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Safety Audit of an Existing Ammonia Plant

IP.com Disclosure Number: IPCOM000218724D
Publication Date: 2012-Jun-06

Publishing Venue

The IP.com Prior Art Database

This text was extracted from a PDF file.
This is the abbreviated version, containing approximately 16% of the total text.

Page 01 of 14

,

THE SAFETY AUDIT OF AN OPERATING PLANT

Bill Brown and S. Madhavan The M.W. Kellogg Company

Houston, Texas, U.S.A.

Presentedat

The M.W. KelloggAmmonia Club Meeting Denver, Colorado

August 1988


Page 02 of 14

SAFETY AUDIT

TABLE OFCONTENTS

Page

Abstract


1. Introduction

1

It. Objectivesof the Audit

2

111. Audit Methodology

2


1. Audit of Systems and Procedures 3

3 3 3

5


a. Leadership and Administration


b. Emergency Planning


c. Hazard Control Procedures


d. RegulatoryCompliance


e. Education and Training


f.- Oeeupationat timtth


g. Protective Equipment


h. Incident Investigationand Reporting


i. Inspections


j. Communications and Meetings


2. Process Safety Audit


IV. S A F WReview of an OperatingAmmonia Plant

0


V. Conclusions and Recommendations

10

APPENDICES


1. Excerpt from Risk Control Performance Evaluation Score Sheet 11


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SAFETY AUDIT

ABSTRACT

The safety audit is an important management tool for assessing the strengths and weaknesses in the plant's overall safety program. The results of the audit assist the management in prioritizing the allocation of the safety budget to obtain the most cost effective results. Systematic evaluation of compliance with established program standards provides an objective audit of the systems and procedures requiredto be in place. There are ten categoriesto be evaluated as described in the paper.

Another aspect of safety is Process Safety which is more technical in nature. A safety review of the process unit can be accomplished by conducting a process review and an incident review.

This paper presents the methodology for conducting a comprehensive safety audit of an operating plant. Also, potential problem areas in an ammonia plant are reviewed from a safety standpoint.


Page 04 of 14

SAFETY AUDIT

1. INTRODUCTION

The term "Safety Audit" has a variety of meanings. For the purposes of this paper we shall define it as a "systematic, critical examination of a process plant to determine if adequate management systems are in place to minimize the risk of a serious incident". This definition places the emphasis on management. The word "incident" has been substituted for accident so that all types of losses are included and not just injury- related accidents.

Conservation of company assets and earning power through proper control of risks is a very important part of management's responsibility. Whenever a Company is involved

--in-the promsing- and shipment-of -chemicals, -the- consequences-resutting from uncontrolled hazards can have a profound effect on the bottom line. The risk control program must receive the attention of the company management and be supported by ample resources.

b-

Traditional Safety Process Safety

Traditional safety involves the protection of the employees and the assets by providing training, implementing safe working procedures, providingand enforcing the wearing of personal protective equipment and instituting loss-mitigatingsafeguards such as fire protectionsystems and emerge...