Topic

Comprehensive Safety

Improvement & Capacity Building

(CSICB)

Presented by :

Jitendra Kumar

DEKRA India

Contents - CSICB

• Introduction to DEKRA

• What is CSICB

• Project Design and Objectives

• Step 1 – Development of SMS

• Step 2 - Gap Analysis (Safety Culture & Process Safety)

• Benchmarking and Implementation Plan

• Step 3 – In house Competence Development

• Step 4 - Implementation, Checks and monitoring

• Step 5 – Sustainability

• Questions…

Our Overview

DEKRA India (Pvt.) Ltd., India

• Indian subsidiary of DEKRA, Germany

• Earlier Chilworth Technology, renamed after DEKRA takeover.

• Established in 2002 to provide a center for excellence for process safety, health and

environmental services in India / Asian region

• Now acquired world-class status among the Asian industries and have over 900 clients in

India alone.

• BST Inc., RCI, Optimus, Russell Consulting are part of same team now.

Process and Behaviour Safety Services

Consultancy Laboratory Testing Trainings Instruments

Our Expertise

We bring together leading national & international expert consultants in the field of process

safety with ISO/IEC Accredited laboratory to provide a single point of contact for Industry’s

Health, Safety & Environmental needs.

If you think Safety is a cost, Try accidents….

• The spotlight that the risk caused by fire accident, which killed 113,961 people

between 2010 and 2014.

• That means 54 people die everyday.

• But injuries and deaths from fire accidents are constantly falling, as per the data

indications.

• This is predominantly due to increasing awareness and resulting preventive /

mitigative measures.

Why CSICB

• Assess how we are performing on Process Safety

• Target what we want to achieve on PS

• Gap assessment

• Benchmarking

• Plan

• Execute

• Review

• Ensure a sustainable solution.

What is CSICB

Step 1 Develop Safety Management System

Step 2 Gap Assessment

Step 3 In-house Competence Development

Step 4 Implementation

Step 5 Sustainable Safety Management.

CSICB

• Process safety

• Reactivity, overpressure, flammability, toxicity, etc.

• Need specialized knowledge and training

• The knowledge may be beyond what can realistically be expected from non-

technical personnel

• For example

• is the relief valve on the reactor big enough to protect against a runaway

reaction?

• Is the emergency relief discharge system adequate to prevent exposure of

personnel to hazardous vapor concentrations?

Hazard Recognition

Step 1 – Development of SMS

To document, where and how Process Safety needs to be

1. Policy & Objectives

2. Corporate level SMS document

3. Site level SMS document

4. Communication & Involvement

5. Training and competence.

These mirror the requirements for competency, good HSE

culture, good HSE management etc.

A. Safety Culture - HSE Profiling

• For Site head, Dept heads & HSE team members

• Assessment sheets

• Walk Through Survey

• Interviews

B. Process Safety

• Assessment & audits

• Review adequacy & compliance

• Effectiveness of corrective actions

• Review work practices & on-job skills

• Categorization of findings.

Step 2 – Gap Analysis - Safety Culture & Process Safety

GRAPH -I

STAGES OFSHE Employee Performance

Reactive Compliance Driven Risk

Management

Continuous

Improvement

Just meeting legislative

requirementIdentifies and

assesses risks

inherent in

operations

0 10 20 30 40 50 60 70 80 90 100

Organization reacts

only after an accident

or incident

LEVEL

Actively seeks

alternative

approaches

and

technologies

Overall Scoring (Benchmarking) of HSE Profiling

Focus on the following aspects:

• Handling of material

• Processing of material

• Chemical Reaction Hazards

• Hazard Identification and Assessment

• Process Control

• Electrostatics Hazard Assessment

• Dust Explosion Hazard Assessment

• Inspection, Testing and Maintenance

• Procedures & SOP’s

• Trainings.

Gap Analysis – Process Safety

DEKRA has world wide benchmarking data of the best industries in business against

which you can compare your performance and set HSE objectives.

Database compiled based across the globe since 1992:

Oil and Gas

Petrochemicals

Pharmaceuticals

Polymers and Plastics

chemicals

Agrochemicals

Explosives.

Benchmarking

The competence development is done as follows:

• Core team selection

• HSE profiling of core team members

• PSM element allocation based on HSE profiling

• Training of core team members

• Sensitization of various level of employees on PSM by training / discussions

• Feedback from core team & all level of employees.

• Competence development of core team

• Handover & hand holding on Process Safety Management to core team

• Supervision for core team.

Step – 3 In house competence Development

Major activities:

• Implementation of Road map

• Trainings based identified needs

• Representative PHAs (such as HAZOP,QRA…)

• Specialized process safety areas (such as static electricity, CRH, dust

explosions)

• Review of procedure and systems

• Inputs for installing sustainable process safety management system

• Formation of working core group from client team

• System for self-assessment.

Step – 4 Implementation, Checks and Monitoring

Major Activities:

• Periodic assessment (as required)

• Reassessment of HSE profiling

• Guidance to ensure sustainability

Output:

• Assessment and progress reports on the safety indicators

• HSE profile report.

Step – 5 Sustainability

Finally

• This is only the start of the journey!

• Good luck!

Questions?