Safety Management System For The Chemical Industry

Code of Practice on Safety Management System for the Chemical Industry
CODE OF PRACTICE ON
SAFETY MANAGEMENT SYSTEM FOR THE CHEMICAL INDUSTRY
Developed jointly by the Oil and Petrochemical Industry Technical & Safety Committee and the Occupational Safety Department, Ministry of Manpower Published in January 2001
This Code of Practice on Safety Management System for the Oil, Petrochemical and Chemical Industries has been developed by a Working Group which comprised representatives from the Oil and Petrochemical Industry Technical and Safety Committee (OPITSC) and the Occupational Safety Department, Ministry of Manpower. The Working Group involved in the preparation of this Code comprised the following members:
Name Chairman : Members : Mr Chan Yew Kwong Mr Ismadi Mohamed Mr Koh Bok Thong Mr Kader Mydin Mr Wang Hui Hua Mr Richard Tan Mr Au Foo Yien Mr Pachaimuthu Sankaran Mr John Tai Mr David Ong Mr Ho Yuen Chuan Mr Albert Lim Mr Leng Ng Tai Ms Cissie Yeung Ms Lam Kit Wing Mr Eric Tang Tong Hai Mr Michael Yan
Organisation Occupational Safety Department (MOM) Occupational Safety Department (MOM) Occupational Safety Department (MOM) Occupational Safety Department (MOM) Chairman, OPITSC (Petrochemical Corporation of Singapore) Chevron Oronite Du Pont Singapore Du Pont Singapore ExxonMobil Singapore ExxonMobil Singapore ExxonMobil Singapore Shell Eastern Petroleum Shell Eastern Petroleum Singapore Chemical Industry Council (Ciba Specialty Chemicals Singapore) Singapore Chemical Industry Council (ISK Singapore) Singapore Refining Company Vopak Terminal Singapore
Contents Page Foreword SPECIFICATION A B 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Scope ________________________________________________________________________5 Definitions _____________________________________________________________________5 Element 1 Safety Policy ________________________________________________________8 Element 2 Safe Work Practices __________________________________________________9 Element 3 Safety Training______________________________________________________10 Element 4 Group Meetings ____________________________________________________12 Element 5 Incident Investigation and Analysis _____________________________________14 Element 6 In House Safety Rules and Regulations__________________________________15 Element 7 Safety Promotion____________________________________________________16 Element 8 Contractors Evaluation, Selection and Control ____________________________18 Element 9 Safety Inspection____________________________________________________20 Element 10 Maintenance Regime _______________________________________________22 Element 11 Hazard Analysis ___________________________________________________24 Element 12 Control of Movement and Use of Hazardous Chemicals ____________________26 Element 13 Occupational Health Programs________________________________________28 Element 14 Emergency Preparedness ___________________________________________30 Documentation Control and Records_______________________________________________32
APPENDICES A B C D List of Safe Work Practices ______________________________________________________33 List of Safety Training Requirements_______________________________________________34 List of In-House Safety Rules and Regulations_______________________________________35 List of Maintenance Regimes ____________________________________________________36
Foreword This Code of Practice has been developed by a Working Group which comprised representatives from the Oil & Petrochemical Industry Technical and Safety Committee and the Occupational Safety Department, Ministry of Manpower. Under section 71B of the Factories (Amendment) Act 1999, the Minister may require the occupier of a certain class or description of factories to implement a Safety Management System for the purpose of ensuring the safety, and protecting the health and welfare of persons employed in the factory. The occupier shall appoint such number of approved auditors to audit the Safety Management System as required and to implement, as far as is practicable, the recommendations of the approved auditor without undue delay. This Code represents a standard of good practice and has been prepared with the objective of formulating the discipline to which these procedures should conform. It stipulates requirements for the 14 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 those involved in the preparation, supervision and execution of processes in major hazardous installations and plants. This Code is also recommended for use by the other manufacturing and general industries as appropriate. 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 with other regulatory requirements, internationally accepted codes and standards and best practices.
Scope
This Code of Practice sets down the basic expectations and requirements of the Safety Management System implemented in a factory in the Oil, Petrochemical & Chemical Industries for the purpose of ensuring the safety and protecting the health of all personnel and workers working in the factory. B Definitions
For the purpose of this Code, the following definitions shall apply B1 Use of Language Shall Should May B2 Contractor means a mandatory requirement means a preferred method of action means a possible method of action
Any company undertaking contract works or providing services of any kind for the factory and shall include all the sub-contractor companies 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, Emergency Preparedness etc. B4 Factory
The expression factory in this Code covers all premises engaged in the processing or manufacturing of petroleum, petroleum products, petrochemicals, petrochemical products and other hazardous chemicals where workers are employed for the purpose of 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 more internationally 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.
B7
HAZOP
Hazard and Operability Study - A formal procedure or technique of systematically investigating each element of a system for all potential deviations from design conditions. Deviations are critically analysed for effects of potential problems and the consequences of 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 of hazardous 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 API 750 or OSHA 1910. B10 Management Systems
The human and technical factors including materials, processes, planning activities, procedures and responsibilities that are necessary 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 which shall provide accurate and adequate description of the identity, physical and chemical properties of the substance, safety and health hazard 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 involving exposure 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 protection and 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 is significant enough to require a change in the process safety information can be brought on line.
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 accident occurs. It frequently includes an analysis of the probabilities. Consequence analysis describes the damage expected and includes loss 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 appoint such number of approved auditors to audit the safety management system at such time and in such manner as the Chief Inspector may 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 on which both employees and management are represented for the purpose of keeping under review circumstances in the factory which 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 or description of factories to implement a safety management system for the purpose of ensuring the safety and protecting the health and welfare of persons employed in the factory. B20 Safety Review
Normally refers to internal audits performed in supplementary to safety audits.
CODE OF PRACTICE ON SAFETY MANAGEMENT SYSTEM FOR THE CHEMICAL INDUSTRY ELEMENT 1: SAFETY POLICY
Objective To establish and maintain a written safety policy, which spells out managements commitment towards safety and the principles that govern safety and health decisions in the factory. Senior management shall ensure that the safety policy is communicated to all employees and relevant contractors and shall establish a Culture that safety and health are valued as basic and fundamental prerequisites for the business of the factory. System Requirements 1.1 An effective Safety Policy shall demonstrate the management commitment towards safety and health improvement, its objectives and directions, including goal setting. The Safety Policy shall incorporate and address the following: 1.1.1 1.1.2 1.1.3 1.1.4 1.1.5 1.2 1.3 1.4 Emphasis on the importance to protect the safety and health and the general well being of every personnel working in the factory. Accountability for the safety and health function by top management. Allocation and delegation of duty and responsibility for safety and health from the top management to the line staff. Responsibility at all levels in preventing incidents. Commitment of sufficient resources towards the achievement of safety and health goals and objectives.
The Safety Policy shall be signed by the most senior management staff of the factory. The Safety Policy shall be effectively communicated to all employees and contractors in the factory. The Safety Policy should be reviewed at defined intervals and updated to ensure relevancy and continuous improvement. 8
ELEMENT 2: SAFE WORK PRACTICES
Objective To establish a system to ensure that safe work practices are carried out in the factory through procedural and administrative control of work, critical operating steps and parameters, pre-startup safety reviews for new and modified plant equipment and facilities, and management of change of plant equipment and process. 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 practices must be developed and implemented for the work operations or processes as specified in the Twelfth Schedule of the Factories Act. The safe work practices should be established after a risk assessment of the work operation or process has been conducted, including hazard identification and risk analysis of the risks associated with the operation or process. The safe work practices shall be clearly written and communicated to all relevant employees and contractors. The safe work practices shall be made readily available to all employees and contractors. Safe work practices, where appropriate, should include a Lockout/ Tagout system for the effective isolation 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 of pipelines and equipment. Depending on the complexity of the factorys operation, a permit to work system should be incorporated into the safe work practices to ensure that all precautionary measures are taken before the commencement of work. The factory should maintain operating procedures for each process. These operating procedures should provide clear understanding of detail operating parameters and limits for safe operation for those who are operating the process. The formulation of operating procedures should begin from design stage and should be reviewed to update changes made in the process. Operating procedures should provide the foundation for operator training and should reflect process safety information.
2.2
2.3
2.4
2.5
2.6
2.7
The factory should establish and implement a Pre-Start-up Safety Review policy/procedure for new equipment, facility or installation to confirm that all process safety elements of this Code are addressed and that their areas of concern are all rectified before the initial commissioning of the new equipment, facility or installation. The Pre-Start-up Safety Review policy/procedure should also apply to new factory or process or factory/process, which has major modification. The factory should establish and implement a Management of Change policy/procedure to address all hazards/concerns that may be introduced by any Change of hardware, procedures or chemicals of the factorys process/facility. The policy/procedure should institute a systematic evaluation of the possible hazards or concerns arising from the Change and ensure that the appropriate measures are in place before approving the Change. Periodic review of all safe work practices shall be carried out to evaluate their relevance and adequacy. Lessons learned from incidents shall, where applicable, be taken into consideration in the review.
2.8
2.9
10
ELEMENT 3: SAFETY TRAINING
Objective To equip employees and contractors at all levels with the knowledge, skills and attitudes relating to the operation 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 scheme shall be devised to identify the safety and health training needs for each level of employees and contractors. Safety Instruction Courses, and other mandatory safety-training courses, shall be provided to all relevant employees. Such courses shall cover the relevant safe work practices established in the factory, hazard identification in work areas and response to emergency situations. All supervisors and workers shall be trained to a competent level expected of their tasks. Where appropriate, workers shall be certified in their skills such as for welding, handling of chemicals and gas testing. All supervisory staff shall be thoroughly trained in the methods and skills required to perform their tasks, such as the proper operation of instruments, tools and equipment, reading and understanding of the documentation provided and their respective role in accident prevention at the workplace. Training shall be provided to all relevant management staff so that they are equipped with the proper understanding of the safety management system and their responsibilities and duties in safety and health in the factory. The training shall also provide them with the tools and techniques needed for managing safety and health effectively at the workplace. Safety orientation or induction shall be conducted for all contractors. Such orientation or induction programs shall include an understanding of the factory's safety and health policy as well as all its rules and regulations. The training programs may include but not limited to the list as specified in Appendix B. The training programs shall be conducted in languages understood by the trainee. The training programs shall be documented and periodically reviewed. The effectiveness of such training shall be measured and reviewed based on feedback from the employees, supervisors, managers and the contractors. The factory shall maintain a record of all the training received by each employee. 11
3.2
3.3
3.4
3.5
3.6
3.7 3.8 3.9
3.10
ELEMENT 4: GROUP MEETINGS
Objective To promote communication and co-operation between management, employees and contractors so as to ensure that issues are addressed and appropriate actions are taken in order to achieve and maintain a safe and healthful work environment. System Requirements 4.1 The factory shall establish a Safety Committee for the purpose of improving, promoting and reviewing of all matters relating to the safety and health of employees. The Safety Committee also acts as a channel for communicating and imparting knowledge and best practices on safety and health to all personnel. The Safety Committee shall have a clearly defined charter with prescribed functions and responsibilities. The composition, functions and duties of the Safety Committee shall be in accordance with the Factories Act and the Factories (Safety Committees) Regulations. The Safety Committee shall be effectively led by the senior management of the factory. The Safety Committee shall be given the necessary support and resources so as to achieve the Committees safety and health objectives. The factory should also establish other group meetings, which may include but not limited to the following: 4.4.1 Tool Box Meetings 4.4.1.1 Tool Box Meetings involving supervisors and workers should be held regularly such as before the commencement of work to provide opportunity for operators and 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 to highlight 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 through safety and health related projects for the purposes of improving the physical work 12
4.2
4.3
4.4
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 4.5.2 4.5.3 4.5.4 4.6 competent for their tasks; in full understanding of their roles and functions; 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 promotional activities, and given the necessary support so that they can effectively perform their duties.
The factory shall establish a mechanism whereby the decisions and actions proposed by the various groups are effectively communicated to persons responsible for their implementation. The mechanism shall also ensure that all outstanding actions are effectively followed through and implemented.
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ELEMENT 5: INCIDENT INVESTIGATION AND ANALYSIS
Objective To establish procedures for incident reporting and investigation so as to identify root causes of incidents and 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 near misses) are reported and recorded promptly. A mechanism shall be set up to report incidents by all personnel including contractors. The factory shall establish written procedures for the investigation into incidents. The procedures should include the criteria for the type and degree of seriousness of incidents to be formally investigated. All incidents investigated shall determine the root causes, circumstances and other indirect contributing factors leading to the incidents. Line managers, supervisors, safety personnel and safety committee members should be included in the investigation team. They shall be adequately trained and equipped with the necessary knowledge and skills for their tasks. A system shall be established to ensure that the findings and recommendations of the investigations are effectively and promptly followed through and implemented. Procedures shall be established to ensure lessons learned from the incidents are proliferated to all relevant personnel in the factory for information and awareness. Analysis of all reported incidents and statistics should be carried out periodically to identify the type, frequency, severity and root causes of incidents. Such information is useful for drawing up safety and health strategic plans, promotional programs and training courses.
5.2
5.3
5.4 5.5 5.6
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ELEMENT 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 a common 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 and health behaviors at the workplace. The rules shall cover the main work operation or process in the factory, which should include but not limited to the list as specified in Appendix C. The safety rules and regulations shall be documented and effectively communicated to all employees and contractors through promotion, training or other means. The rules shall be made readily available to all employees and contractors. The safety rules and regulations shall be effectively implemented and vigilantly enforced in the factory. All employees and contractors shall comply with the rules and regulations at all times. The safety rules and regulations shall be in conformance with the regulatory requirements. Rules that are non-statutory shall conform to international standards or best practices. The factory shall establish and implement disciplinary or corrective procedures for failure to observe any of the rules. The factory shall establish procedures to periodically review the safety rules and regulations to ensure its relevance and effectiveness. Records of such review shall be maintained.
6.2
6.3 6.4 6.5 6.6
15
ELEMENT 7: SAFETY PROMOTION
Objective To raise and maintain safety and health awareness among all employees and contractors and to demonstrate the managements commitment towards safety and health excellence in the factory. System Requirements 7.1 The factory shall develop and conduct promotional programs to demonstrate clearly the managements commitment and leadership in promoting good safety and health behaviors and practices in the factory. Safety and health promotional activities should be organised regularly and should include but not limited to the following: 7.2.1 7.2.2 7.2.3 7.2.4 7.2.5 7.2.6 7.2.7 7.2.8 7.2.9 7.3 Display of the corporate safety policy and commitment at strategic locations in the factory's premises; Conduct of structured or thematic safety campaigns with active employees and contractors participation; Display of incident statistics and safety performance charts; Conduct of topical safety talks; Screening of safety videos; Formation of safety improvement teams; Display of signs, posters or other visual material to increase safety awareness or to highlight a particular safety issue; Issuance of safety handbooks or brochures to both employees and contractors to increase safety awareness, as part of personal safety training; and Conduct of first-aid and emergency response exercises and drills.
7.2
The factory should encourage all contractors to be actively involved in the safety promotional activities.
16
7.4
All personnel, including contractors should be encouraged to make positive suggestions to improve safety at the workplace. The factory may set up a safety suggestion scheme to encourage employees' participation. The factory should establish an incentive program to encourage group safety effort. A measurable standard should be developed to assess the group safety performance. Rewards, commendations and appropriate recognition for outstanding group safety performance shall be presented to the deserving recipients by a top management staff.
7.5
17
ELEMENT 8: CONTRACTOR EVALUATION, SELECTION AND CONTROL
Objective To establish a system to evaluate contractors safety performance as part of the selection and control process so that only contractor who can meet the factorys safety performance standards and requirements are permitted to work in the factory. System Requirements 8.1 The factory shall establish and document a system for assessment and evaluation of contractors to ensure that only competent and qualified contractors are selected and permitted to carry out contracted works in the factory. The system for evaluation and selection of contractors shall consider basic safety performance indicators such as contractors safety policy and safety management system, safety track records, competency and qualification of contractors personnel, safety training records and safe work procedures. In pursuant to the system for evaluation and selection of contractors, the factory may incorporate a formal system for pre-approval of contractors for major and specialised work in the factory. In such a system, only pre-approved contractors are invited to tender for work in the factory. New contractors who are not in the pre-approved list will have to be subjected to the evaluation and selection process prior to inclusion in the pre-approved list. Upon selection of the contractor, the factory should maintain a written contract with the said contractor in which the safety and health responsibilities and obligations of the contractor should be clearly spelt out. Prior to the commencement of work, the factory shall ensure that the contractor personnel working in the factory are given the proper safety induction training. The induction training shall cover key areas such as procedures for the reporting of incidents and emergency situations and basic in house rules and regulations. The factory shall establish procedures to effectively monitor and control the safety performance of the contractors working in the factory. The procedures shall ensure that the contractors safety performance is in conformance with internal standards and is within the limits as specified in the contract. The factory should maintain and record safety performance statistics for contractor companies 18
8.2
8.3
8.4
8.5
8.6
8.7
working in the factory. 8.8 8.9 8.10 The factory shall document procedures for the inspection and checking of contractors' equipment before they can be taken into use in the factory. The factory shall establish procedures to ensure that contractors, whose safety performance is found unacceptable, promptly and effectively carry out proper corrective action. The factory should document a written disciplinary policy to demerit or penalise contractors or their workers for breaching the internal safety standards and rules and regulations.
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ELEMENT 9: SAFETY INSPECTION
Objective To establish a system to verify compliance with the relevant regulatory requirements, in-house safety rules and regulations and safe work practices. System Requirements 9.1 The factory shall develop and implement a written program for formal and planned safety inspections to be carried out in the factory. The program should include safety committee inspection, routine safety inspection, plant and equipment inspection and other special or surprise inspection. The factory shall develop a list of protocol or checklist for identifying workplace hazards and classifying the major findings. The protocol or checklist used for the safety inspections shall be designed such that it involves a thorough and systematic check of the factory's workplace, equipment, tools, materials and work practices. The factory shall establish performance standards for the safety inspections. The standards shall specify the following: 9.3.1 9.3.2 9.3.3 9.4 The competency of the safety inspector appropriate training shall be provided to personnel involved in the inspection; The frequency of the safety inspection shall commensurate with the factorys business operations; and The scope and coverage of the safety inspection.
9.2
9.3
The factory shall establish procedures to ensure that prompt corrective actions are taken to address or eliminate the unsafe conditions/hazards and substandard behaviors/acts found during the safety inspections. The procedures shall define the following: 9.4.1 9.4.2 9.4.3 The acceptable time frame for implementation of corrective actions, The specific responsibilities of personnel involved in the implementation of the corrective and follow-up action; and The method of verification and monitoring of corrective actions carried out. 20
9.5
The factory shall establish a feedback system to ensure that critical findings from safety inspections are effectively communicated to relevant personnel for implementation of corrective action and for general awareness. The factory shall establish an evaluation program to evaluate and check the safety inspection system to verify its effectiveness and to ensure that standards are met.
9.6
21
ELEMENT 10: MAINTENANCE REGIMES
Objective To establish a system to maintain at all times the integrity of all plant, machinery and equipment used in the factory so as to prevent any failure of these equipment due to a lack of maintenance or repair, which can result in unsafe situations. System Requirements 10.1 10.2 The factory shall establish a maintenance program to ensure that the mechanical integrity of critical plant equipment is maintained. 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 the equipment and machinery on a continuos basis; 10.2.2 Establishment of a corrosion control program to maintain the integrity of critical equipment and machinery and piping systems; 10.2.3 Development and documentation of work practices and maintenance procedures that shall take into consideration the safety and health exposure of personnel to the work operations and the associated risks to the environment during the carrying out of maintenance work. The work practices and maintenance procedures shall incorporate safety precautionary measures such as Lockout/Tagout System and Permit-to-Work Systems. Supplemental or special work procedures, which may include job safety or risk 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 maintenance procedures; 10.2.5 Establishment of procedure or system to ensure that the material used in the maintenance of critical equipment continue to meet design specification, and any changes in material shall be appropriately reviewed before use (such as consideration through a management of change review process); and 10.2.6 Development of a long-term maintenance plan for periodic maintenance of major and critical equipment. The plan shall be reviewed annually to take into consideration the inspection findings, incident reports and regulatory requirements. 22
10.3
The factory shall establish a control system to ensure that critical safety devices, which control or monitor the safety of process equipment operation (such as safety alarms, control and shutdown equipment), are tested and maintained periodically. The types of equipment, instruments or systems that may be considered as safety critical devices may include but not limited to the list as specified in Appendix D: The control system may include but not limited to the list as specified in Appendix D:
10.4 10.5
23
ELEMENT 11: HAZARD ANALYSIS
Objective To methodically identify, evaluate and control hazards in the processes of a factory. The process of Hazard Analysis shall be documented and shall include measures over a serious scenario that can occur in a factory and the necessary corrective or control measures that can be incorporated to mitigate the frequency 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 case scenario 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 be considered when carried out by qualified on-site persons. Techniques such as gas dispersion and fire explosion modelling of vapour releases techniques may be applied for the evaluation; 11.1.3 Development and implementation of the measures to prevent the worst case scenario from 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 prevent or/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 one or more internationally recognised methodologies such as Checklist, What if checklist, Hazop, Failure Mode & Effect Analysis (FMEA) and Fault Tree Analysis. Established inhouse methodologies should also be considered; 11.2.2 Implementation of recommendations to address the significant hazards identified in the review; 11.2.3 Establishment of a system to accomplish the recommendations with proper documentation; and 24
11.2.4 Conduct of fresh reviews for new process changes, projects of new facilities, lesson from incidents and as and when the need arises. 11.3 11.4 The factory shall establish a program to schedule the respective plans as specified in 11.1 and 11.2. The factory shall communicate the recommendations of the respective plans as specified in 11.1 and 11.2 to all persons involved in the process.
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ELEMENT 12: CONTROL HAZARDOUS CHEMICALS
OF
MOVEMENT
AND
USE
OF
Objective To establish a system to identify and manage all hazardous chemicals in the factory through the provision of Material Safety Data Sheets and procedures for proper use, storage, handling and movement of the hazardous chemicals. System Requirements 12.1 The factory shall establish a control program for the management of hazardous chemicals. The program shall include and incorporate the following: 12.1.1 The maintenance of a register of hazardous chemicals in use in the factory. Each hazardous chemical shall be accompanied with the appropriate Material Safety Data Sheet (MSDS) to facilitate the risk assessment process and training of employees on proper 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, handling and safe use of the hazardous chemicals; 12.1.3 The appointment of competent persons who has adequate knowledge of the properties of 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 to determine whether the chemical can be used, handled and disposed without undue risk to employees safety and health or to the environment. 12.2 All storage tanks, vessels and containers used to store or contain the hazardous chemicals shall be: 12.2.1 of good construction, sound material, adequate strength and free from patent defect and shall be properly maintained; 12.2.2 provided with proper labels on the external walls with information such as the name and properties of the chemical contained therein and the hazards associated with the chemicals; and 12.2.3 subjected to periodic inspection of its structures, fittings and attachment to ensure its 26
structural and mechanical integrity. 12.3 The total inventory of the hazardous chemicals stored in the factory at the process area or at other designated storage areas shall not be in excess of the capacity necessary for production requirements; and The hazardous chemicals shall be stored in designated areas, which shall be suitable for the chemicals and secured against unauthorised access. The chemicals shall be returned to the designated areas when not in use. Incompatible hazardous chemicals shall not be stored in the same storage areas. If this is not practicable, they shall be stored in areas separated from one another by physical barriers such as walls and floors or by other suitable means. Adequate training shall be provided to all personnel and contractors who may be exposed to the hazardous chemicals. Training shall also be provided to the related personnel whenever a new hazardous chemical is introduced into the process. Warning notices in languages understood by the relevant persons specifying the danger of the hazardous chemicals shall be placed at all entrances to any workroom and at appropriate locations where hazardous chemicals are used or stored. Periodic exposure assessment on related personnel and contractors shall be carried out. Appropriate environmental monitoring shall be followed up based on the exposure assessment results. Suitable measures shall be implemented to prevent or minimise exposure based on the environmental monitoring results and the permissible exposure limits. Regular medical surveillance for personnel and contractors exposed to the hazardous chemicals shall be performed.
12.4
12.5
12.6
12.7
12.8
12.9
12.10 Establishment and implementation of procedures for disposal of hazardous chemicals shall be carried out in accordance with regulatory requirements or manufacturers recommendations.
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ELEMENT 13: OCCUPATIONAL HEALTH PROGRAMS
Objective To identify, evaluate and control occupational health hazards to protect all personnel from developing occupational diseases or illnesses arising from their exposure to specific occupational health hazards present in the work environment and to establish policies and programs to protect all workers from specific occupational health hazards. System Requirements 13.1 The factory shall ensure that for every hazardous chemical used, produced or otherwise encountered in the operations, there are available: 13.1.1 Information to identify and evaluate the related safety and health hazards. The factory shall ensure that appropriate Material Safety Data Sheet (MSDS) is provided for each chemical used; 13.1.2 Precautionary advice for the safe transport, storage, use and disposal of the hazardous chemicals; 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 nature of the hazards, safe handling procedures, personal protection and emergency actions for 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 of their usage; 13.2.4 Pre-employment and annual audiometric examinations of all exposed workers; and 13.2.5 Training and education of workers. 28
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 control measures; 13.3.3 Selection, provision and maintenance of suitable respirators and supervision of their usage; 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 PREPAREDNESS
Objective To establish written emergency response plans to mitigate consequences arising from potential emergency 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 clear scope, roles and responsibilities; and 14.1.3 Maintain an up-to-date emergency response plan 14.2 14.3 The emergency response plan shall be documented and effectively communicated. 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 emergency procedures 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 time to the emergency situations
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14.4 14.5
The factory shall establish a program of drills and exercises to assess the preparedness of the factory for prompt and effective response to emergency situations. The factory shall establish effective first-aid programs to provide first-aid and emergency treatment to victims of an accident. This would include provision of adequate first-aid facilities and trained first-aiders.
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15
DOCUMENTATION CONTROL AND RECORDS
System Requirements 15.1 The general documentation requirements are given separately in each element. The factory shall establish a central documentation control and record system to integrate these documentation requirements and to ensure that they are complied with. As the system progresses, the quantity of documents and drawings increases and a foundation numbering and management system is essential for traceability of these documentation. Documented procedures shall be prepared for operations and maintenance of process systems and items of plant, machinery and equipment. These documentation procedures shall include the various requirements of the work permit controls, pre-startup safety review and management of change. Each controlled document shall contain the following: a) b) c) d) e) f) 15.4 15.5 15.6 a unique identifier the date of issue the date of any revision a revision number a descriptive title an authorising signature by a responsible person from the occupier
15.2
15.3
The occupier shall keep and maintain a master list of each controlled document and the persons or parties issued with such documents. The controlled documents may be revised at any time. Revisions shall be authorised by the person who certified the original documents. Revised controlled documents shall be issued by the authorising person to those on the master list and all copies of the previous issues shall be declared superseded. One copy of the superseded document shall be retained by the authorising body. The factory shall document and maintain all regulatory documentation requirements. The documents shall conform to the conditions of the said requirement in content, format and authorisation.
15.7
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APPENDIX A ELEMENT 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; and u) Diving operation.
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APPENDIX B ELEMENT 3 - SAFETY TRAINING
B1 a) b) c) d) e) f) g) h) i) j) k) l) m) n) o) p) q) r) s) t) u) v) w)
Every factory shall establish training programs, which may include, but not limited to the following: Training for Safety Managers; Training for Safety Auditors; Training for Safety Officers; Training for Safety Coordinators; Training for Safety Committee members; Training for Safety Inspectors, in particular Hot Work Certification; Training for Competent Person for Hazardous Chemicals; Training for First-Aiders; Training for Noise Monitoring Officer; Training for Fire Watchmen or Attendant; Training for Crane Operators; Training for Lifting Supervisors; Training for Riggers; Training for Signalman; Training for Scaffolders; Training for Operators of Explosive Powered Tools; Training for Boiler Attendant; Training for Steam Engineers; Training for Contractors; Safety Orientation/Induction Training for new employees and Contractors; Refresher training of experienced workers to highlight the specific changes and issues; Training for Emergency Response Personnel; and Training on the requirements and the effective use of Personal Protective Equipment.
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APPENDIX C ELEMENT 6 - IN HOUSE RULES & REGULATIONS
C1 a) b) c) d) e) f) g) h) i) j)
A set of basic in-house rules and regulations shall be developed to regulate safety at the workplace. The rules may include; but not limited to the following: Compliance with safe work practices and permit-to-work system; Injury reporting; Incident and hazard reporting; The safe use and handling of materials such as hazardous chemicals and substances; Use and maintenance of machinery, tools and equipment; Use and maintenance of electrical equipment; Use of personal protective equipment; Housekeeping and cleanliness; Fire prevention; and Prohibition of horseplay and misuse of equipment.
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APPENDIX D ELEMENT 10 - MAINTENANCE REGIME
D1 a) b) c) d) e) f) g) h) D2 a) b) c) d)
The types of equipment, instruments or systems that may be considered as safety critical devices may include; but not limited to the following: Pressure Relieving Devices such as Safety Valves; Vacuum Relieving Devices; Shutdown Systems Automatic trips, cut-ins and cut-outs; High Priority Alarms; Compressor anti-surge systems; Pump low-flow recycle loop; Detectors and Alarms for accidental release of harmful and hazardous substances and fires; and Critical temperature, pressure and level cut-out devices. The control system may include; but not limited to the following: Identification of the list of safety critical devices; Designation of responsibility and accountability for the approved list of safety critical devices; The frequency and scope of testing of the devices; 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; and f) Documentation of test records which shall be reported to the responsible person for acknowledgement and implementation of corrective action.
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Safety Management System For The Chemical Industry

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