do it yourself audit

8/14/2019 Do It Yourself Audit

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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

do it yourself audit

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