Transcript Implementation of IS-18001

IMPLEMENTATION
OF IS-18001
AT HWP(KOTA)
Presented by
A.K. NARANG
Dy. Manager (Safety & Environment)
Heavy Water Plant (Kota)
HEAVY WATER PLANT
Sethu
2
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 IS18001 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 H2S
H2S gas is flammable, explosive & highly toxic.
It’s auto ignition temperature is 260C 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
Structure
Responsibility/Authority
Procedure
Resources
IS 18001 is standard for management system and not for
OH&S performance.
OH&SMS Requirements
• 4.0 OH&SMS Requirements
– 4.1
– 4.2
• 4.2.1
• 4.2.2
• 4.2.3
General Requirements
Commitment and Policy
Leadership and Commitment
Initial OH&S review
OH&S Policy
OH&SMS Requirements
Planning
• 4.3
Accountability and Responsibility
4.3.2 Identification of hazards and
Assessment
Control of Risks
• 4.3.1
•
• 4.3.2.1 Hazard
•
Identification
4.3.2.2 Risk Assessment & Control
• 4.3.3
• 4.3.4
• 4.3.5
Legal and Other Requirements
Objectives, Targets and Performance
Indicators
Initial and Ongoing Programmes
&
OH&SMS Requirements
Implementation and Operation
• 4.4
• 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
Response
• 4.4.3.4 Critical Incident Recovery
and
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.
Rev. No.
Page No.
Date
OHSMS/IR
00
1
18-10-2003
S.
No.
Parameter
Norm
Status
Recommendation
Remarks
1.
4.1
General 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.
4.2
Commitment & policy
OH&S Policy
Reviewed
Nil
3.
4.2.1
Leadership &
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
4.2.2
Initial OHS Review
a. Identification of gap between the
existing systems & the requirement
of this standard.
b.
Identification of hazard & risk
assessment
Under progress
NiI
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
4.
Prepared by :
Reviewed by :
Approved by :
/
Guidance for the Use of Specification
Management
Review
Continual
Improvement
Checking &
Corrective
Implementation
Action
& Operation
Initial Status
Review
OH&S Policy
Planning
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
S.
No.
A
B
C
D
E
F
G
H
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
CONTENTS
Description
Section No.
Contents
Abbreviations
List of Sections with Code
Distribution List
Amendment Sheet
Definitions
Profile of HWP-K
Profile of HWP-K
General Requirements
Commitment and Policy
Planning
Implementation and Operation
AOHSM/A
AOHSM/B
AOHSM/C
AOHSM/D
AOHSM/E
AOHSM/F
AOHSM/G
AOHSM/H
AOHSM/01
AOHSM/02
AOHSM/03
AOHSM/04
Measurement and Evaluation
Management Review
Common Health & Safety
Procedure
Annexure Figure – 1A
(CHSP/01 to CHSP/13)
Annexure 1
(OHS objectives and on-going
Annexure 2
programme)
(Record to be maintained by
Annexure 3
MR)
(List of Safety and Occupational
Annexure 4
Health Reports)
(List of the Sectional
Annexure 5
Document)
(Annexure
Planning)6
(List of Reference Documents)
Annexure – 7
(Master
List
Annexure
– 8of Records Files)
AOHSM/05
AOHSM/06
AOHSM/07
AOHSM/08
AOHSM/
Annexure 1
AOHSM/
Annexure 2
AOHSM/
Annexure 3
AOHSM/
Annexure 4
AOHSM/
Annexure
AOHSM/ 5
(Master List of Records / Files)
Clause IS:18001
Prepared by
Revision No. 2.01
Annexure 6
AOHSM/
Annexure
AOHSM/ 7
Annexure 8
Reviewed by
Date : 20-01-2004
Doc No. : AOHSM/A
IS
18001
Req.
4.1
4.2
4.3
4.4
Rev.
No.
2.00
2.01
2.00
2.00
2.01
2.01
2.00
2.00
2.00
2.00
2.01
2.01
Page
no.
1
2
4
5
6
7
8
10
11
12
14
25
4.5
4.6
-
2.01
2.00
2.01
29
30
31
-
2.01
2.01
74
75
-
2.00
76
-
2.00
77
-
0.00
1 pg.
-
0.00
1 pg.
-
0.00
2 pgs.
-
0.00
7 pgs.
-
0.00
3 pgs.
Approved by
Page no. 1 of 77
Other Supporting Documents
Sectional
Manual.
Occupational
Health
Legal & Other Requirement
Risk Assessment & Control
&
Safety
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
Sr.No.
1.
Objectives
To
reduce
Occupational
Health & Safety
Hazards
OHS OBJECTIVES AND ON-GOING
PROGRAMME
Programmes
Audiometric study of the
employees exposed to
high noise level areas.
Procurement of new PPE –
Fall Arrester System
Procurement of modified
scaffolding.
Procurement of SO2
Monitors
Procurement of new B.A.
Sets
Modifications in handling
of lime powder
2.
3.
4.
To
enhance
competence
of
employees
including
contractor
personnel.
To review Safety
Manual
Promoting
employees health
awareness
Clause IS:18001
Prepared by
Revision No. 2.01
To introduce new topics in
safety trainings
To conduct half a day
training programme for
contractor personnel
Revision of safety manual
with the help of other
sections.
Organising health
awareness programme for
employees with the help of
external agencies.
Reviewed by
Date : 20-01-2004
Doc. No. : AOHSM/Annexure 1
Target Dates &
Target Figures
Feb.,
2004 &
presently 0
target
16 &
Mar., 2004
employees0
presently
target
02 &
Procured
presently 0
target
01 &
Mar.,2004
presently 01
target
01 &
May,2004
target 2 nos.
Mar.,2004 &
presently SPM =
3367 μg/m3
target less than
Jan.,2004
1000 μg/m&3
To include 3 new
topics
Continuous
process &
100% contractor’s
personnel
May,2004 &
presently 0.00
Revision 01 to be
May,2004
prepared &
Min. 30 nos.
employees are to
be covered
Performance
Indicators
Agency
Responsible
No. of employees
covered for
audiometric text
Dy. M (S&E)
Completion of the
job within time.
Dy. M (S&E)
Procurement
within time.
Dy. M M(M)
Availability of SO2
monitor
Dy. M (S&E)
Completion within
the time
CFO
Reduction of dust
level.
Dy. PM
Awareness
among the
employees
No. of the
contractor’s
personnel
covered.
Revision within
Dy. M (S&E)
No. of employees
covered.
Superintendent
Training &
Public
Awareness
time
Approved by
Page no. 75 of 77
Dy. M (S&E)
Dy. M (S&E)
Risk assessment and control
• Establish and maintain procedures
assessment and control of risks,
for
– 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
Medium
Low
Frequency F
3
2
1
Low
4
3
2
Medium
5
4
3
High
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
3x2 =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-2
Control 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)
Work Activity:
EXAMPLE-3
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
Marks allotted –1
: Low
Risk level = 2 (not significant)
RISK ASSESSMENT FORMAT
Sr.
No.
Work
Activity /
Situation
Events
Sub –
activity
Hazard
Situation
Normal
Abnor
mal
Emerge
ncy
Present
Control
measur
es
Severit
y “S”
Probability “P”
Risk
level
Exposu
re
duratio
n “E”
Securit
yx
probabi
lity
Freque
ncy of
Exposu
re “F”
Action
to be
taken
HWP–K
S
.
N
o
HAZARDS IDENTIFICATION AND RISK ASSESSMENT
Subactivi
ty
Work
activity /
Condition /
Events
Hazard
Situation
N
o
r
m
a
l
1
E
m
er
ge
nc
y
Sev
erit
y
“S”
TS-SOHSM-04
1.00
January 20, 2004
1 of 4
Probability
“P”
Ris
k
lev
el
Expo
sure
durat
ion
“E
Freq
uenc
y of
Expo
sure
“F”
Sev
erit
yx
pro
ba
bili
ty
Action
to be
taken
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-SOHSM05 Page 4of
6
Excess exposure of
Ozone while taking
the Xeroxing.
Supplier has already
taken the action while
designing the machine.
Low
Low
Low
01
Refer OCP
TS-SOHSM05 Page 4of
6
Exposure of light
while
taking
Xeroxing of thick
books.
Avoid the thick
books.
Low
Low
Low
01
Control
measures are
Drawing
development through
engineering
plan
printer.
Excess exposure of
Ozone while taking
the print.
Supplier has already
taken the action while
designing the machine.
Low
Low
Low
01
Refer OCP
TS-SOHSM05 Page 4of
6
Cyclostyling
Duplicating
ink
Stopping leakage
of the ink.
Low
Low
Low
01
Refer OCP TSSOHSM-05
Page 4of 6
Ammonia
printing
drawings
of
Xeroxing
2
3
A
b
n
o
r
m
a
l
Present Control
measures
Section No.
Rev No.
Date
Page
4
Prepared by:
Reviewed by:
adequate
Approved by:
REQUIREMENT OF REVIEWING THE RISK
ASSESSMENT
1. 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 IS18001.
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.
Comparison of management of OH&S aspects of
HWPs with IS 18001 & advantages/ positive points
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 All the activities
activities
are covered
4.2.3 OH&S Policy
Exists
--
4.3 Planning
4.3.1 Accountability and
Responsibility
It was not documented
fully.
It is now
documented at all
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
--
4.3.2 Identification of
Hazards & Assessment and
Control of Risks
4.4 Implementation and
Operational
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
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.
4.4.3 Operational Control
4.4.3.1 Design and engineer- Exists
ing control
--
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
4.5.1 Inspection & Testing
Exists
--
4.5.2 Internal Audit
Audit by
Internal audit by
corporate office personnel from within the
is conducted
organization is required
4.5 Measurement and
Evaluation
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