implementation of is-18001 at hwp(kota) presented by a.k. narang dy. manager (safety &...

IMPLEMENTATION OF IS-18001AT HWP(KOTA)

Presented by

A.K. NARANGDy. Manager (Safety &

Environment)

Heavy Water Plant (Kota)

2HEAVY WATER PLANTSethu

Heavy Water Plant (Kota) is an ISO-9001, ISO-14001 & IS-18001 certified industry.

Heavy Water Plant(Kota) has got IS-18001 certification in April 2004 by BIS (Bureau of Indian Standards)

Heavy Water Plant(Kota) is the sixth, industry in India accredited with IS-18001, certified by Bureau Indian Standards.

Heavy Water Plant (Kota) is the first unit among Department of Atomic Energy accredited with IS-18001 certificate.

BRIEF ABOUT

HEAVY WATER PLANT (Kota) Heavy Water Plant (Kota) is engaged in

production of Heavy Water which is a strategic Nuclear Material.

Heavy Water is used as moderator as well as coolant in Natural Uranium Reactor (PHWR).

Heavy Water Production at HWP(K) is based on Hydrogen Sulfide Water bi-thermal exchange process.

About 200 Tonns of H2S is used at HWP(Kota).

Toxicity of H2SH2S gas is flammable, explosive & highly toxic.

It’s auto ignition temperature is 260C with explosive range 4.3 - 44% concentration in air.

H2S has rotten egg smell. It smells at about 0.05 ppm concentration of H2S & TLV is 10 ppm. Fatal concentration of H2S is about 1000 ppm.

Adequate Engineering Design Safety features have been incorporated since the design stage at Heavy Water Plant (Kota).

Elaborate preventive & curative measures exist at HWP(Kota) to combat with any H2S gas leak.

On Site & Off Site Emergency Preparedness plan exists at HWP(K).

Implementation of QMS, EMS & OHSMS (Occupational Health & Safety Management System) have helped HWP(Kota) in its productivity, good safety records and establishment of safety culture.

Heavy Water Plant(Kota) has completed 601 days without any reportable disabling injury.

Various Awards Received by HWPK –

1. Atomic Energy Regulatory Board (AERB) Safety award for its best safety performance among all operating units of Depot. Of Atomic Energy for the year 2000.“

2. National Energy Conservation Award – 2001” second prize in Chemical Sector by “Ministry of Power” Government of India.

3. ISO-9001 & ISO-14001 from M/s. BVQI. in March, 2002.

4. National Energy Conservation Award – 2002” CERTIFICATE OF MERIT in Chemical Sector by Ministry of Power” Government of India.

5. INDUSTRIAL SAFETY GOLD AWARD by NGO (M/s. Greentech Foundation) consecutively for the last two years.

6. ENVIRONMENT EXCELLANCE GOLD AWARD by NGO (M/s. Greentech Foundation) consecutively for the last three years.

7. Best Plant Performance Award consecutively for the last three years.

8. YOGYATA-PRAMAN PATRA from ‘National Safety Council of India’.

9. Successful certification of IS-18001 (Occupational Health and Safety Management System by BIS).

Benefits of OHSMS

• Minimize risk to employees & others • Improved business performance• Better control of top management• Emphasis on preventive, not merely on

corrective strategies or actions.• System requires continual improvement.• Establishes responsible image in the

market

It took about nine months, from initiation to final audit by Certifying Agency. During this period various activities like awareness training, preparation of various documents, adequacy audit & compliance of recommendations during adequacy audit and pre-audit of Bureau of Indian Standards.

Management System

StructureResponsibility/AuthorityProcedureResourcesIS 18001 is standard for management system and not for OH&S performance.

OH&SMS Requirements

• 4.0 OH&SMS Requirements– 4.1 General Requirements– 4.2 Commitment and Policy

•4.2.1 Leadership and Commitment

•4.2.2 Initial OH&S review•4.2.3 OH&S Policy

OH&SMS Requirements• 4.3 Planning

• 4.3.1 Accountability and Responsibility

• 4.3.2 Identification of hazards and Assessment & Control of Risks

• 4.3.2.1 Hazard Identification• 4.3.2.2 Risk Assessment & Control• 4.3.3 Legal and Other Requirements• 4.3.4 Objectives, Targets and

Performance Indicators• 4.3.5 Initial and Ongoing Programmes

OH&SMS Requirements• 4.4 Implementation and Operation

• 4.4.1 Ensuring Capability• 4.4.1.1 Resources – human, physical and

financial• 4.4.1.2 Training, Awareness and

Competence• 4.4.2 Support Action• 4.4.2.1 Communication• 4.4.2.2 Reporting• 4.4.2.3 Documentation• 4.4.2.4 Document Control• 4.4.2.5 Records and Information

Management

OH&SMS Requirements

– 4.4 Implementation and Operation

•4.4.3 Operational Control•4.4.3.1 Design and Engineering•4.4.3.2 Purchasing•4.4.3.3 Contingency Preparedness

and Response•4.4.3.4 Critical Incident Recovery

Plan

OH&SMS Requirements

– 4.5 Measurement and Evaluation

•4.5.1 Inspection and Testing•4.5.2 Internal Audit•4.5.3 Non-conformance,

Corrective and

Preventive Action – 4.6 Management Review

Preparation of HWP(K) for establishing OHSMS – IS-18001

• Heavy Water Plant (Kota) took initial OH&S review at the first step.

• Our existing systems was compared with the various paras of IS-18001.

• Various activities to be carried out were planned.

• A format of initial OHSMS review is as follows:

HWP-K

INITIAL OH&S MANAGEMENT SYSTEM REVIEW

Doc. No. OHSMS/IRRev. No. 00Page No. 1Date 18-10-2003

S. No.

Parameter Norm Status Recommendation / Remarks

1. 4.1General requirements

Integration with existing management system Balance & resolve conflicts Align OH&S with overall business

Not Integrated Integrate with existing ISO 9001 & ISO 14001 document

2. 4.2Commitment & policy

OH&S Policy Reviewed Nil

3. 4.2.1Leadership & Commitment

a. Define & demonstrate leadership &commitment by top management

Yes, by policy Nil

b. Commitment from all Yes, by active participation of workmen in safety committees, suggestions, completions and following safety procedure

Nil

4. 4.2.2Initial OHS Review

a. Identification of gap between the existing systems & the requirement of this standard.

Under progress NiI

b. Identification of hazard & risk assessment

Completed Nil

c. Assessment of level of knowledge & compliance with OH & S standard & legislation

To be done Training to be imparted

d. Comparison of current arrangements with best practice & performance in the organisations employment.

AERB, HWB & internal guidelines available and followed. Refer safety manual

Nil

Prepared by : Reviewed by : Approved by :

Guidance for the Use of Specification

Continual Improvement Initial Status

Review

OH&S Policy

PlanningImplementation & Operation

Checking & Corrective Action

Management Review

OH & S Policy

Heavy Water Plant (Kota) has well defined Occupational Health & Safety Policy which is given as below:

Preparation of APEX Occupational Health & Safety Manual

This is an APEX manual which serves as reference for OHSMS implementation at HWP(Kota).

Initial preparation was done by HWP(K). Subsequently corrections were incorporated on the recommendation of BIS during adequacy audit.

The document covers all the points of IS-18001.

HWP – K CONTENTS Doc No. : AOHSM/A

S.No.

Description Section No.

IS 18001 Req.

Rev. No.

Page no.

A Contents AOHSM/A - 2.00 1B Abbreviations AOHSM/B - 2.01 2C List of Sections with Code AOHSM/C - 2.00 4D Distribution List AOHSM/D - 2.00 5E Amendment Sheet AOHSM/E - 2.01 6F Definitions AOHSM/F - 2.01 7G Profile of HWP-K AOHSM/G - 2.00 8H Profile of HWP-K AOHSM/H - 2.00 101. General Requirements AOHSM/01 4.1 2.00 112. Commitment and Policy AOHSM/02 4.2 2.00 123. Planning AOHSM/03 4.3 2.01 144. Implementation and

OperationAOHSM/04 4.4 2.01 25

5. Measurement and Evaluation

AOHSM/05 4.5 2.01 296. Management Review AOHSM/06 4.6 2.00 307. Common Health & Safety

Procedure (CHSP/01 to CHSP/13)

AOHSM/07 - 2.01 31

8. Annexure Figure – 1A AOHSM/08 - 2.01 749. Annexure 1

(OHS objectives and on-going programme)

AOHSM/ Annexure 1

- 2.01 75

10. Annexure 2(Record to be maintained by MR)

AOHSM/Annexure 2

- 2.00 76

11. Annexure 3(List of Safety and Occupational Health Reports)

AOHSM/ Annexure 3

- 2.00 77

12. Annexure 4(List of the Sectional Document)

AOHSM/ Annexure 4

- 0.00 1 pg.

13. Annexure 5 (Planning)

AOHSM/ Annexure 5

- 0.00 1 pg.

14. Annexure 6(List of Reference Documents)

AOHSM/ Annexure 6

- 0.00 2 pgs.

15. Annexure – 7(Master List of Records Files)

AOHSM/ Annexure 7

- 0.00 7 pgs.

16. Annexure – 8 (Master List of Records / Files)

AOHSM/ Annexure 8

- 0.00 3 pgs.

Clause IS:18001 Prepared by Reviewed by Approved byRevision No. 2.01 Date : 20-01-2004 Page no. 1 of 77

Other Supporting Documents

Sectional Occupational Health & Safety Manual.

Legal & Other Requirement

Risk Assessment & Control

Sectional Occupational Health & Safety Manual

This consists of :-

Organizational Health & Safety Policy

OHS objectives and ongoing program

Sectional objectives and ongoing program

Identification of Hazards and Risk Assessment

HWP – K OHS OBJECTIVES AND ON-GOING PROGRAMME

Doc. No. : AOHSM/Annexure -1

Sr.No. Objectives Programmes Target Dates & Target Figures

Performance Indicators

Agency Responsibl

e 1. To reduce

Occupational Health & Safety Hazards

Audiometric study of the employees exposed to high noise level areas.

Feb.,2004 &presently 0target 16 employees

No. of employees covered for audiometric text

Dy. M (S&E)

Procurement of new PPE – Fall Arrester System

Mar., 2004 &presently 0target 02

Completion of the job within time.

Dy. M (S&E)

Procurement of modified scaffolding.

Procured &presently 0target 01

Procurement within time.

Dy. M M(M)

Procurement of SO2 Monitors

Mar.,2004 &presently 01target 01

Availability of SO2 monitor

Dy. M (S&E)

Procurement of new B.A. Sets

May,2004 &target 2 nos.

Completion within the time

CFO

Modifications in handling of lime powder

Mar.,2004 &presently SPM = 3367 μg/m3

target less than 1000 μg/m3

Reduction of dust level.

Dy. PM

2. To enhance competence of employees including contractor personnel.

To introduce new topics in safety trainings

Jan.,2004 &To include 3 new topics

Awareness among the employees

Dy. M (S&E)

To conduct half a day training programme for contractor personnel

Continuous process &100% contractor’s personnel

No. of the contractor’s personnel covered.

Dy. M (S&E)

3. To review Safety Manual

Revision of safety manual with the help of other sections.

May,2004 &presently 0.00Revision 01 to be prepared

Revision within time

Dy. M (S&E)

4. Promoting employees health awareness

Organising health awareness programme for employees with the help of external agencies.

May,2004 &Min. 30 nos. employees are to be covered

No. of employees covered.

Superintendent Training & Public Awareness

Clause IS:18001 Prepared by Reviewed by Approved byRevision No. 2.01 Date : 20-01-2004 Page no. 75 of 77

Risk assessment and control

• Establish and maintain procedures for assessment and control of risks, – To determine priorities of the level of risks of

injury/illness/damage/loss of property associated with each identified hazard for the purpose of control

– Priority for control increases with the increase in established level of risk

• Plan the management and control of activities that can or may pose a significant risk on the health and safety of employees and public

Principle of Risk Assessment

Classify work activities

Identify hazards

Determine risks

Decide if risk is tolerable

Prepare risk control action plan

Review adequacy of action plan

Evaluation of Risk

Risk Tolerance

• Classify Work

• Identify Hazards

• Determine Risk

• Decide if Risk is tolerable

IDENTIFICATION OF HAZARDS AND RISK

ASSESSMENT The Methodology followed for identification & assessment of OH&S activities are based on records and task analysis.

The risk assessment was conducted, taking in to account the existing controls in three categories as high, medium and low for each risk components i.e.

1. Severity

2. Frequency

3. Exposure

BASIS OF SEVERITY

ASSESSMENT

Severity is defined in three levels.

1. Low : Marks allotted – 1

2. Medium : Marks allotted – 3

3. High : Marks allotted – 5

BASIS OF THE LEVELS

Severity levels.

1.Low : It may not require even first aid treatment.

2.Medium : It shall require first aid treatment

3.High : It will involve even hospitalization

PROBABILITY OF HAZARDS

Probabilities of hazards is defined by cross matrix of exposure duration “E” and frequency F

High 3 4 5

Medium 2 3 4

Low 1 2 3

Low Medium High

Frequency F

Exp

osu

re

Du

rati

on

E

EXPOSURE LEVEL DURATION

Low : for <½ an hour.

Medium : for < 1 hours and >½ an hour.

High : more than one hour.

FREQUENCY OF EXPOSURE

Low : Once in a shift.

Medium : >1 and < 3 in shift.

High : 3 in a shift.

ASSESSMENT OF THE RISK

Risk Level = Severity “S” x Probability of Hazard “P”

The risk having, risk levels 6 and above are considered significant risks.

The significant risks are to be taken care by Operating Control Procedure (OCP) / Standard Operating Procedure (SOP).

The significant risks are also to be taken care by Ongoing Management Programme (OMP).

EXAMPLES FOR RISK ASSESSMENT

Work activity / Situation / Condition / Event

Lime handling

Identified Hazard

1.Dust

2.Skin Problem

Present Control Measures

Dust Respirator

Hand Gloves / Gumboots/ Apron (PPE)

EXAMPLES FOR RISK ASSESSMENT

Risk Assessment

Severity : Level Medium Marks allotted = 3

Frequency : Medium Marks allotted = 2

Exposure duration : Low Marks allotted = 1

Probability Cross matrix of frequency and exposure duration is 2.

Risk level Severity x Probability

3 x 2 = 6

Remarks : It is a significant risk.

EXAMPLE-2

Work Activity:

Replacement of valves and maintenance of flange joints.

Hazards Involved:

Fall from height

EXAMPLE-2Control Measures:

Erect scaffolding wherever required and use of safety belts etc.

Risk Assessment:

Severity : Medium Marks allotted - 3

Frequency : Medium Marks allotted - 3

Exposure : Medium Marks allotted – 3

Probability = Cross Matrix of exposure and frequency = 3, risk level = 9 (Significant risk)

EXAMPLE-3Work Activity:

Liquid Sampling / Gas Sampling

Identified Hazards:

1. H2S Exposure

2. Hot Touch

Present Control Measures:

1. BA set

2. Use of hand gloves

EXAMPLE-3

Risk Assessment:

Severity : Low Marks allotted – 1

Frequency: Medium Marks allotted – 2

Exposure : Low Marks allotted –1

Risk level = 2 (not significant)

RISK ASSESSMENT FORMATSr. No.

Work Activity / Situation Events

Sub – activity

Hazard Situation Present Control measures

Severity “S”

Probability “P” Risk level

Action to be taken

Normal Abnormal

Emergency

Exposure duration “E”

Frequency of Exposure “F”

Security x probability

HWP–K HAZARDS IDENTIFICATION AND RISK ASSESSMENT

Section No. TS-SOHSM-04Rev No. 1.00Date January 20, 2004Page 1 of 4

S. No

Work activity / Condition / Events

Sub- activi

ty

Hazard Situation Present Control measures

Severit

y “S”

Probability “P”

Risk level

Action to be taken

Norma

l

Abnormal

Emergency

Exposure

duration “E

Frequency of

Exposure “F”

Severity x probabilit

y

1

Ammonia printing of drawings

Exposure of ammonia gas

Ammonia bottle stored in cool place. Bypass ducked provided. Exhaust fan in the room is mounted.

Low Low Low 01 Refer OCP TS-SOHSM-05 Page 4of 6

2

Xeroxing Excess exposure of Ozone while taking the Xeroxing.

Supplier has already taken the action while designing the machine.


Exposure of light while taking Xeroxing of thick books.

Avoid the thick books.

Low Low Low 01 Control measures are

adequate

3

Drawing development through engineering plan printer.

Excess exposure of Ozone while taking the print.

Supplier has already taken the action while designing the machine.


4

Cyclostyling Duplicating ink

Stopping leakage of the ink.


Prepared by: Reviewed by: Approved by:

REQUIREMENT OF REVIEWING THE RISK

ASSESSMENT1.The assessment is reviewed to

identify missing hazards, if any.

2.The assessment is reviewed once in three years.

3. The assessment is reviewed if there is modification / change in procedure/ change in equipment.

Certification process completed in three steps

by BIS

1.Adequacy Audit.

2.Pre Certification Audit.

3.Final Audit.

Adequacy Audit

During Adequacy Audit by BIS, Adequacy of all the documents were checked w.r.t. various elements of IS-18001.

BIS suggested various recommendations for improving the documents and accordingly documents were updated.

Pre-certification Audit

BIS Representatives visited the Site and verified the systems as per the documents. Again recommendations were put by BIS to improve the systems. Recommendation were complied.

Final Certification Audit

BIS Representatives at Site cross examined and verified the systems as per the documents and after satisfying our established Occupational Health & Safety Management System w.r.t. all the elements of IS-18001 recommended for certification in April - 2004.

IS-18001 Certificate

It is worthwhile to mention that as Heavy Water Plant (Kota) was already following the Atomic Energy (Factors) Rules, the statutes and guidelines issued by AERB in letter and spirit. Therefore, it was quite easy to implement IS 18001.

Oh&s Elements Existing Systems at HWPs

Advantages/ Positive points

4.1 General requirements Safety & Occupational health section exists. It is also integrated with the overall management system

Documentation is improved

4.2 Commitment & Policy

4.2.1 Leadership and Commitment

Exists --

4.2.2 Initial OH&S Review It was existing for major activities

All the activities are covered

4.2.3 OH&S Policy Exists --

Comparison of management of OH&S aspects of HWPs with IS 18001 & advantages/ positive points

4.3 Planning

4.3.1 Accountability and Responsibility

It was not documented fully.

It is now documented at all

4.3.2 Identification of Hazards & Assessment and Control of Risks

4.3.2.1 Identification of hazards

Job safety analysis is done for major hazardous jobs

Job safety analysis is done for all activities.

4.3.2.2 Assessment and control of risks

Does not exists Risk level is determined for all activities

4.3.3 Legal and other requirements

Exists --

4.3.4 Objectives, Targets & Performance Indicators

Exists --

4.4 Implementation and Operational

Heavy Water Plant (Kota) has acquired IS 18001 in April 2004 and became the first DAE unit accredited with IS 18001. HWP (Thal) has also completed the final audit by certifying agency & they are expecting IS 18001 certification by end 2004. HWP (Tuticorin) has already implemented IS 18001 and ready for the final audit by the certifying agency.

4.4.1 Ensuring Capability

4.4.1.1 Resources

4.4.1.2 Training, awareness and competence

4.4.2 Support Action

4.4.2.1 Communication

4.4.2.2 Reporting

4.4.2.3 Documentation

4.4.2.4 Document control

4.4.2.5 Record and information Management

4.4.3 Operational Control

4.4.3.1 Design and engineer-ing control

Exists --

4.4.3.2 Purchasing Exists --

4.4.3.3 Contingency preparedness & response

Exists --

4.4.3.4 Critical incident recovery plan

Not exists External agency is identified & kept on panel

4.5 Measurement and Evaluation

4.5.1 Inspection & Testing Exists --

4.5.2 Internal Audit Audit by corporate office is conducted

Internal audit by personnel from within the organization is required

4.5.3 Non-conformance, Corrective & Preventive Action

Exists in the form of minutes of meeting and/ or inspection reports of safety surveillance committee/ plant safety committee.

--

4.6 Management Review Review is carried out every four months through Tri-annual safety and health status reports.

Conclusion: Implementation of IS 18001 has improved documentation, responsibility, accountability, performance and image of the plant. All the activities of sections are analyzed to know their hazards and risk level. Therefore, corrective actions are planned to reduce the risk at an acceptable level. It is a tool for continual improvement.

THANK YOU