do it yourself audit
TRANSCRIPT
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OBJECTIVE OF SELF-AUDIT
To take stock of position status Review existing systems and procedures Identify TIMELY recommendation for
incident prevention
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BENEFITS of Incident prevention
AVOID UNPLANNED INTERRUPTION
BUSINESS CONTINUITY
IMAGE PROTECTION REPUTATION MANAGEMENT
RESPONSIBLE CARE
GOOD CORPORATE CITIZEN
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SOME AUDIT REFERENCES
BIS 14489
5 STAR
ISRS OHSAS
DUPONT SYSTEMS
DOW CHECKLIST PSM
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TYPICAL AUDIT METHODOLOGY
Field Audit Personal Interaction/Feedback* Open/Frank Sit-in Sessions* Documentation review
*Highly Enthusiastic Motivated EmployeeParticipation/Involvement VITAL
for sustainable EHS Partnership performance.
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BIS14489 ELEMENTS
Occupational Safety and Health Policy
OS & H Organisation set up
Education and training
Employees participation
Motivational & Promotional measures
Safety Rules & Manual
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Contd ...
Compliance with Statutory requirements Risk Assessment including Hazard
Identification Safety Inspections Housekeeping
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Contd ..
Machine guarding Electrical and Personal Safeguarding Ventilation/Illumination/Noise Environment monitoring Medical Exams Safe Operating Procedures Work Permits
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Contd ..
Fire Prevention/Protection/and Firefighting systems
Emergency preparedness plan Management of Change Transportation of Hazardous
substances Waste Treatment
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Contd ..
Storage area Safety Contractor safety Systems
Safety for customers Accident reporting and analysis First Aid Facilities PPE Security Management Proactive Improvement Plans
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BASE INPUTS
INHERENT STRENGTHS SAFETY MANAGEMENT SYSTEM
ADOPTED BUILT-IN SAFETY/ENGINEERED
CONTROLS
PROACTIVE INITIATIVES RISK REDUCTION MEASURES ANY OTHER ADOPTED
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ILLUSTRATIVE CHECK SHEETS.DEVELOP OWN SITE-SPECIFIC LIST
BY INTERNAL INVOLVEMENT.SAFETY ORGANISATION
Safety Policy
Safety Organization Structure Safety Systems & Planning
Safety Committees Training Procedures & Levels
Safety Promotional Activities
Incident Management
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ENGINEERING
Built in Safety Features Engineering Codes Followed Design Code Practiced Manuals Drawings
P & Ids
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MECHANICAL/INSPECTION
Preventive, Predictive, Reliability basedMaintenance Procedures
Rotating Equipment, vibration & fatigue etc History Cards Inventory Management connected with Mechanical Condition Monitoring, NDT Inspections
PLES, RLA
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INSTRUMENTATION
Interlocks, Trips, Alarms, Fail Safe andRedundancy
Specifications of Set values (Original &Operating), C v checks
Gauges, Calibration and Testing records,Operation Range marking
Instrumentation Air (Source & OperabilityConditions), Buffer Tank
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Contd..
Dew Point Control, Moisture & Oil Tests,Changeover configuration
Emergency back-up, FailSafe (UPS) DCS/SCADA/PLC, Watchdog Relay
Configuration(as applicable) Built-in Engineered Controls List
Built-in Safety Integrity Checks--EFCV, ROV, ESD,Rupture Discs, Explosion Vents, Failsafe functiontests
Existing StatusLevels of Redundancy
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Contd ..
Redundancy Gap OffsetAdministrativeControls, SOPs
By-pass authorisation and RestorationProcedures
Enclosures & Protection
Safety Valves List & Records
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ELECTRICAL
ELECTRICAL Earthing, Bonding, Static & Lightning Protection
Earth Pit Values and Layout Flame Arrestors
Transformers Oil Sumps
Fire Partition Walls
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Contd..
MCC Panels, Residual energy discharge rods
Single line diagrams
Housing, Enclosures
Access, Entry Control Lock-out & Tag-out Procedures
Substations, Rubber mats, Shock treat charts
Pressurisation
Water Proofing & Grading
Dust/ Moisture Seals, Caution signs
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Contd..
Hazardous Area Classification Cables, Trenches, Fire retardation, smoke
detection etc., Temporary electrical connection safeguards
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FIRE PROTECTION
FIRE PROTECTION AND PREVENTION
Reservoirs/Static Holding Tanks
Fire Water Augmentation Tanks
Fixed Installation
Fire Tender
Foam System and Inventories
Portable Appliances
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Contd..
Response Team Preparedness Plans
Emergency Mock Drills Process Emergency Mock Drills Review
Utilities House Keeping
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INCIDENT REVIEW & ANALYSIS
Report Formats Review Procedures Information Sharing Avoid Repeat Measures (Root Cause Fix) Publishing Findings Follow up System First Aid Reporting, Treatment & Review
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STATISTICS/RECOGNITION
Statistical Compilation Comparison with Standard and Best
Industrial Practices BENCHMARKING Reward and Recognition
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HOUSEKEEPING
Documented schedules
Supervisor implementation procedures
Stacking and storage Labeling and displays
Scrap Management systems
Warehouse maintenance
Cleaning and draining systems .
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TRAINING
Class Room
Field
On the job
Refresher Advanced
Skills
First Aid
Fire Fighting Emergency preparedness.
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TRAINING MODE
Verbal Audio Audio visual Multi-media Hands-0n Recall sessions
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TRAINING APPROACH
SAFETY approach can be utilized in Training approachS Show (Train)A Ask(Feedback, Quiz, Demo)F Follow Up (Non-Conformity/error--Correct, Prevent,
EnrichE Encourage (constructive suggestions, Continual
improvement methods T Teach (Job Safety Analysis)Y --Yearning ( Create a voluntary urge to FOLLOW safe work
practices)
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INDUSTRIAL HYGIENE
Lighting Noise
Heat Emissions (Dust, Fume, Mist, Vapour) Discharges
Landscaping Afforestation
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CHEMICALS/HAZARDOUS MATERIALS
List of Chemicals Storage segregation Categorisation Exposure controls Exposure limits Exposure prevention management Antidotes Medicare plans Health monitoring/well-being plans
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STATUTORY COMPLIANCE
Factories Act, Statutory Registers Petroleum Rules IBR IER MSIHC Rules PLI Water Act, Air Act Environment Protection Act 1986 And Rules
Amended Time To Time SMPV etc
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CHANGE MANAGEMENT
Change Management SOP Change Management Checklist
Standards & Codes reference document Modifications List Document management
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PRESSURE VESSELS
Listing Test Records
Inspection Schedules Gas Cylinders Storage/Certificates
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HAZMAT PIPING
Routing Supports,Flanges,Bolts,Threads, Gaskets
Spark Arrestors Earthing/ Bonding Vents/Drains/Elbows
Line Relief Valves, Isolation valves, Other valves Integrity Checks
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HAZMAT SPILL PREVENTION MEASURES
Storage Design Dyking
Grading, Sloping, Collection Pits, Seals, and Traps Containment, Bunds, Embankment, Seperators,
Vapour seals, Transfer, Disposal Methods
Spill Clean Up, Neutralisation, Safety Checks
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Self-regulate
Despite any type of essential external audits, the bestway forward is proactive self-regulation by structuredinternal audits by multi-disciplinary team with a
prescribed frequency involving area personnel. The data obtained is to be sorted, categorised,
prioritised based on review in a constituted safetycommittee and the success depends on implementationof risk mitigation measures.
The illustrated check sheets need adaptation andenhancement to suit individual site profiles.
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List of Abbreviations BIS Bureau of Indian standards
DCS Distributed Control System
EFCV Excess Flow Check Valve ESD Emergency Stop Device
IBR Indian Boiler Regulations
IER Indian Electricity Rules
IPS Indian Petroleum Rules
ISRS International Safety Rating System
MCC Motor Control Centre
NDT Non Destructive Testing
OHSAS Occupational Health and Safety Assessment Series
OS & H Occupational Safety & Health
P&ID Piping & Instrumentation Diagram PLC Programme Logic Controller
PLES Plant Life Extension Study
PLI Public Liability Insurance
PPE Personal Protection Equipment
PSM Process Safety Management
RLA Residual Life Analysis
ROV Remote Operated Valve
SCADA Supervisory Control And Data Acquisition
SMPV Static and Mobile Pressure Vessel
SOP Standard Operating Procedure