Case Study: Safety Audit of Ammonia Plant at Auro Textiles (A Unit Of Vardhman Textiles Limited.)

Case Study: Safety Audit of Ammonia Plant at Auro Textiles  (A Unit Of Vardhman Textiles Limited.)

Client Overview:

Auro Textiles, a unit of Vardhman Textiles Limited, engaged HSE Risk Management Services Private Limited to conduct a comprehensive Safety Audit of their Ammonia Plant. The objective was to assess and enhance safety measures related to the storage and handling of Ammonia, ensuring compliance with legal requirements and company safety policies.

Process Description:

The Ammonia Plant at Auro Textiles is equipped with storage facilities for Ammonia, crucial for the Kyoto Machine operations.

Safety Audit Concept:

Modern safety practices emphasize the importance of Safety Audits to evaluate compliance with safety standards set by the company, government regulations, and international norms. Safety Audits identify potential hazards, recommend corrective actions, and verify the implementation of safety protocols to mitigate risks associated with hazardous materials like Ammonia.

 Statutory Requirements:

• As per Manufacture, Storage and Import of Hazardous Chemical Rules, 1989 (consolidated version with subsequent amendments), Rule 10(4) “The occupier of both the new and the existing industrial activities shall carry out an independent safety audit of the respective industrial activities with the help of an expert, not associated with such industrial activities.”

• As per Manufacture, Storage and Import of Hazardous Chemical Rules, 1989 (consolidated version with subsequent amendments), Rule 10(6) “The occupier shall update the safety audit report once a year by conducting a fresh safety audit and forward a copy of it with his comments thereon within 30 days to the concerned Authority.”

Safety Audit Process:

1.  Opening Meeting: HSE Risk Management Services conducted an opening meeting with Auro Textiles to discuss the audit scope, objectives, methodology, and schedule. Auro Textiles provided insights into their manufacturing processes and current Occupational Safety and Health (OS & H) systems.

2.  Examination:

• The audit team reviewed compliance with all 31 elements of the OS & H system outlined in IS-14489.

• They examined procedures, guidelines, documents, training records, management information systems (MIS), and conducted compliance audits.

• Specific records as per IS-14489 were checked to ensure regulatory compliance.

• The audit questionnaire was used to verify adherence to safety standards.

• Licenses were reviewed to confirm compliance with legal requirements.

• They assessed the status of previous audit recommendations to track improvements over time.

3.  Site Round:

• Auditors conducted comprehensive site rounds across various departments of the Ammonia Plant.

• They observed safety practices, identifying areas for improvement and noting commendable practices that could be shared as best practices.

4.  Closing Meeting:

• Following the audit, a closing meeting was held to discuss findings, observations, and recommendations.

• The audit team presented a compliance status report for each element of the OS & H system.

• Recommendations were provided to enhance safety protocols, training programs, documentation, and monitoring systems. 

Safety Audit Methodology:

Challenges:

The audit identified challenges such as the complexity of handling Ammonia safely and ensuring seamless integration of safety policies across all operational levels.

Recommendations:

Based on audit findings, recommendations included improving training programs, enhancing documentation standards, and implementing advanced monitoring systems to strengthen safety measures at the Ammonia Plant.

Conclusion:

The Safety Audit of the Ammonia Plant at Auro Textiles by HSE Risk Management Services was instrumental in identifying key safety improvements and ensuring compliance with regulatory standards. It underscored the importance of proactive safety management practices and continuous improvement in handling hazardous chemicals to maintain a safe working environment.

This case study highlights how Safety Audits play a crucial role in safeguarding personnel, facilities, and the environment from the risks associated with hazardous materials like Ammonia in industrial settings.