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Safety Audit in Chemical Industry
- 1. Safety Audit in Chemical Industry Contact Detail(for full Report) : [email protected]
- 2. 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)
- 4. 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.
- 5. Need Of Safety Bhopal Gas Disaster : • 25 to 40 tones Methyl isocyanate (MIC) leaked
- 6. • 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
- 7. 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.
- 8. 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).
- 9. Implementation of safety Safety Week Safety Calendars Celebration of National Safety Day Safety Inspection and Audit Programme
- 10. 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
- 11. 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
- 12. 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
- 13. Types of Audit Safety Audit External audit designated State regulatory authority consultancy agency Internal Audit safety committee of the unit
- 14. 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
- 15. Focus of a Safety Audit How Institutional responses centralize attention to safety Personal Protective Equipment(PPE) Environmental impact Process plant
- 16. Process of a Safety Audit
- 17. 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
- 18. 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
- 19. 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
- 20. Auditing Methodology Initiating the OS&H Audit Preparing the OS&H Audit Executing the OS&H Audit OS&H Audit Documents
- 21. Audit Scope Audit Frequency Initiating the OS&H Audit Audit Plan Audit Team Assignments Working Documents of the Audit Team Questionnaire of Preliminary Information Preparing the OS&H Audit
- 22. Opening Meeting Representation 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
- 23. 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
- 24. Occupational Health and Safety Administration (OSHA)
- 25. 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).
- 26. 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.
- 27. 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.
- 28. OSHA Inspection • Inspections are initiated without advance notice • Performed by highly trained compliance officers, and based on the following priorities: 1. Imminent danger 2. Worker complaints and referrals. 3. Catastrophes – fatalities or hospitalizations. 4. Targeted inspections – particular hazards, high injury rates
- 29. PSM Audit Guidelines • Audit Guideline for Documentation • Interrelationship of Elements
- 31. 1. Checklist • Chemical Hazards 1. Transportation of Hazardous Substances 2. Handling of Hazardous Substances 3. Material Safety Data Sheet (MSDS) 4. Spill Control measures 5. Bulk Chemical Storages 6. Gas Cylinders 7. Labeling and Color Coding 8. Hazardous Waste management
- 32. 2.Report 1. Introduction to Audit: 2. Executive summary 3. Audit Profile 4. Company Profile Detail 5. System Element 6. Plant / Section wise Observation and Recommendation 7. Judgment of Compliance 8. System Ability 9. List of Annexures
- 33. The Plan-Do-Check-Act (PDCA) cycle
- 36. Corrective Action Preventive Action (CAPA ) • 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:
- 38. 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.
- 39. Thank You