Skc5173 Week 7 Safety Audit

8/13/2019 Skc5173 Week 7 Safety Audit

1/25

Prepared by

Associate Prof. Dr. Mohamad Wijayanuddin Ali

Chemical Engineering Department

Universiti Teknologi Malaysia


2/25

What is Safety Audits?

Safety audit is a systematic approach of reviewing or making a critical

examination of safety program at a particular company to make sure a high

standard of safety is maintained according to all legislation and regulations.

Types of Safety Audits

Process Safety Management System Audit - review to make sure thatsystems are in place to manage risk.

Process Safety Audits - to assure that operating facilities have been

designed, constructed, operated and maintained such that safety and

health are being protected.

Compliance Review- to confirm that facilitysoperations comply with laws

and regulations as well as company policies, procedures and practices.


3/25

Objectives of Safety Audits

The overall audit is designed at affecting improvement and

change.

The aims are to develop or maintain the policy, the organization

and system.

This is often achieved by incorporating performance standards.

One such standard might be the number of lost -time injuries in

which case related indicators are identified and set.


4/25

Performance indicators are factors which enables the early identification ofdegrading elements in safety performance.

They are usually derived from critical plant operating parameters which

affect health , safety and the environment.

Performance indicators can be derived from variously levels of anoperating system for example:

Component level

Safety function level

Plant level

Management level

Performance Indicators


5/25

There are in general two types of performance indicators :

1) direct indicators

2) indirect indicators.

Direct indicators are measures of safety outcomes:

incident/accident rates

lost-time injuries

releases and losses during operation



6/25

Indirect indicators are defined as specific measurements of theperformance of the various safety program elements and this includes

organizational and management processes such as accountability and

responsibility .

Some example of specific indicators that reflect safety managementaccountability and responsibility may include :

a policy statement

management commitment

requirements for procedures

individual performance measurement



7/25

Other examples of performance indicators which may be monitoredinclude:

the economic viability of the plant and its various production

zone

the availability for production of plant

the frequency and mean duration of unavailability of plant

the number and frequency of operating incidents

the staff turnover per category

a record of new technological evolution



8/25

One of the most widely used performance indicators is a review of

operating incidents .

This involves investigating the company's incidents file to identify :

incidents considered most significant for safety and availability

even sequences that contributed to development of these

malfunctions

direct and indirect causes

repeated incidents for a particular installation with a giventeam or material

lessons drawn by the operators and/or the logistics services



9/25

An audit can be based either on a checklist/action list or on a point

system .

The checklist method usually consist of a list of actions or

recommendations which need to be met and the list may be graded

in terms of priorities .

The point systems is applied to award a certain score to each of the

element assessed.

The main advantages of the point system is the ease at which

improvement can be measured.

However , wrong emphasis tends to be placed obtaining a good

score and hence critical areas may be overlooked.

Audit Framework


10/25

Technical safety audits usually seek out particulars hazard at a specific

time relating to the equipment or process which could lead to correction

of that hazard without addressing the underlying reason why that

hazardous condition existed .

Safety management system audits ensure the management system are

in place to preclude the creation of hazards and hence the detection of

breakdown in the system could lead to the prevention of that particular

hazard in the future

Audit Framework


11/25

Safety Audit Methods

1) British Safety Council 5 Star Scheme (1987, United Kingdom)

Currently lists 72 minimum standards under 5 program elements :

Premises and housekeeping

Electrical, mechanical and personal safeguarding

Fire protection and prevention

Accident recording and investigation

Safety organization

Scores on a sliding scale.

Points scored are then expressed as a percentage of points available

and "stars" are awarded accordingly.

A written report is also provided by the auditor and all findings and

recommendations are documented.


12/25


2) CHASE System

- Available in print-based manual and also as software for IBM-PC

compatible machine

- latest version has 400 questions in 12 sectionsManagement of Legal Require

Management of Tools, Equipment, Fixtures and Fittings

Management of Machinery and Plant

Management of Chemicals and Substances

Management of Vehicles


13/25

2) CHASE System

Management of Energy

Management of Health

Management of Tasks

Management of People

Management of Feedback for Health and Safety

Management of Change

Management of Emergencies

Each question requiring a "yes "/ "no" answer and score accordingly.



14/25

3) COURSAFE

- Available in computer software

- Has 729 questions divided into 9 sections

- Based on yes, no and not applicable questions

- Results can be produced as scores, percentages or graphs

- Rely heavily on the person doing the assessment



15/25

3) COURSAFE - the nine sections are :

Policy and objective

Systems, plants and vehicles

Chemicals and substances

Energy useRecording and auditing

Health and welfare

Contractors and third parties

Managing fire protection

Supervisors and training



16/25

4) International Safety rating System (ISRS)

- list 580 questions from 20 elements :

Leadership and administration

Health control

Program evaluation system

Engineering controls

Personal communications

Emergency preparednessOrganizational rules

Accident/incident analysis


A points system is used to

evaluate each safety

element and from this an

International Star Rating is

ascribed


17/25

4) ISRS 20 elements (continued)

General promotion

Group meetingPersonal protective equipment

Management training

Planned inspections

Task analysis and procedures

Accident/incident investigation

Task observation

Employee training

Hiring & placement

Purchasing controls

Off-job safety



18/25

5) MANAGER

- Used by Technica Ltd and has 4 main areas

System norms - standards, procedures

Pressures - monotony and stress, responsibility, confidence anduncertainty, design support

Resources - manning, skills level, equipment and

man/machines interface, communication channel etc and their

reliabilityCommunication - information flow between people, written

documentation



19/25

5) MANAGER

The main objective of MANAGER is to meet the need for reviewing management

controls and the effect they have on the frequency of occurrence of a hazardous

event.

The structure of the questionnaire employed is strongly influenced by the concept

of Performance Shaping Factors which are defined as influences which arepresent in the design, operation and human interactions in complex technological

systems.

The response to the questions would be graded as being average, better than

average or worse than average.

The method of quantification is based on supplying multiplication factors between

0.1 and 100, where 1 is the generic or "average" plant.



20/25

DU PONT Safety System

Du Pont is acknowledge in safety performance by the chemical

industry

Their plants all over the world have excellent record

Their management system was based on their company Ten

Principles of Safety

Their management system, Safety Training Observation Program

(STOP) based on premise that major improvement in safety can

result from eliminating unsafe acts



21/25

DU Pont 10 Principles of SafetyAll injuries and occupational illness can be prevented

Management is directly responsible and accountable for preventing

injuries and illness

Working safely is a condition of employment

Training is an essential element for safe workplaces

Safety audits must be conducted



22/25

DU Pont 10 Principles of Safety

All deficiencies must be corrected promptly

It is essential to investigate all unsafe practices and incidents withinjury potential, as well as all injuries

Safety off the job is as important as safety on the job

It is good business to prevent illness and injuries

People are the most critical element in the success of a safety

and health program



23/25

An effective emergency plan should be one which at the leastincorporates the following:

Site's evacuation procedures

Assignment of responsibilities of specific individualsEstablishment of means of emergency communication

Designation of an emergency control center which is

fully equipped

Emergency Response Management


24/25

Typical documentation for emergency response planning required

during safety audit :Facility description, including organization and staffing

Emergency response plans

Plot plans

Facility or company policy regarding emergencyresponse planning

Description of emergency systems and equipment

Emergency organization plan

Description of process hazards

Description of external resources and supportorganizations

Regulations applicable to the facility

Emergency Response Management


25/25

The benefits of a safety audit may be summarized as follow:

enables management to evaluate the effectiveness of its

safety program.

it shows management what area are deficient and require

corrective action.

as a monitoring tool if it is administrated at regular-scheduledintervals because it will indicate relative increase or decrease in

effectiveness of the areas that are being measured

a continuing safety audit program will serve to maintain

employee safety consciousness at a high level if corrective actions are undertaken as needed will convince

employees that management a serious about implementing

safety program.

Benefits of Safety Audits

Documents

Skc5173 Week 7 Safety Audit