safety audit observations & recommmendations
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pillai_sreejith@hotmail.com
Safety Audit Tips, Observations &
Recommendations
India
P.G. Sreejith
Part 1
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Safety Audit Preparation
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Pre -Safety Audit Guidance
• Send the data request (records, reports that you want the client to keep ready for auditing) and audit plan in advance to client
• Prepare checkpoints based on specific hazards of the industry that you are planning to audit
• Collect all possible accident information for the particular plant and industry
pillai_sreejith@hotmail.com
Pre -Safety Audit Guidance
• Send the data request (records, reports that you want the client to keep ready for auditing) and audit plan in advance to client
• Prepare checkpoints based on specific hazards of the industry that you are planning to audit
• Collect all possible accident information for the particular plant and industry
pillai_sreejith@hotmail.com
Safety Audit Guidance
• Plan the audit (based on defined scope and coverage) and to the extent possible to stick to the plan
• Do a thorough audit, inspect all areas, equipment
• Meet and discuss with maximum number of operators / technicians
• Ask specific, relevant questions
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Safety AuditUseful Tips
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Be keen and watchful!
• Be a keen observer while auditing.
• Look for exhibits in plant notice boards, accident statistics, etc.
• Spent more time in newly built / modified plant (drawing updation, electrical single line diagram, process change procedure/MoC)
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Compare!!
• Compare adjacent / similar equipment, phase currents, phase temperatures, conditions, features, shapes when you move around in plant and you could notice:
• Modifications• Rise in temperature• Different type of equipment• Protection devices
Comparison (with comparables) can give lots of valuable hints!!
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Safety Observations &
RecommendationsProcess
ChemicalElectrical
InstrumentationMechanical
Occupational HealthFire
Ergonomics
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Residual Current operated Circuit Breakers (RCCBs)
• Try tripping a few of them – you will find generally 80%+ bypassed. Investigate and solve the problem technically than readily agreeing to the common ‘Nuisance Tripping’ tactic followed by many.
• Check if the right sensitivity RCCBs are installed.
• UPS loads, HF circuits, DC circuits, etc. requires special type (Super immunized) RCCBs.
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Process Changes (for Hazardous plants)
• Take a few old Plant Change Control Procedure (PCCP) / Management of Change (MoC) procedures from the technical services file and check if the relevant drawings are updated. Mostly you will most of the P&IDs are not updated. Check a few modifications!!
• See if review of Hazardous Area Classification (HAC) is part of PCCP / MoC. 90% of the cases, you will not find HAC review in PCCP /MoC.
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Process Control Room
• Select 2/3 ESD (Emergency Shut Down) /trip loops and visit the field instruments associated. You could find some serious flaws (bypassing, maintenance issues, fail safe valve positions, associated gauge readings)
• Check the trip & alarm bypass register in the control room. Possibly many will be bypassed for long duration and there would not be any record/control.
• Check if the P&IDs are updated to reflect the recent 3 to 4 process modifications
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Pressure Vessels• Check a few PRVs
physically to ensure that they the isolation valves installed below are in line and are not closed
• Do a sample check with the pressure vessel list available to see if any new pressure vessels are left out
• An isolation valve upstream PRV will help to isolate while doing PRV maintenance jobs
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Re-Order Level (ROL) for Personal Protective Equipment (PPE)
• Check the ROL (defined minimum inventory level) in stores for critical / special PPE in stores, such as:
• Gas masks / cartridges• Chemical splash-proof goggles
Note:
ROL is to be defined on consumption levels and potential requirement. ROL needs periodic review to avoid high inventory levels.
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Electrical Protection Relays
• Check for red flags in relays that indicates that the relay has operated. Find out the reason!
• See if the triple protection relays (common CDG relays from English Electric make) and check if the over current settings are the same (R & B phases will have over current protection)
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Transformers
• Check if the winding and oil temperatures are set uniform for all transformers
• See if the bucholtz relay valves are in open condition
• Check for moisture content test reports for transformers that are located near cooling water plant areas / where moisture is present in atmosphere
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Toxic Release and Wind Sock
• Fluorescent and illuminated wind socks (at strategic locations) helps in night time evacuations
• Check if wind socks are installed in areas where there is possibility of toxic release
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Electrical Testing & Measuring Instruments
• Some big plants calibrate the protection relays with a secondary current injection kit, available internally. See if this master relay is calibrated by a reputed external test agency
• Check if the insulation resistance and earth resistance testers are duly calibrated
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First Aid
• Analyze FA box consumption patterns to reveal issues in certain process units, such as:
• Unit A –more head aches• Unit B –slip & fall cases
The FA consumption analysis could help you to identify occupational health issues in some plant areas!
• Do not keep medicines in FA boxes. The plant doctor may be consulted.
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Electrical Test Lamps
• Ask electricians if they use test lamps and if yes, check test lamps used by them. Recommend use of double test lamps in series instead of single lamp.
• Single test lamps will explode if tested on 440 volt circuits injuring electricians
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Hazardous Area Zone 1 pockets
• Check if Ex e ( Increased Safety) equipment are installed in zone 1 areas
Notes:• Hazardous Areas need to be classified if flammable chemicals
are having a flash point less than 65 degree C
• Zone 1 area: Area where flammable vapour / gases can exist in normal operating conditions
• IS 5572 allows only Ex d or Ex d e type equipment in zone 1 areas
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Temperature Classification for hazardous areas
• Check Ex d (flame proof) equipment name plates to see if T-classification aspect is taken care in equipment selection based on the chemical
Note:
Maximum surface temperature of electrical equipment should not be more than the Auto Ignition Temperature (AIT) of the chemicals that are handled / stored where the equipment are located
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Surge & Lightning Protection
• Direct lightning protection (Franklin rods, horizontal air terminations) will not protect electronic equipment (UPS, TV, Communication equipment, field instruments, EPBAX, weigh bridges) from surges and transients.
• Surge protection devices are to be additionally installed
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Emergency Management Plan (EMP)
• Check if all the telephone numbers are updated
• See if the new / modified hazards (new chemical storage tanks / toxic gas) are considered in the EMP
• Electrical sub station / cable cellar fires are considered as emergency scenarios in EMP?
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Rear Electrical panel side identification
• Both front & rear sides (if they can be opened) of electrical panels require to be identified.
• Accidents have occurred where electricians isolated one feeder in the front and opened the wrong live panel on the rear side, resulting in fatal accident!
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Orientation of Pressure Relief Valve pipe ends /vents
• Check out if the orientation of PRV vents is away from walk ways / platforms, etc.
• This becomes crucial when PRVs are connected to process vessels that contain toxic gases
• Also look for isolated PRVs!! Look for PRV handle positions.
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Chemical compatibility
• Check storage/handling/mixing of chemicals based on their compatibility
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Welding
• Gas tests to be done in hazardous areas at:
• Location where welding machine is kept• Location where welding is done
• Welding machine to have both lead and return cables having same length
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Work Permits
• Doing audit, look out for a pump / motor /panel under repair and if you find one, check for:
• Valid work permit• If power is positively isolated or not (lock out,
tagged out) at the feeder
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AFFF Fire Fighting Foam
• Quality of AFFF to be tested periodically as per manufacturers guidelines/ NFPA 11(once in a year recommended)
• Foam stock to be reviewed based on OISD 116
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OH Medical Centre Records
• Analyze the OH centre records to identify trends that will help you to identify:– OH illness in some plant areas– Injury cause categorization– Certain months in an year where accidents
are more– Certain shifts and time where more injuries
are recorded
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Accident Reports
• Analyze accident reports for a minimum period of 2 years to categorize and identify trends
• Check a few reports to verify if root cause has been identified and acted upon
• Check the training sessions to check if the accidents are discussed for the benefit of other employees
• Check if accidents of the similar nature repeats! An obvious indication that management is not bothered of accident prevention
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Lightning Protection 1
• Installing a vertical air terminal at the top most point in a plant may or may not protect the plant
• This ‘notional volumetric cone of protection’ defined by standards and the actual lightning strike cases do not match
• Install horizontal air terminals atop all buildings that you want to protect
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Lightning protection 2
• Earth all metal structures, vessels, tanks to dissipate lightning discharge
• Number of down conductors and its routing are important in the lightning protection design
• Test Links installed on every down conductor helps in effective maintenance
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Fire Hydrant System 1• Check if the jockey pump is in manual / auto
mode. Jockey pump has to be in auto mode• If jockey pump is in manual mode, then there is
possibly a un-identified persistent leak (which is possibly underground)
• Ensure adequate diesel stock for the engine driven fire pump
• An emergency light should be available in Fire pump room
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Fire Hydrant System 2
• It is a good practice to paint the feeder that feeds fire water pump motor red with the caution, ‘DO NOT SWITCH OFF’
• Install smoke detectors in fire water pump house
• Use infra red hotspot detector (while the fire pump motor is running / when under trial) on the cable terminations to identify hotspots
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Smoke Detectors
• Maintain a clearance of 1 meter between smoke detector and A/C air outlet (smoke will be blown away by the air which could result in delayed smoke detection)
• Check the Fire Alarm (FA) panel for healthy condition
• Check for redundant power supply for FA panel• If FA panel has a stand-by battery, check its
healthiness by switching off the main power
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HAZOP Recommendations
• Check the HAZOP worksheet to see if the causes are addressed by way of additional safeguards and not only the consequences
• Ensure that nodes are selected so that no part of pipeline / equipment are missed out
• Node selection should be carried out to make the HAZOP process less complex
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Critical Process Instrumentation
• Are the critical instruments identified based on ESD loops, etc.?
• Check if sufficient spares are available for all critical instruments
• While carrying out field visit, physically check some critical field instruments to ensure that they are in circuit and not bypassed!
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Safety Training• Check if the safety training sessions are
relevant to the plant hazards and past accidents?
• Check the training efficacy by interacting with training participants
• Is participant feedback acted upon?• Are past accidents included in training
programmes?• Competency of faculty satisfactory?
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P.G. Sreejith
Thanks!!Be on the look out for Part 2
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