Safety Audit of A Petroleum Refinery

SAFETY AUDIT OF A
PETROLEUM REFINERY
TOPICS
1. Introduction
2. Objectives
3. Classification
4. OSHA and ACTS in India, OISD
5. Some Standards
6. Advantages and Disadvantages
PETROLEUM REFINERY
Also called as OIL REFINERY is an industrial
process plant where CRUDE OIL is transformed and
refined into more useful products such as
NAPHTHA
GASOLINE
DIESEL FUEL
PETROL
JET FUEL
ASPHALT BASE
LPG etc…..
SAFETY AUDIT
A safety audit is a structured
process whereby information is collected
relating to the efficiency , effectiveness and
reliability of a company’s
total health and safety
management system
SAFETY AUDIT IS
- Risk Management tool for an organisation
- Improvement tool for an organisation.
Any safety audit must have both

management and operational approach.
Safety Audit is MANDATORY for Hazardous

industries.
SAFETY AUDIT . WHY?
- To assess a company’s processes , procedures
and financial records.
- To ensure a safe work place.
- To identify risks in work area.
- To check the effectiveness of a safety system.
- To identify design deficiencies.
FOCUS OF SAFETY AUDIT
- Environmental Impact
- Process plant
- Personal Protective Equipment (PPE)
- How Institutional responses centralize
attention to Safety.
INTERNAL AUDIT
Also called as first party audit and is
performed within an organization. This is
conducted by auditors who are employed by
organization. This is
done to measure its
strengths and
weaknesses against
its own procedures or
methods.
EXTERNAL AUDIT
This is further classified into two types:
Second party audit
Third party audit
SECOND PARTY AUDIT
This is performed on a supplier by a

customer or by a contracted organization
on behalf of a customer. Second party
audits are subject to the rules of the
contract law . Second party audits tend to
be more formal than the first party audits
because audit results could influence the
customers purchasing decisions.
THIRD PARTY AUDIT
This is performed by an audit organization

independent of both customer and supplier
and is free of any conflict of interest. This may
result in certification or recognition or license
approval or a penalty issuance.
Independence of audit organization is the key
factor here.
CLASSIFICATION OF AUDITS
1.Fire Safety Audit
2.Electrical Safety Audit
3.Road Safety Audit

FIRE SAFETY AUDIT
ELECTRICAL SAFETY
1. Physical Inspection to identify electrical
hazards
2. Review of Plant Lighting Protection System
3. Review of electrical preventive maintenance
system
4. Review of importance given to electrical
safety
5. Review of earthing system
ROAD SAFETY AUDIT
1. Road functioning and surroundings

2. Cross Sections of the roads
3. Alignments of the roads
4. Service and rest areas
5. Traffic signings and markings
REQUIREMENTS
Safety auditing is a core safety

management activity providing a means
of identifying potential problems before
they have an impact on SAFETY . Basic
requirements for audit are:
AUDITEE
AUDIT TEAM
CLIENT
AUDIT CHECKLIST
1. Transportation of Hazardous substances
2. Handling of Hazardous substances
3. Material Safety data sheet
4. Bulk Oil Storages
5. Gas Cylinders
6. Labelling and Colour coding
7. Hazardous Waste Management
AUDIT PROCESS
1.PLAN
2. DO
3. CHECK
4. ACT
PHASES OF AN AUDIT
- Audit Preparation
- Audit Performance
- Audit Reporting
- Audit Follow-up and Closure

AUDIT PROCEDURES
There are normally five audit
procedures to obtain audit evidence. These
include : Inquiry
Observation
Examination or Inspection
Re-Performance
Computer Assisted Audit Technique
Occupational Safety and Health
Administration is an agency of US
Department of Labour .This is responsible for
worker safety and health protection.
SAFETY AUDIT IN INDIA
 BRITISH FACTORIES ACT
 EXPLOSIVES ACT (1884)
 PETROLEUM ACT (1934)
 INSECTICIDE ACT (1968)
 MINES ACT (1952)
 FACTORIES ACT (1948-87)
ACT , POLICY AND ISO
Environmental Protection act (1986)
Factories act (1948,87)
Quality Policy (ISO-9001)
Environmental Policy (ISO-14001)
OISD
Oil Industry Safety Directorate is a

technical directorate under the Ministry of
Petroleum and Natural gas that formulates
and coordinates the implementation of a
series of self regulatory measures aimed at
enhancing the oil and gas industry in INDIA.
OBJECTIVES OF OISD
- To conduct audits to ensure compliance.
- To standardize procedures in the areas of
design, operation and maintenance with a
view to achieve the highest safety standards in
a cost effective manner.
- To maintain continuous follow-up on
compliance to OISD audit action points.
- To analyse incidents happening in oil and gas
industry to identify root cause and formulate
action plan.
FUNCTIONS AND RESPONSIBILITIES
- To carry out periodic safety audits

- To ensure implementation of all standards
for industrial hygiene
- To review in plant training programmes
- To grant consent to operate on any
offshore rig
- To review practices in handling and
storage.
STANDARDS FOR SAFETY AUDIT
National Standards
- IS 14489:1998
International Standards
- British 5 Star Audit
- OSHA
Support Standards
- Indian Standards (BIS)
- OISD Standards
OISD STANDARDS
1. OISD-STD-105 Work Permit System
2. OISD-STD-106 Pressure Relief and disposal
system
3. OISD-STD-108 Safe handling and storage
4. OISD-STD-114 Safe handling of hazardous
chemicals
5. OISD-STD-116 Fire protection facilities
6. OISD-RP-124 Predictive maintenance practices
7. OISD-STD-125 Inspection and maintenance of
mechanical seals.
EXONNMOBIL REFINERY
EXPLOSION (2015)
BP AMERICA REFINERY
EXPLOSION (2005)
- K. RAHUL VENKAT
- 316106203003
- 4/4 CPE

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SAFETY AUDIT OF A

- Risk Management tool for an organisation

- Improvement tool for an organisation.

Any safety audit must have both

Safety Audit is MANDATORY for Hazardous

This is performed on a supplier by a

This is performed by an audit organization

2.Electrical Safety Audit

3.Road Safety Audit

1. Road functioning and surroundings

Safety auditing is a core safety

- Audit Follow-up and Closure

Oil Industry Safety Directorate is a

- To carry out periodic safety audits

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