safety management

Code of Pract ice on Safe ty Management Sys tem for the Chemical Industry

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CODE OF PRACTICE ONSAFETY MANAGEMENT SYSTEM FOR THECHEMICAL INDUSTRY

Developed jointly by the Oil and Petrochemical Industry Technical & Safety Committeeand the Occupational Safety Department, Ministry of Manpower

Published in January 2001


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This Code of Practice on Safety Management System for the Oil, Petrochemical and Chemical Industrieshas been developed by a Working Group which comprised representatives from the Oil andPetrochemical Industry Technical and Safety Committee (OPITSC) and the Occupational SafetyDepartment, Ministry of Manpower.

The Working Group involved in the preparation of this Code comprised the following members:

Name Organisation

Chairman : Mr Chan Yew Kwong Occupational Safety Department (MOM)

Members : Mr Ismadi Mohamed Occupational Safety Department (MOM)Mr Koh Bok Thong Occupational Safety Department (MOM)Mr Kader Mydin Occupational Safety Department (MOM)

Mr Wang Hui Hua Chairman, OPITSC(Petrochemical Corporation of Singapore)

Mr Richard Tan Chevron OroniteMr Au Foo Yien Du Pont SingaporeMr Pachaimuthu Sankaran Du Pont SingaporeMr John Tai ExxonMobil SingaporeMr David Ong ExxonMobil SingaporeMr Ho Yuen Chuan ExxonMobil SingaporeMr Albert Lim Shell Eastern PetroleumMr Leng Ng Tai Shell Eastern PetroleumMs Cissie Yeung Singapore Chemical Industry Council

(Ciba Specialty Chemicals Singapore)Ms Lam Kit Wing Singapore Chemical Industry Council

(ISK Singapore)Mr Eric Tang Tong Hai Singapore Refining CompanyMr Michael Yan Vopak Terminal Singapore


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Contents

PageForeword

SPECIFICATION

A Scope ________________________________________________________________________5

B Definitions _____________________________________________________________________5

1 Element 1 – Safety Policy ________________________________________________________8

2 Element 2 – Safe Work Practices __________________________________________________9

3 Element 3 – Safety Training______________________________________________________10

4 Element 4 – Group Meetings ____________________________________________________12

5 Element 5 – Incident Investigation and Analysis _____________________________________14

6 Element 6 – In House Safety Rules and Regulations__________________________________15

7 Element 7 – Safety Promotion____________________________________________________16

8 Element 8 – Contractors Evaluation, Selection and Control ____________________________18

9 Element 9 – Safety Inspection____________________________________________________20

10 Element 10 – Maintenance Regime _______________________________________________22

11 Element 11 – Hazard Analysis ___________________________________________________24

12 Element 12 – Control of Movement and Use of Hazardous Chemicals ____________________26

13 Element 13 – Occupational Health Programs________________________________________28

14 Element 14 – Emergency Preparedness ___________________________________________30

15 Documentation Control and Records_______________________________________________32

APPENDICES

A List of Safe Work Practices ______________________________________________________33B List of Safety Training Requirements_______________________________________________34C List of In-House Safety Rules and Regulations_______________________________________35D List of Maintenance Regimes ____________________________________________________36


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Foreword

This Code of Practice has been developed by a Working Group which comprised representatives fromthe Oil & Petrochemical Industry Technical and Safety Committee and the Occupational SafetyDepartment, Ministry of Manpower.

Under section 71B of the Factories (Amendment) Act 1999, the Minister may require the occupier of acertain class or description of factories to implement a Safety Management System for the purpose ofensuring the safety, and protecting the health and welfare of persons employed in the factory. Theoccupier shall appoint such number of approved auditors to audit the Safety Management System asrequired and to implement, as far as is practicable, the recommendations of the approved auditor withoutundue delay.

This Code represents a standard of good practice and has been prepared with the objective offormulating the discipline to which these procedures should conform. It stipulates requirements for the14 elements of the Safety Management System as specified in the Thirteenth Schedule of the Factories(Amendment) Act 1999.

It is generally intended for personnel in the Oil, Petrochemical and Chemical industry, especially thoseinvolved in the preparation, supervision and execution of processes in major hazardous installations andplants. This Code is also recommended for use by the other manufacturing and general industries asappropriate. It forms a basis for audit and review of the Safety Management System.

This Code recommends compliance with the Factories Act and its subsidiary legislations, as well as withother regulatory requirements, internationally accepted codes and standards and best practices.


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A Scope

This Code of Practice sets down the basic expectations and requirements of the Safety Management System implemented in afactory in the Oil, Petrochemical & Chemical Industries for the purpose of ensuring the safety and protecting the health of allpersonnel and workers working in the factory.

B Definitions

For the purpose of this Code, the following definitions shall apply

B1 Use of Language

Shall - means a mandatory requirementShould - means a preferred method of actionMay - means a possible method of action

B2 Contractor

Any company undertaking contract works or providing services of any kind for the factory and shall include all the sub-contractorcompanies engaged by the main contractor.

B3 Elements

A grouping of expectations into a key safety management system focus area such as Safety Policy, Safety Training, EmergencyPreparedness etc.

B4 Factory

The expression “factory” in this Code covers all premises engaged in the processing or manufacturing of petroleum, petroleumproducts, petrochemicals, petrochemical products and other hazardous chemicals where workers are employed for the purposeof trade or for gain.

B5 Hazard Analysis

A thorough, organised and systematic approach used to identify, evaluate and control hazards by the application of one or moreinternationally recognised techniques/methodologies. Checklists, “What-if” Checklists, Failure Mode and Effect Analysis (FMEA),Fault Tree Analysis, and Hazops are examples of accepted hazard analysis techniques.

B6 Hazardous Chemicals/Substances

Substances and chemicals used, handled or stored in a factory, which are toxic, corrosive or flammable.


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B7 HAZOP

Hazard and Operability Study - A formal procedure or technique of systematically investigating each element of a system for allpotential deviations from design conditions. Deviations are critically analysed for effects of potential problems and the consequencesof failure reviewed, and safeguards assessed for adequacy.

B8 Lockout/Tagout System

A system designed to help safeguard employees from unexpected start-up of machinery or equipment or the release ofhazardous energy during servicing or maintenance work.

B9 Management of Change

A procedure that records, schedules, addresses and monitors hazards that may be introduced by any change to the design,operation or maintenance of plant machinery and equipment in accordance with internationally recognised standards such as API750 or OSHA 1910.

B10 Management Systems

The human and technical factors including materials, processes, planning activities, procedures and responsibilities that arenecessary to achieve and maintain the requirements of this Standard.

B11 Material Safety Data Sheet (MSDS)

Information label or leaflet to be provided by the supplier or manufacturer of any toxic, corrosive or flammable substance whichshall provide accurate and adequate description of the identity, physical and chemical properties of the substance, safety and healthhazard information, precautions to be taken and safe handling information.

B12 Occupier

In relation to a factory, a person who occupies or uses a premises as a factory.

B13 Personal Protective Equipment (PPE)

Personal protective clothing and appliance to be provided and maintained for all persons employed in any process involvingexposure to hazardous conditions and substances. The specific aspects of PPE to be addressed include System Requirements,Eye and Face protection, Respiratory protection, Head protection, Foot protection, Electrical protective equipment, Ear protectionand Hand protection.

B14 Pre-Startup Safety Review (PSSR)

A pre-startup safety review is normally carried out before any new process facility or modified facility – when the modification issignificant enough to require a change in the process safety information – can be brought on line.


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B15 Procedure

A written description of how a specific task should be accomplished.

B16 Risk Assessment

Risk assessment includes scenario identification and consequence analysis. Scenario identification describes how an accidentoccurs. It frequently includes an analysis of the probabilities. Consequence analysis describes the damage expected and includesloss of life, damage to the environment or capital equipment and days outage.

B17 Safety Audit

Under section 71B of the Factories (Amendment) Act 1999, the occupier of a certain class or description of factories shall appointsuch number of approved auditors to audit the safety management system at such time and in such manner as the Chief Inspectormay require, and to implement the recommendations of the approved auditor without undue delay as far as is practicable.

B18 Safety Committee

The occupier of a factory, in which 50 or more persons are for the time being employed, shall establish a safety committee onwhich both employees and management are represented for the purpose of keeping under review circumstances in the factorywhich affect or may affect the safety or health of the persons employed in the factory.

B19 Safety Management System

Under section 71B of the Factories (Amendment) Act 1999, the Minister may, by Order, require the occupier such class ordescription of factories to implement a safety management system for the purpose of ensuring the safety and protecting the healthand welfare of persons employed in the factory.

B20 Safety Review

Normally refers to internal audits performed in supplementary to safety audits.


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CODE OF PRACTICE ON SAFETY MANAGEMENT SYSTEMCODE OF PRACTICE ON SAFETY MANAGEMENT SYSTEMFOR THE CHEMICAL INDUSTRYFOR THE CHEMICAL INDUSTRY

ELEMENT 1: SAFETY POLICY

Objective

To establish and maintain a written safety policy, which spells out management’s commitment towardssafety and the principles that govern safety and health decisions in the factory. Senior management shallensure that the safety policy is communicated to all employees and relevant contractors and shallestablish a Culture that safety and health are valued as basic and fundamental prerequisites for thebusiness of the factory.

System Requirements

1.1 An effective Safety Policy shall demonstrate the management commitment towards safety andhealth improvement, its objectives and directions, including goal setting. The Safety Policy shallincorporate and address the following:

1.1.1 Emphasis on the importance to protect the safety and health and the general well beingof every personnel working in the factory.

1.1.2 Accountability for the safety and health function by top management.

1.1.3 Allocation and delegation of duty and responsibility for safety and health from the topmanagement to the line staff.

1.1.4 Responsibility at all levels in preventing incidents.

1.1.5 Commitment of sufficient resources towards the achievement of safety and health goalsand objectives.

1.2 The Safety Policy shall be signed by the most senior management staff of the factory.

1.3 The Safety Policy shall be effectively communicated to all employees and contractors in thefactory.

1.4 The Safety Policy should be reviewed at defined intervals and updated to ensure relevancy andcontinuous improvement.


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ELEMENT 2: SAFE WORK PRACTICESELEMENT 2: SAFE WORK PRACTICES

Objective

To establish a system to ensure that safe work practices are carried out in the factory through proceduraland administrative control of work, critical operating steps and parameters, pre-startup safety reviews fornew and modified plant equipment and facilities, and management of change of plant equipment andprocess.

System Requirements

2.1 Every factory shall establish and implement safe work practices for its main operation or process,which may include, but not limited to the list as specified in Appendix A. Safe work practicesmust be developed and implemented for the work operations or processes as specified in theTwelfth Schedule of the Factories Act.

2.2 The safe work practices should be established after a risk assessment of the work operation orprocess has been conducted, including hazard identification and risk analysis of the risksassociated with the operation or process.

2.3 The safe work practices shall be clearly written and communicated to all relevant employees andcontractors. The safe work practices shall be made readily available to all employees andcontractors.

2.4 Safe work practices, where appropriate, should include a Lockout/ Tagout system for the effectiveisolation of the energy sources associated with the plant or equipment that is being worked on,including, but not limited to, hydraulic, electrical, pneumatic as well as mechanical isolation ofpipelines and equipment.

2.5 Depending on the complexity of the factory’s operation, a permit to work system should beincorporated into the safe work practices to ensure that all precautionary measures are takenbefore the commencement of work.

2.6 The factory should maintain operating procedures for each process. These operating proceduresshould provide clear understanding of detail operating parameters and limits for safe operationfor those who are operating the process. The formulation of operating procedures should beginfrom design stage and should be reviewed to update changes made in the process. Operatingprocedures should provide the foundation for operator training and should reflect process safetyinformation.


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2.7 The factory should establish and implement a Pre-Start-up Safety Review policy/procedure fornew equipment, facility or installation to confirm that all process safety elements of this Code areaddressed and that their areas of concern are all rectified before the initial commissioning of thenew equipment, facility or installation. The Pre-Start-up Safety Review policy/procedure shouldalso apply to new factory or process or factory/process, which has major modification.

2.8 The factory should establish and implement a Management of Change policy/procedure toaddress all hazards/concerns that may be introduced by any “Change” of hardware, proceduresor chemicals of the factory’s process/facility. The policy/procedure should institute a systematicevaluation of the possible hazards or concerns arising from the “Change” and ensure that theappropriate measures are in place before approving the “Change”.

2.9 Periodic review of all safe work practices shall be carried out to evaluate their relevance andadequacy. Lessons learned from incidents shall, where applicable, be taken into considerationin the review.


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ELEMENT 3: SAFETY TRAININGELEMENT 3: SAFETY TRAINING

Objective

To equip employees and contractors at all levels with the knowledge, skills and attitudes relating to theoperation or maintenance of facilities so as to work in a safe and reliable manner.

System Requirements

3.1 An effective training program shall be established to train employees at all levels. A schemeshall be devised to identify the safety and health training needs for each level of employees andcontractors.

3.2 Safety Instruction Courses, and other mandatory safety-training courses, shall be provided to allrelevant employees. Such courses shall cover the relevant safe work practices established inthe factory, hazard identification in work areas and response to emergency situations.

3.3 All supervisors and workers shall be trained to a competent level expected of their tasks. Whereappropriate, workers shall be certified in their skills such as for welding, handling of chemicalsand gas testing.

3.4 All supervisory staff shall be thoroughly trained in the methods and skills required to perform theirtasks, such as the proper operation of instruments, tools and equipment, reading andunderstanding of the documentation provided and their respective role in accident preventionat the workplace.

3.5 Training shall be provided to all relevant management staff so that they are equipped with theproper understanding of the safety management system and their responsibilities and duties insafety and health in the factory. The training shall also provide them with the tools and techniquesneeded for managing safety and health effectively at the workplace.

3.6 Safety orientation or induction shall be conducted for all contractors. Such orientation or inductionprograms shall include an understanding of the factory's safety and health policy as well as allits rules and regulations.

3.7 The training programs may include but not limited to the list as specified in Appendix B.

3.8 The training programs shall be conducted in languages understood by the trainee.

3.9 The training programs shall be documented and periodically reviewed. The effectiveness of suchtraining shall be measured and reviewed based on feedback from the employees, supervisors,managers and the contractors.

3.10 The factory shall maintain a record of all the training received by each employee.


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ELEMENT 4: GROUP MEETINGSELEMENT 4: GROUP MEETINGS

Objective

To promote communication and co-operation between management, employees and contractors so asto ensure that issues are addressed and appropriate actions are taken in order to achieve and maintaina safe and healthful work environment.

System Requirements

4.1 The factory shall establish a Safety Committee for the purpose of improving, promoting andreviewing of all matters relating to the safety and health of employees. The Safety Committeealso acts as a channel for communicating and imparting knowledge and best practices on safetyand health to all personnel.

4.2 The Safety Committee shall have a clearly defined charter with prescribed functions andresponsibilities. The composition, functions and duties of the Safety Committee shall be inaccordance with the Factories Act and the Factories (Safety Committees) Regulations.

4.3 The Safety Committee shall be effectively led by the senior management of the factory. TheSafety Committee shall be given the necessary support and resources so as to achieve theCommittee’s safety and health objectives.

4.4 The factory should also establish other group meetings, which may include but not limited to thefollowing:

4.4.1 Tool Box Meetings

4.4.1.1 Tool Box Meetings involving supervisors and workers should be held regularlysuch as before the commencement of work to provide opportunity for operatorsand workers to discuss safety and health issues in relation to their work.

4.4.1.2 During the meeting, the supervisor should review the work to be carried out tohighlight the potential hazards and necessary safety precaution to be taken,such as issues pertaining to the use of Personal Protective Equipment.

4.4.2 Safety Improvement Teams

The factory should set-up group based Safety Improvement Teams to work throughsafety and health related projects for the purposes of improving the physical work


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environment and to reduce unsafe human behaviours in the factory.

4.5 The management shall ensure that the personnel participating in the above meetings are:

4.5.1 competent for their tasks;4.5.2 in full understanding of their roles and functions;4.5.3 committed to the improvement of safety and health in the workplace. It is important that

all workers are inculcated with positive attitudes towards safety and health promotionalactivities, and

4.5.4 given the necessary support so that they can effectively perform their duties.

4.6 The factory shall establish a mechanism whereby the decisions and actions proposed by thevarious groups are effectively communicated to persons responsible for their implementation.The mechanism shall also ensure that all outstanding actions are effectively followed through andimplemented.


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ELEMENT 5: INCIDENT INVESTIGATION AND ANALYSISELEMENT 5: INCIDENT INVESTIGATION AND ANALYSIS

Objective

To establish procedures for incident reporting and investigation so as to identify root causes of incidentsand to implement effective corrective measures or systems to prevent recurrence.

System Requirements

5.1 The factory shall establish written procedures to ensure that all incidents (accidents and nearmisses) are reported and recorded promptly. A mechanism shall be set up to report incidentsby all personnel including contractors.

5.2 The factory shall establish written procedures for the investigation into incidents. The proceduresshould include the criteria for the type and degree of seriousness of incidents to be formallyinvestigated. All incidents investigated shall determine the root causes, circumstances and otherindirect contributing factors leading to the incidents.

5.3 Line managers, supervisors, safety personnel and safety committee members should beincluded in the investigation team. They shall be adequately trained and equipped with thenecessary knowledge and skills for their tasks.

5.4 A system shall be established to ensure that the findings and recommendations of theinvestigations are effectively and promptly followed through and implemented.

5.5 Procedures shall be established to ensure lessons learned from the incidents are proliferatedto all relevant personnel in the factory for information and awareness.

5.6 Analysis of all reported incidents and statistics should be carried out periodically to identify thetype, frequency, severity and root causes of incidents. Such information is useful for drawing upsafety and health strategic plans, promotional programs and training courses.


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ELEMENT 6: IN-HOUSE SAFETY RULES AND REGULATIONSELEMENT 6: IN-HOUSE SAFETY RULES AND REGULATIONS

Objective

To establish written safety rules and regulations for all personnel in the factory so as to inculcate acommon understanding of their safety and health obligations and responsibilities.

System Requirements

6.1 A set of basic safety rules and regulations shall be formulated in the factory to regulate safety andhealth behaviors at the workplace. The rules shall cover the main work operation or process inthe factory, which should include but not limited to the list as specified in Appendix C.

6.2 The safety rules and regulations shall be documented and effectively communicated to allemployees and contractors through promotion, training or other means. The rules shall be madereadily available to all employees and contractors.

6.3 The safety rules and regulations shall be effectively implemented and vigilantly enforced in thefactory. All employees and contractors shall comply with the rules and regulations at all times.

6.4 The safety rules and regulations shall be in conformance with the regulatory requirements. Rulesthat are non-statutory shall conform to international standards or best practices.

6.5 The factory shall establish and implement disciplinary or corrective procedures for failure toobserve any of the rules.

6.6 The factory shall establish procedures to periodically review the safety rules and regulations toensure its relevance and effectiveness. Records of such review shall be maintained.


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ELEMENT 7: SAFETY PROMOTIONELEMENT 7: SAFETY PROMOTION

Objective

To raise and maintain safety and health awareness among all employees and contractors and todemonstrate the management’s commitment towards safety and health excellence in the factory.

System Requirements

7.1 The factory shall develop and conduct promotional programs to demonstrate clearly themanagement’s commitment and leadership in promoting good safety and health behaviors andpractices in the factory.

7.2 Safety and health promotional activities should be organised regularly and should include butnot limited to the following: -

7.2.1 Display of the corporate safety policy and commitment at strategic locations in thefactory's premises;

7.2.2 Conduct of structured or thematic safety campaigns with active employees andcontractors participation;

7.2.3 Display of incident statistics and safety performance charts;

7.2.4 Conduct of topical safety talks;

7.2.5 Screening of safety videos;

7.2.6 Formation of safety improvement teams;

7.2.7 Display of signs, posters or other visual material to increase safety awareness or tohighlight a particular safety issue;

7.2.8 Issuance of safety handbooks or brochures to both employees and contractors toincrease safety awareness, as part of personal safety training; and

7.2.9 Conduct of first-aid and emergency response exercises and drills.

7.3 The factory should encourage all contractors to be actively involved in the safety promotionalactivities.


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7.4 All personnel, including contractors should be encouraged to make positive suggestions toimprove safety at the workplace. The factory may set up a safety suggestion scheme toencourage employees' participation.

7.5 The factory should establish an incentive program to encourage group safety effort. Ameasurable standard should be developed to assess the group safety performance. Rewards,commendations and appropriate recognition for outstanding group safety performance shall bepresented to the deserving recipients by a top management staff.


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ELEMENT 8: CONTRACTOR EVALUATION, SELECTIONELEMENT 8: CONTRACTOR EVALUATION, SELECTIONAND CONTROLAND CONTROL

Objective

To establish a system to evaluate contractor’s safety performance as part of the selection and controlprocess so that only contractor who can meet the factory’s safety performance standards andrequirements are permitted to work in the factory.

System Requirements

8.1 The factory shall establish and document a system for assessment and evaluation of contractorsto ensure that only competent and qualified contractors are selected and permitted to carry outcontracted works in the factory.

8.2 The system for evaluation and selection of contractors shall consider basic safety performanceindicators such as contractor’s safety policy and safety management system, safety trackrecords, competency and qualification of contractor’s personnel, safety training records and safework procedures.

8.3 In pursuant to the system for evaluation and selection of contractors, the factory may incorporatea formal system for pre-approval of contractors for major and specialised work in the factory. Insuch a system, only pre-approved contractors are invited to tender for work in the factory. Newcontractors who are not in the pre-approved list will have to be subjected to the evaluation andselection process prior to inclusion in the pre-approved list.

8.4 Upon selection of the contractor, the factory should maintain a written contract with the saidcontractor in which the safety and health responsibilities and obligations of the contractor shouldbe clearly spelt out.

8.5 Prior to the commencement of work, the factory shall ensure that the contractor personnelworking in the factory are given the proper safety induction training. The induction training shallcover key areas such as procedures for the reporting of incidents and emergency situations andbasic in house rules and regulations.

8.6 The factory shall establish procedures to effectively monitor and control the safety performanceof the contractors working in the factory. The procedures shall ensure that the contractor’s safetyperformance is in conformance with internal standards and is within the limits as specified in thecontract.

8.7 The factory should maintain and record safety performance statistics for contractor companies


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working in the factory.

8.8 The factory shall document procedures for the inspection and checking of contractors' equipmentbefore they can be taken into use in the factory.

8.9 The factory shall establish procedures to ensure that contractors, whose safety performance isfound unacceptable, promptly and effectively carry out proper corrective action.

8.10 The factory should document a written disciplinary policy to demerit or penalise contractors ortheir workers for breaching the internal safety standards and rules and regulations.


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ELEMENT 9: SAFETY INSPECTIONELEMENT 9: SAFETY INSPECTION

Objective

To establish a system to verify compliance with the relevant regulatory requirements, in-house safetyrules and regulations and safe work practices.

System Requirements

9.1 The factory shall develop and implement a written program for formal and planned safetyinspections to be carried out in the factory. The program should include safety committeeinspection, routine safety inspection, plant and equipment inspection and other special orsurprise inspection.

9.2 The factory shall develop a list of protocol or checklist for identifying workplace hazards andclassifying the major findings. The protocol or checklist used for the safety inspections shall bedesigned such that it involves a thorough and systematic check of the factory's workplace,equipment, tools, materials and work practices.

9.3 The factory shall establish performance standards for the safety inspections. The standards shallspecify the following:

9.3.1 The competency of the safety inspector – appropriate training shall be provided topersonnel involved in the inspection;

9.3.2 The frequency of the safety inspection – shall commensurate with the factory’s businessoperations; and

9.3.3 The scope and coverage of the safety inspection.

9.4 The factory shall establish procedures to ensure that prompt corrective actions are taken toaddress or eliminate the unsafe conditions/hazards and substandard behaviors/acts found duringthe safety inspections. The procedures shall define the following:

9.4.1 The acceptable time frame for implementation of corrective actions,

9.4.2 The specific responsibilities of personnel involved in the implementation of the correctiveand follow-up action; and

9.4.3 The method of verification and monitoring of corrective actions carried out.


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9.5 The factory shall establish a feedback system to ensure that critical findings from safetyinspections are effectively communicated to relevant personnel for implementation of correctiveaction and for general awareness.

9.6 The factory shall establish an evaluation program to evaluate and check the safety inspectionsystem to verify its effectiveness and to ensure that standards are met.


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ELEMENT 10: MAINTENANCE REGIMESELEMENT 10: MAINTENANCE REGIMES

Objective

To establish a system to maintain at all times the integrity of all plant, machinery and equipment used inthe factory so as to prevent any failure of these equipment due to a lack of maintenance or repair, whichcan result in unsafe situations.

System Requirements

10.1 The factory shall establish a maintenance program to ensure that the mechanical integrity ofcritical plant equipment is maintained.

10.2 The maintenance program should include but not limited to the following:

10.2.1 Establishment of an appropriate inspection program to monitor the condition of theequipment and machinery on a continuos basis;

10.2.2 Establishment of a corrosion control program to maintain the integrity of critical equipmentand machinery and piping systems;

10.2.3 Development and documentation of work practices and maintenance procedures thatshall take into consideration the safety and health exposure of personnel to the workoperations and the associated risks to the environment during the carrying out ofmaintenance work. The work practices and maintenance procedures shall incorporatesafety precautionary measures such as Lockout/Tagout System and Permit-to-WorkSystems. Supplemental or special work procedures, which may include job safety orrisk analysis, shall be included when undertaking high-risk work activities;

10.2.4 Conduct of relevant training of personnel involved in the work practices and maintenanceprocedures;

10.2.5 Establishment of procedure or system to ensure that the material used in themaintenance of critical equipment continue to meet design specification, and anychanges in material shall be appropriately reviewed before use (such as considerationthrough a management of change review process); and

10.2.6 Development of a long-term maintenance plan for periodic maintenance of major andcritical equipment. The plan shall be reviewed annually to take into consideration theinspection findings, incident reports and regulatory requirements.


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10.3 The factory shall establish a control system to ensure that critical safety devices, which controlor monitor the safety of process equipment operation (such as safety alarms, control andshutdown equipment), are tested and maintained periodically.

10.4 The types of equipment, instruments or systems that may be considered as safety criticaldevices may include but not limited to the list as specified in Appendix D:

10.5 The control system may include but not limited to the list as specified in Appendix D:


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ELEMENT 11: HAZARD ANALYSISELEMENT 11: HAZARD ANALYSIS

Objective

To methodically identify, evaluate and control hazards in the processes of a factory. The process ofHazard Analysis shall be documented and shall include measures over a serious scenario that can occurin a factory and the necessary corrective or control measures that can be incorporated to mitigate thefrequency or severity of the risks associated with the scenario event.

System Requirements

11.1 The factory shall evaluate potential accidental scenarios of the processes in the factory premises.The evaluation plan shall include the following:

11.1.1 Analysis and consideration of a range of probable cases and selection of a worst casescenario that can cause the most harmful safety and health effect to the factory;

11.1.2 Assessment of the harmful effects that can be caused by the worst case scenario.Depending on the scenario, qualitative evaluation of the harmful effects can beconsidered when carried out by qualified on-site persons. Techniques such as gasdispersion and fire explosion modelling of vapour releases techniques may be appliedfor the evaluation;

11.1.3 Development and implementation of the measures to prevent the worst case scenariofrom occurring and/or mitigation of the potential effects and impacts; and

11.1.4 Documentation of the above, and approval by the most senior person in the factory.

11.2 The factory shall review each process to address hazards by recommending action to preventor/and mitigate the effect of the hazards. The review plan shall include the following:

11.2.1 Assignment of a multi-discipline team to perform the review and the application of oneor more internationally recognised methodologies such as Checklist, What if checklist,Hazop, Failure Mode & Effect Analysis (FMEA) and Fault Tree Analysis. Established in-house methodologies should also be considered;

11.2.2 Implementation of recommendations to address the significant hazards identified in thereview;

11.2.3 Establishment of a system to accomplish the recommendations with properdocumentation; and


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11.2.4 Conduct of fresh reviews for new process changes, projects of new facilities, lesson fromincidents and as and when the need arises.

11.3 The factory shall establish a program to schedule the respective plans as specified in 11.1 and11.2.

11.4 The factory shall communicate the recommendations of the respective plans as specified in 11.1and 11.2 to all persons involved in the process.


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ELEMENT 12: CONTROL OF MOVEMENT AND USE OFELEMENT 12: CONTROL OF MOVEMENT AND USE OFHAZARDOUS CHEMICALSHAZARDOUS CHEMICALS

Objective

To establish a system to identify and manage all hazardous chemicals in the factory through the provisionof Material Safety Data Sheets and procedures for proper use, storage, handling and movement of thehazardous chemicals.

System Requirements

12.1 The factory shall establish a control program for the management of hazardous chemicals. Theprogram shall include and incorporate the following:

12.1.1 The maintenance of a register of hazardous chemicals in use in the factory. Eachhazardous chemical shall be accompanied with the appropriate Material Safety DataSheet (MSDS) to facilitate the risk assessment process and training of employees onproper handling techniques and precautionary measures to observe during its use,handling and storage;

12.1.2 The establishment of procedures for proper receipt, storage, issue, distribution, handlingand safe use of the hazardous chemicals;

12.1.3 The appointment of competent persons who has adequate knowledge of the propertiesof the hazardous chemicals to administer the control of the chemicals; and

12.1.4 The prohibition of purchase or trial use of all hazardous chemicals until its chemical,physical and toxicological properties have been reviewed in a risk assessment todetermine whether the chemical can be used, handled and disposed without undue riskto employee’s safety and health or to the environment.

12.2 All storage tanks, vessels and containers used to store or contain the hazardous chemicals shallbe:

12.2.1 of good construction, sound material, adequate strength and free from patent defect andshall be properly maintained;

12.2.2 provided with proper labels on the external walls with information such as the name andproperties of the chemical contained therein and the hazards associated with thechemicals; and

12.2.3 subjected to periodic inspection of its structures, fittings and attachment to ensure its


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structural and mechanical integrity.

12.3 The total inventory of the hazardous chemicals stored in the factory at the process area or atother designated storage areas shall not be in excess of the capacity necessary for productionrequirements; and

12.4 The hazardous chemicals shall be stored in designated areas, which shall be suitable for thechemicals and secured against unauthorised access. The chemicals shall be returned to thedesignated areas when not in use.

12.5 Incompatible hazardous chemicals shall not be stored in the same storage areas. If this is notpracticable, they shall be stored in areas separated from one another by physical barriers suchas walls and floors or by other suitable means.

12.6 Adequate training shall be provided to all personnel and contractors who may be exposed tothe hazardous chemicals. Training shall also be provided to the related personnel whenever anew hazardous chemical is introduced into the process.

12.7 Warning notices in languages understood by the relevant persons specifying the danger of thehazardous chemicals shall be placed at all entrances to any workroom and at appropriatelocations where hazardous chemicals are used or stored.

12.8 Periodic exposure assessment on related personnel and contractors shall be carried out.Appropriate environmental monitoring shall be followed up based on the exposure assessmentresults. Suitable measures shall be implemented to prevent or minimise exposure based on theenvironmental monitoring results and the permissible exposure limits.

12.9 Regular medical surveillance for personnel and contractors exposed to the hazardous chemicalsshall be performed.

12.10 Establishment and implementation of procedures for disposal of hazardous chemicals shall becarried out in accordance with regulatory requirements or manufacturer’s recommendations.


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ELEMENT 13: OCCUPATIONAL HEALTH PROGRAMSELEMENT 13: OCCUPATIONAL HEALTH PROGRAMS

Objective

To identify, evaluate and control occupational health hazards to protect all personnel from developingoccupational diseases or illnesses arising from their exposure to specific occupational health hazardspresent in the work environment and to establish policies and programs to protect all workers fromspecific occupational health hazards.

System Requirements

13.1 The factory shall ensure that for every hazardous chemical used, produced or otherwiseencountered in the operations, there are available:

13.1.1 Information to identify and evaluate the related safety and health hazards. The factoryshall ensure that appropriate Material Safety Data Sheet (MSDS) is provided for eachchemical used;

13.1.2 Precautionary advice for the safe transport, storage, use and disposal of the hazardouschemicals;

13.1.3 Safe work procedures in relation to the hazardous chemicals;

13.1.4 Adequate training for employees and contractors so that they shall understand the natureof the hazards, safe handling procedures, personal protection and emergency actionsfor all hazardous chemicals that they are likely to encounter at the workplace; and

13.1.5 Expertise to conduct the necessary occupational health program.

13.2 The factory shall establish a Hearing Conservation Program, which shall include the following:

13.2.1 Regular monitoring of noise levels;

13.2.2 Reduction of noise levels through engineering and administrative control measures;

13.2.3 Selection, provision and maintenance of suitable hearing protectors and supervision oftheir usage;

13.2.4 Pre-employment and annual audiometric examinations of all exposed workers; and

13.2.5 Training and education of workers.


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13.3 The factory shall establish a Respiratory Protection Program, which shall include the following:

13.3.1 Regular monitoring of air contaminants;

13.3.2 Reduction of air contaminant levels through engineering and administrative controlmeasures;

13.3.3 Selection, provision and maintenance of suitable respirators and supervision of theirusage;

13.3.4 Training in the proper use of respirators and education on the health hazards; and

13.3.5 Ensuring that there is proper fit of respirators.


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ELEMENT 14: EMERGENCY PREPAREDNESSELEMENT 14: EMERGENCY PREPAREDNESS

Objective

To establish written emergency response plans to mitigate consequences arising from potentialemergency situations.

System Requirements

14.1 The factory shall establish procedures to:

14.1.1 Identify emergency situations and their impacts;

14.1.2 Implement emergency response plans for each level of the organisation, with clearscope, roles and responsibilities; and

14.1.3 Maintain an up-to-date emergency response plan

14.2 The emergency response plan shall be documented and effectively communicated.

14.3 The emergency response plan shall include the following:

14.3.1 Establishment of Emergency Team and their duties and responsibilities;

14.3.2 Appointment of Emergency Superintendent who shall command the emergencyprocedures in accordance with the requirements of the emergency response plan;

14.3.3 Procedure for notification and raising of alarms;

14.3.4 Procedure for initial response to emergency situations such as preliminary fire-fighting,first-aid and containment responses;

14.3.5 Procedure for evacuation and rescue;

14.3.6 Capability of in-house resources such as rescue and medical facilities; and

14.3.7 Capability of nearest government response agency, their roles and the response timeto the emergency situations


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14.4 The factory shall establish a program of drills and exercises to assess the preparedness of thefactory for prompt and effective response to emergency situations.

14.5 The factory shall establish effective first-aid programs to provide first-aid and emergencytreatment to victims of an accident. This would include provision of adequate first-aid facilities andtrained first-aiders.


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1515 DOCUMENTATION CONTROL AND RECORDSDOCUMENTATION CONTROL AND RECORDS

System Requirements

15.1 The general documentation requirements are given separately in each element. The factory shallestablish a central documentation control and record system to integrate these documentationrequirements and to ensure that they are complied with. As the system progresses, the quantityof documents and drawings increases and a foundation numbering and management system isessential for traceability of these documentation.

15.2 Documented procedures shall be prepared for operations and maintenance of process systemsand items of plant, machinery and equipment. These documentation procedures shall includethe various requirements of the work permit controls, pre-startup safety review and managementof change.

15.3 Each controlled document shall contain the following:

a) a unique identifierb) the date of issuec) the date of any revisiond) a revision numbere) a descriptive titlef) an authorising signature by a responsible person from the occupier

15.4 The occupier shall keep and maintain a master list of each controlled document and the personsor parties issued with such documents.

15.5 The controlled documents may be revised at any time. Revisions shall be authorised by theperson who certified the original documents.

15.6 Revised controlled documents shall be issued by the authorising person to those on the masterlist and all copies of the previous issues shall be declared superseded. One copy of thesuperseded document shall be retained by the authorising body.

15.7 The factory shall document and maintain all regulatory documentation requirements. Thedocuments shall conform to the conditions of the said requirement in content, format andauthorisation.


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APPENDIX AAPPENDIX A

ELEMENT 2 - SAFE WORK PRACTICESELEMENT 2 - SAFE WORK PRACTICES

A1 Every factory shall establish and maintain safe work practices for its activities, which may include,but not limited to the following:

a) Hot work;b) Work involving the use, handling and transportation of any hazardous, volatile, corrosive or

flammable chemical, material or solvent in significant quantities;c) Dismantling of any pipe or equipment that contains or has contained any flammable or toxic

substance;d) Entry or work in a confined space;e) Spray painting;f) Grit-blasting work;g) High pressure jetting;h) Hydrostatic or pneumatic pressure testing of pipelines and equipment;i) Functional testing of pipelines and valves (mechanical; electrical; pneumatic or hydraulic);j) Work at excessive heights;k) Erection and dismantling of scaffolds;l) Installation of equipment;m) Demolition of equipment;n) Radiography work;o) Hot tapping;p) Chemical cleaning;q) Electrical work;r) Explosive powered tools;s) Crane and lifting operation;t) Excavation; andu) Diving operation.


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APPENDIX BAPPENDIX B

ELEMENT 3 - SAFETY TRAININGELEMENT 3 - SAFETY TRAINING

B1 Every factory shall establish training programs, which may include, but not limited to the following:

a) Training for Safety Managers;b) Training for Safety Auditors;c) Training for Safety Officers;d) Training for Safety Coordinators;e) Training for Safety Committee members;f) Training for Safety Inspectors, in particular Hot Work Certification;g) Training for Competent Person for Hazardous Chemicals;h) Training for First-Aiders;i) Training for Noise Monitoring Officer;j) Training for Fire Watchmen or Attendant;k) Training for Crane Operators;l) Training for Lifting Supervisors;m) Training for Riggers;n) Training for Signalman;o) Training for Scaffolders;p) Training for Operators of Explosive Powered Tools;q) Training for Boiler Attendant;r) Training for Steam Engineers;s) Training for Contractors;t) Safety Orientation/Induction Training for new employees and Contractors;u) Refresher training of experienced workers to highlight the specific changes and issues;v) Training for Emergency Response Personnel; andw) Training on the requirements and the effective use of Personal Protective Equipment.


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APPENDIX CAPPENDIX C

ELEMENT 6 - IN HOUSE RULES & REGULATIONSELEMENT 6 - IN HOUSE RULES & REGULATIONS

C1 A set of basic in-house rules and regulations shall be developed to regulate safety at theworkplace. The rules may include; but not limited to the following:

a) Compliance with safe work practices and permit-to-work system;b) Injury reporting;c) Incident and hazard reporting;d) The safe use and handling of materials such as hazardous chemicals and substances;e) Use and maintenance of machinery, tools and equipment;f) Use and maintenance of electrical equipment;g) Use of personal protective equipment;h) Housekeeping and cleanliness;i) Fire prevention; andj) Prohibition of horseplay and misuse of equipment.


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APPENDIX DAPPENDIX D

ELEMENT 10 - MAINTENANCE REGIMEELEMENT 10 - MAINTENANCE REGIME

D1 The types of equipment, instruments or systems that may be considered as safety criticaldevices may include; but not limited to the following:

a) Pressure Relieving Devices such as Safety Valves;b) Vacuum Relieving Devices;c) Shutdown Systems – Automatic trips, cut-ins and cut-outs;d) High Priority Alarms;e) Compressor anti-surge systems;f) Pump low-flow recycle loop;g) Detectors and Alarms for accidental release of harmful and hazardous substances and fires; andh) Critical temperature, pressure and level cut-out devices.

D2 The control system may include; but not limited to the following:

a) Identification of the list of safety critical devices;b) Designation of responsibility and accountability for the approved list of safety critical devices;c) The frequency and scope of testing of the devices;d) Procedure for testing, acceptable limits and criteria for passing the test. The procedure may also

include criteria for special testing exemption by designated management;e) Relevant training of personnel involved in the testing and maintenance of the devices; andf) Documentation of test records which shall be reported to the responsible person for

acknowledgement and implementation of corrective action.

safety management

Documents

safety policy

safety training

safety promotion

safety inspection

safety committee opitsc

house safety rules

occupational safetydepartment

management sys tem