Safety Audit in Chemical Industry

Safety audit in chemical industry
introduction
 Safety is the non–desirable condition of being protected

against non desirable activities
 Chemical plant safety
 Major problematic area of chemical industry
 Occupational exposure limit
 PPEs (personal protective equipment )

Need of safety
Bhopal gas disaster :
25 to 40 tones methyl isocyanate (MIC)
leaked
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 health
environment
-More than 8000 people were killed
-and thousands of people affected by
gas
Protective systems , refrigeration

system , scrubbing system and
flare system were out of service
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 Is related to 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 calendar
Calibration of
national safety day
Safety inspection
and audit program
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 Audit team Client

• an • Team of • An
organization auditors who organization
to be audit are suitably which
qualified appoints
auditing
agency
Work site audit also provide an evaluation of
compliance to occupational health and safety
administration ( OSHA ) stander relating to
ergonomics , respirator use , hearing
conservation and use of personal protective
equipment
Objective safety Audit
To advise the To recommended

company the risk measures for
To assess the
To identify the involved in plant improving the
safety slandered
potential hazard and measure to effectiveness of
maintained
be taken to avoid existing
risk organizations
Types of audit
Safety audit
External audit Internal audit
Designated Safety
Consultancy
state regulatory committee of
agency
authority the unit
Statutory requirement
1. Under section 7 (a) and section 68-0,98j (ii) of factory act

1948 (1986) and the Gujara196t 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
Personal
responses
protective
centralize
equipment
attention to
safety
Environmental
Process plant
impact
Process of a safety audit
Opening meeting
Pre audit data with top
management to Plant study
collection brief about the
study
Close out meeting

Final report ranking
discussion in audit
of recommendation
finding and action
for easy
for immediate
implementation
implementation
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 teams approval
 Audit teams may decide to make their work public
or not
Desired outcome
Discovering gaps
in safety and
accountability
Protect your
Never expertise
greatest asset…
in process
your employees
Increase
Suggest safety
workplace
solution
safety pride
Improved the
Reduce incidents
environment and
and injuries
personnel safety
Auditing methodology
OS&H audit
Initiating the Preparing the Executing the
documentatio
OS&H audit OS&H audit OS&H audit
n
Initiating the Preparing the
OS&H audit OS&H audit
Audit scope Audit plan
Audit Audit team

frequency assignments
Working
documents of
the audit team
Questionnaire
of preliminary
information
Executing the OS&H audit
OS&H audit document
Opening Audit report
meeting preparation
Representation
Report content
of organization
Report
Examination
distribution
Audit
recommendation
Closing meeting
with auditee
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 -1980s
 Voluntary protection program ( VVP )
 OSHA enforces numerous safety and health
standers
 OSHA Hazard communication standard and
the standard on process safety
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 standers
 Employers must find and correct safety
and health problems
Health and safety standers of OSHA
Limits on hazardous chemical exposure
Employee access to hazard information
Requirements for the use of personal protective

equipment
Requirements to prevent falls and hazards from

operating dangerous equipment
OSHA Inspection
 Inspection are initiated without advance

notice
 Performed by highly trained compliance
officers and based on the following priorities :
1. Imminent danger
2. Worker complaint
3. Catastrophes _ fatalities or hospitalization.
4. Targeted inspections – particular
hazard ,high injury rates .
PSM audit guidelines
 audit guidelines for documentation
 Interrelationship of Elements
Documentation
checklist Report
Transportation of
Introduction to audit
hazardous substance
Chemical handling Executive summary
Material safety data

Audit profile
sheet
Company profile
Spill control measure
detail
Bulk chemical
System element
storage
Planet wise
Gas cylinders
observation
Labeling and color Judgment of

code compliance
List of annexures
Corrective action prevention action
(CAPA)
 Corrective action is aiming to correct an

existing non conformity and to avoid
reoccurrence of the same non conformity
 Prevention action is aiming to avoid the
initial occurrence of a non conformity by
proactively implementing improvement .
 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
-Plat form to establish and maintain effective chemical management
policies
-Took afresh look at the areas which needed improvement
Disadvantages
-It can be time consuming
-Takes managers away from their day to day work
-Can be misused by unscrupulous managers
Thank you

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What is the main reason behind the Bhopal gas disaster?

What is the main reason behind the Bhopal gas disaster?

What are the objectives of conducting a safety audit?

What are the objectives of conducting a safety audit?

Safety audit in chemical industry

 Safety is the non–desirable condition of being protected

 Chemical plant safety

 Major problematic area of chemical industry

 Occupational exposure limit

 PPEs (personal protective equipment )

Occupational health and safety is about

Protective systems , refrigeration

So safety audit is the tool to utilize safety

Union carbide was aware of the risks as

 Environment protection act 1986

Safety auditing is a core safety management activity , providing a

Auditee Audit team Client

To advise the To recommended

External audit Internal audit

1. Under section 7 (a) and section 68-0,98j (ii) of factory act

2. Under section 10 (1) , schedule 8 of the manufacture , storage

Close out meeting

 Do not discuss details

Audit scope Audit plan

Audit Audit team

 OSHA has been particularly concerned about

 By law , employers must provide their

Limits on hazardous chemical exposure

Employee access to hazard information

Requirements for the use of personal protective

Requirements to prevent falls and hazards from

 Inspection are initiated without advance

 audit guidelines for documentation

Chemical handling Executive summary

Material safety data

Labeling and color Judgment of

 Corrective action is aiming to correct an

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