Water Industry Process Automation & Control Monthly - April 2024
Safety Audit in Chemical Industry
1. Safety Audit in Chemical Industry
Contact Detail(for full Report) :
patel_vishal29196@yahoo.com
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)
3.
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.
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
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
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
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
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:
37.
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.
