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Code o f Prac t ice on Safe ty Management Sys tem for the Chemical Industry

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CODE OF PRACTICE ONSAFETY MANAGEMENT SYSTEM FOR THE

CHEMICAL 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 Industries

has been developed by a Working Group which comprised representatives from the Oil andPetrochemical 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 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 Oronite

Mr Au Foo Yien Du Pont Singapore

Mr Pachaimuthu Sankaran Du Pont SingaporeMr John Tai ExxonMobil Singapore

Mr David Ong ExxonMobil Singapore

Mr Ho Yuen Chuan ExxonMobil Singapore

Mr Albert Lim Shell Eastern Petroleum

Mr Leng Ng Tai Shell Eastern Petroleum

Ms 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______________________________________________________33

B List of Safety Training Requirements_______________________________________________34

C List of In-House Safety Rules and Regulations_______________________________________35

D 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 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.




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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 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 - means a mandatory requirement

Should - means a preferred method of action

May - 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-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 Analys is

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.




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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 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 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.




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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 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.




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CODE OF PRACTICE ON SAFETY MANAGEMENT SYSTEMCODE OF PRACTICE ON SAFETY MANAGEMENT SYSTEM

FOR 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 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 shallestablish 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 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 top

management 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 the

factory.

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

continuous 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 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.

2.2 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.

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 and

contractors.

2.4 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.

2.5 Depending on the complexity of the factory’s operation, a permit to work system should be

incorporated 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 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.




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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 thenew 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.

2.8 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 factory’s 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”.

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 consideration

in 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 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.

3.2 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.

3.3 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.

3.4 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.

3.5 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.

3.6 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.

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 such

training 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 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.

4.2 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.

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 the

Committee’s safety and health objectives.

4.4 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 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 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




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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 promotional

activities, 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 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 ANALYSISELEMENT 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 incidentsby all personnel including contractors.

5.2 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.

5.3 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.

5.4 A system shall be established to ensure that the findings and recommendations of the

investigations are effectively and promptly followed through and implemented.

5.5 Procedures shall be established to ensure lessons learned from the incidents are proliferated

to 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 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.




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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 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 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 all

employees and contractors through promotion, training or other means. The rules shall be made

readily available to all employees and contractors.

6.3 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.

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 to

observe any of the rules.

6.6 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.




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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 to

demonstrate 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 the

management’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 but

not limited to the following: -

7.2.1 Display of the corporate safety policy and commitment at strategic locations in the

factory's premises;

7.2.2 Conduct of structured or thematic safety campaigns with active employees and

contractors 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 to

highlight 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 promotional

activities.




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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.

7.5 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.




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ELEMENT 8: CONTRACTOR EVALUATION, SELECTIONELEMENT 8: CONTRACTOR EVALUATION, SELECTION

AND CONTROLAND CONTROL

Objective

To establish a system to evaluate contractor’s safety performance as part of the selection and control

process so that only contractor who can meet the factory’s 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.

8.2 The system for evaluation and selection of contractors shall consider basic safety performance

indicators such as contractor’s safety policy and safety management system, safety track

records, competency and qualification of contractor’s personnel, safety training records and safe

work procedures.

8.3 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.

8.4 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.

8.5 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.

8.6 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 contractor’s safety

performance is in conformance with internal standards and is within the limits as specified in the

contract.

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' equipment

before they can be taken into use in the factory.

8.9 The factory shall establish procedures to ensure that contractors, whose safety performance is

found unacceptable, promptly and effectively carry out proper corrective action.

8.10 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 INSPECTIONELEMENT 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 committeeinspection, routine safety inspection, plant and equipment inspection and other special or

surprise inspection.

9.2 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.

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

specify the following:

9.3.1 The competency of the safety inspector – appropriate training shall be provided to

personnel involved in the inspection;

9.3.2 The frequency of the safety inspection – shall commensurate with the factory’s business

operations; 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 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 The acceptable time frame for implementation of corrective actions,

9.4.2 The specific responsibilities of personnel involved in the implementation of the corrective

and 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 corrective

action and for general awareness.

9.6 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.




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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 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 The factory shall establish a maintenance program to ensure that the mechanical integrity of critical 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 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.




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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.

10.4 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:

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 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 appliedfor 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 in-

house 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




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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 The factory shall establish a program to schedule the respective plans as specified in 11.1 and

11.2.

11.4 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 OF MOVEMENT AND USE OFELEMENT 12: CONTROL OF MOVEMENT AND USE OF

HAZARDOUS CHEMICALSHAZARDOUS CHEMICALS

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. Theprogram 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 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 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




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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 at

other 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 the

chemicals and secured against unauthorised access. The chemicals shall be returned to the

designated areas when not in use.

12.5 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.

12.6 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.

12.7 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.

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 the

environmental monitoring results and the permissible exposure limits.

12.9 Regular medical surveillance for personnel and contractors exposed to the hazardous chemicals

shall be performed.

12.10 Establishment and implementation of procedures for disposal of hazardous chemicals shall be

carried 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 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.




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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 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 PREPAREDNESSELEMENT 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 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 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 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.

14.5 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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1515 DOCUMENTATION CONTROL AND RECORDSDOCUMENTATION 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.

15.2 Documented procedures shall be prepared for operations and maintenance of process systemsand 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.

15.3 Each controlled document shall contain the following:

a) a unique identifier

b) the date of issue

c) the date of any revision

d) a revision number e) a descriptive title

f) 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 persons

or parties issued with such documents.

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

person who certified the original documents.

15.6 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.

15.7 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.




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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; and

u) 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; and

w) 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 the

workplace. 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; and

j) 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 critical

devices 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; and

h) 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; and

f) Documentation of test records which shall be reported to the responsible person for

acknowledgement and implementation of corrective action.

cp sms chemical industry

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