry (e.g. fertilizer petrochemical,pesticide ) detailed listings /checklists would need tobe prepared. Therefore selection of elements andsub-elements should be done using the professional

judgment of the auditor, based on the type and sizeof the industry and other aspects.


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Management SystemThe essential elements of safety management system

to be audited are given below :

1 Safety, Health & Environment ( SHE ) Policyi ) Managements commitment to SHEii ) Accountability and Responsibility

iii ) Implementationiv ) Policy review

2 Safety and Health Organizational Set-upi ) Safety Department

- Structure- Responsibilitiesii ) Occupational Health Servicesiii ) Safety Committee


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3 Education and Training

i ) Induction training for new employees-Category-Topics-Duration

-Feedback-Methodology

ii ) Periodic Training

-Category

-Topics-Duration-Periodicity-Feedback-Methodology


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4 ) Communication / Motivation /Promotion in Safetyi) Safety suggestion schemeii) Safety competitions- Safety performance- Housekeeping

- Safety essay, slogan and posteriii) Display Board informationiv) Safety publicationsv) Safety week / Day celebrations

5 ) Safety Inspectionsi) Periodic inspectionii) Routine inspectioniii) Special inspection


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6) Accident Reporting, Investigation and

Implementation of Recommendations

i) Reportable- Fatal- Serious- Othersii) Non-Reportable

iii) Dangerous occurrences / Near misses7) Maintenance of Accident Statistics and its

Utilization

i) Accident rate per 1000 workers employedii) Frequency rateiii) Severity- Type-wise and cause-wise analysis ofaccidents


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8) Safety Audits

i) External auditsii) Internal audits

- Self

- Corporate

9) Personal Protective

Equipmentsi) Types and selection

ii) Training and motivationiii) Enforcement

iv) Maintenance

v) Testing

P / Pl M difi i P d


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10) Process / Plant Modification Procedure

( including Technology Change )

11) Safe Operating Procedurei) Implementationii) Review

12) Work Permit System

i) Line breakingii) Confined space entry

iii) Hot workiv) Electrical lockout and tag systemv) Excavationvi) Working at heightvii) Working on fragile


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13) Fire Fighting System

i) Selection of fire fighting equipment

ii) Fire fighting proceduresiii) Fire fighting teamiv) Communication systemv) Drillsvi) Inspection and maintenance of fire fighting

equipments14) Health and Safety Improvement Plan /

Targets

i) Accident / Incident rate reduction

ii) Improvement in environmental standards


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15 Prevention of Occupational Diseasesi) Identification of areas with potential for occupationaldiseasesii) Engineering control measuresiii) Administrative control measures

16) Work Environment Monitoring System

i) In-plant facilitiesii) Assistance from outside organizations

17) Medical Examinationi) Pre-employmentii) Periodical


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18) Material Safety Data Sheetsi) Preparation

ii) Updates

iii) Dissemination

19) Emergency Preparedness Plan ( On-site / off-

site )

i) Emergency response systemii) Emergency alarm system

iii) Mock drills

iv) Co-ordination with the local authorities

v) Education of general publicvi) Communication with the public


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20) Hazardous Waste Treatment and

Disposal

i) Incineration of solid waste

ii) Efficient treatment

iii) Disposal

iii) Air pollution control measures

21) Transportation of Hazardous Materialsi) Provision of informationii) Emergency response


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22) Hazard Identification

i) Checklist

ii) What if ? review of operations

iii) Hazard and operability study ( Hazop )

iv) Fault Tree Analysisv) Mond and Dow index

23) Contractor Safety Systems

24) New Equipment Review / Inspection


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Technical Aspects

The essential elements of a technical safety audit are

based on the scope of the audit. These may be actedin a particular plant / operation / aspect or mayextend to technical safety aspects of the entire

factory.

The following technical aspects are to be looked into in detail while carrying out the safety audit.1) Building and Structuresi) Location and lay-out

ii) Conforming to standards

iii) Stability certificateiv) Escape routes and exitsv) Fire-proof constructionvi) Lighting arrestor


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2) Operational Safety and Procedures

i) Availability and compliance of operating andsafety manualsii) Control of operating parametersiii) Start-up and shut-down procedures

iv) Venting / Scrubbing systemsv) Running of emergency equipmentduring power failurevi) Cleaning and tank entry procedures

vii) Work permit systemsviii) Precautions against endothermic /exothermic run-away reactions


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3) Chemical Process Safetyi) Plant lay out

- Separation and isolation, - Drainage,- Enclosed spacesii) Material compatibilityiii) Contamination control

iv) Physical facilitiesv) Inspection and maintenancevi) General containment and controlsvii) Instrumentation

viii) Piping systemsix) Protective systems ( not quality control)x) Electrical equipmentxi) Pressure vessels

ii) P d


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xii) Pumps and compressorsxiii) Reactionsxiv) Venting

xv) Interlock devices for critical operationsand equipmentsxvi) Over-pressure: relief devicesxvii) Continuous operation of neutralizationsystem and connecting it with diesel generating setin case of power failurexviii) Connecting critical equipment with dieselgenerating set in case of total power failurexix) Alarm warning system in case of emergency

xx) Indication and alarm system for processparameters controlxxi) Installation of fail-safe instruments


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4 Handling and Storage of Chemicalsi) Site selection

-Storage area away from buildings or

structures , - Distances as per the statutory

regulations , - Well ventilated area , - Easy

access from the control room

ii) Alarm and indications

- High level alarm , - High pressure & high

temperature alarms , - Isolation of the tank ,-Remote control valve

iii) Fencing

iv) Distance between two tank


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v) Dyke walls with drainage systemvi) Display of caution notice

vii) Support for above ground tanksviii) Ventingix) Valvesx) Level measurementxi) Pumpsxii) Sources of ignitionxiii) Lighting

xiv) Marking of tanks , connections andfittingsxv) Gas leakages and control


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xvi) Safety valves discharge connection tothe neutralization system / flarexvii) Flame proof fittingsxviii) Electrical grounding of the vesselsand pipe linesxix) Diesel generating set connected to the

emergency power supplyxx) Minimizing of inventoryxxi) Storage of chemicals under lowpressure

xxii) House keepingxxiii) Fire fighting arrangement andprovision of static water


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xxiv) Extension of liquid inlet line to avoid static

charge

xxv) Personal protective equipments

xxvi) Hydraulic testing and inspection of

pipelines

xxvii) Material safety data sheetxxviii) Trem (Transit Emergency ) card

xxix) Emergency information panel

xxx) Labeling of packaging material

xxxi) Loading and unloading procedurexxxii) Transport emergency preparedness

xxxiii) Emergency kit / fire fighting equipment


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(5) Fire and Explosion hazards

1 Fire prevention- No smoking restricted area-Periodic checking & continuity of ear thing-Prevention of spillages

-Accumulation of waste and combustible inprocess areas-Water sprinklers-Fire alarms-Lightning arrestor-Flame proof fittings-Flame arrestor-Static charge

-Fire exits


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2- Fire Protection-Location and capacity of fire hydrant pump-Booster pump and standby pump

-Hydrant pump starting system and procedure-Static water quantityLayout of linesSpace between the hydrantsWater jet monitorsHydrant boxesFoam requirement

3- Fire extinguishers :

Testing and certification by competent authorities

Fire siren systemFire fighting team

Fire fighting training

Mutual aid scheme


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(6) Material Handling

i) Manual handling :

Procedures-Handling aids-Condition of material handling areas

ii) Lifting machinery and tackles :

-Selection-Design criteria-Inspection and testing-Compliance with standards

-Periodic checking and maintenance-Storages-Safe working load, identification, markings etc.-Slinging practices


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iii) Material Handling procedures :

-Stacking and restacking procedures :-Compliance with standards-Load bearing capacity

-Stacking stability-Safe handling procedure for chemicals andexplosives-Storage facilities ( adequacy & suitability )

including pallets-Clearance and passages-Provision of aisles


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7) Machine Guardingi) Types of guards

ii) Guarding materialsiii) Maintenance of guardsiv) Periodic inspection

8) Pumps and Compressorsi) Pressure design of casing

ii) Rating of in stream pipingiii) Check valves / Control valvesiv) Suction piping and over pressurev) Isolation valvevi) Speed control

vii) Design temperature controlviii) Leakagesix) Lubricationx) Reverse flow / rotationxi) Vibration / Alignment


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9) Inspection & Testing of Pressure Vessels

i) Schedule and inspection and testingii) Testing and inspection reportsiii) Compliance with standardsiv) Inspection and testing of pressure relief valves andrupture discs

10 Personal Protective Equipments

- Selection and suitabilityi) Proper useii) Display

iii) Inspection and testingiv) Maintenancev) Proper storage


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11) Electrical Hazards

i) Area classification

ii) Selection and use of electrical appliances

iii) Overload and short-circuit devices

iv) Power isolation procedures

v) Electrical fire-fighting devices

vi) Flame proof fittings

vii) Lightning arrestorviii) Ear thing / Earth leakage circuit breaker

ix) Lock out and tagging procedures


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12) Instrumentation

i) Provision and suitability of instrument in

process / equipmentii) Instrument calibration proceduresiii) Tripping devices for control of processparameters

iv) Fail-safe instrumentation proceduresv) Periodic maintenance proceduresvi) Testing and inspection proceduresvii) Checking against response time

viii) Effects of humidity and temperature oninstrumentsix) Back-up proceduresx) Checking of air ( quality, pressure, etc )


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13) Preventive Maintenance

i) Schedule

ii) Maintenance checklist / reportsiii) Equipment change-over schedule

iv) Review of equipment failures

14) Pollution Systemi) Effluent treatment plant

ii) Air pollution control and monitoring

iii) Hazardous wastes disposal

iv) Noise pollution


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15) Emergency Preparedness

i) Organization

ii) Emergency planningiii) Emergency control centeriv) Escape routesv) Assembly pointsvi) Evacuation proceduresvii) Communication within the plantviii) Identification of hazardous areasix) Key personnelx) Emergency response equipments

xi) First aid and medical facilityxii) Communication ( authorities and public )xiii) Dispersion modelsxiv) Training and drills


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16) Boilers / Furnaces

i) Compliance with statutory requirements

ii) Feed water piping

iii) Steam outlet piping

iv) Quality of waterv) Drum water level

vi) Maintenance of instrument

vii) Gas burner control

viii) Interlocks


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viii) Interlocksix) Shut-off valvesx) Dampers

xi) Low pressure, high pressure alarmsxii) Pressure and vacuum relief valvesxiii) Flame arrestor on discharge of relief valvesxiv) Stack height

xv) Emergency relief devicexvi) Monitoring of stack emissionxvii) Economizer and super heaterxviii) Access to control valvesxix) Inspection of furnace liningxx) Explosion hazardsxxi) Fuel controlxxii) Insulationsxxiii) Measurement of heat stress

17) H d T l d P t bl P T l


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17) Hand Tools and Portable Power Tools

i) Selection

ii) Maintenance

iii) Quality

iv) Storage

v) Guarding

vi) Ear thing of portable power tools

18) Lighting / illumination

i) Type of lighting

ii) Illumination levelsiii) Compliance with standards

iv) Ratio of contrast

v) Glare

vi) Maintenance of fixtures and fittings

19) H k i


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19) House-keeping

i) Floor surface

ii) Cleanliness and tidinessiii) Disposal binsiv) Fencing of dangerous spots andditches

v) Covering of trenches and pitsvi) Steps, ladders, staircases, ramps,walkwaysvii) Passages

viii) Drainageix) Work platformsx) Left over materialsxi) Stacking


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IMPORTANT ASPECT FOR ACCIDENT

PREVENTATION

TO

PREVENT

ACCIDENT

HAZARD IDENTIFICATION

-HAZOP

-HAZAN-FAULT TREE ANALYSIS

-EVENT TREE ANALYSIS

-DOW INDEX

-SAFETY AUDIT

-SAFETY INSPECTION

WORK PERMIT SYSTEM-MECH. MAINTENANCE PERMIT

-ELEC. MAINTENANCE PERMIT

-HOT WORK PERMIT

-COLD WORK PERMIT

-VESSEL ENTRY PERMIT

-WORK AT HEIGHT PERMIT

-ESCAVATION PERMIT

-E.T.C. PERMIT

JOB SAFETY ANALYSIS

I

SAFE OPERATING PRACTICE

I

TRAINING


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170 How is the medical emergency communication with localbodies and other organizations ensured ? Give details.

171 Is any alternate power source identified ? Give details.172 What is the medical emergency response system ? Give

details.

173 Are you a member of any MUTUAL-AID-SCHEME of yourarea ? If so give details.

174 How many emergency alarm system (s) is / are available ?Give details.

22) PLANT LAYOUT AND AREACLASSIFICATION

175 What is the system of classification of hazardous zones in the plant for

electrical installations ? Please specify.176 Whether periodic inspection and preventive maintenance of electrical

installations is done by a qualified person and record is maintained ?

177 Whether plant layout with area classification has been displayed atappropriate place (s) ?


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THANKS

Safety Audit Ppt Representation (2)

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