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 Employee
Participation/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 Fire

fighting 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 based

Maintenance 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 and

Redundancy
• Specifications of Set values (Original &
Operating), Cv checks
• Gauges, Calibration and Testing records,
Operation Range marking
• Instrumentation Air (Source & Operability
Conditions), Buffer Tank

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 Contd..

• Dew Point Control, Moisture & Oil Tests,

Changeover configuration
• Emergency back-up, Fail—Safe (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 function
tests
• Existing Status—Levels of Redundancy
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 Contd ..

• Redundancy Gap Offset—Administrative

Controls, SOPs
• By-pass authorisation and Restoration
Procedures
• 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 approach

S—Show (Train)
A—Ask—(Feedback, Quiz, Demo)
F—Follow Up (Non-Conformity/error--Correct, Prevent,
Enrich
E—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 best
way forward is proactive self-regulation by structured
internal 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 safety
committee and the success depends on implementation
of risk mitigation measures.
• The illustrated check sheets need adaptation and
enhancement 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

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