Koppers Performance Chemicals - Health, Safety & Compliance Audit

• Document No.

• Audit Title

• Client / Site

• Conducted on

  Date

• Prepared by

• Location
  Address

• Personnel

1.0 - Previous Audit Review

• Has the previous KPCNZ Safety & Compliance Audit been reviewed?

  Yes

  No

  N/A

• Have all outstanding actions from the previous been completed? if no list all outstanding actions.

  Yes

  No

  N/A

2.0 - Fire Prevention & Emergency Response

• 2.1 - Evacuation & Emergency plan displayed and understood by all employees?

  Yes

  No

  N/A

• 2.2 - Evacuation & Emergency procedures discussed regularly?

  Yes

  No

  N/A

• 2.3 - Extinguishers in place, clearly marked for type of fire?

  Yes

  No

  N/A

• 2.4 - Extinguishers recently serviced? (Check 6 monthly punch mark on tabs.)

  Yes

  No

  N/A

• 2.5 - Extinguishers clear of obstructions?

  Yes

  No

  N/A

• 2.8 - Adequate direction notices for fire exits?

  Yes

  No

  N/A

• 2.10 - Exits clear of obstructions?

  Yes

  No

  N/A

• 2.11 - Fire alarm system functioning correctly?

  Yes

  No

  N/A

• 2.12 - Have employees been trained in Emergency shutdown procedures?

  Yes

  No

  N/A

• 2.13 - Has the placement of equipment been checked such that there are no evacuation hazards?

  Yes

  No

  N/A

• 2.14 - Emergency telephone numbers up to date and displayed? Check the Emergency Contact List Register (KPCNZ-SHE-REG-003)

  Yes

  No

  N/A

3.0 - General Lighting

• 3.1 - Good natural lighting?

  Yes

  No

  N/A

• 3.3 - Light fittings clean and in good condition?

  Yes

  No

  N/A

• 3.4 - Emergency exit lighting operable?

  Yes

  No

  N/A

• 3.5 - Plant lighting adequate

  Yes

  No

  N/A

4.0 - Building & General Site Safety.

• 4.1 - Floor surfaces even and uncluttered?

  Yes

  No

  N/A

• 4.2 - Entry and walkways kept clear?

  Yes

  No

  N/A

• 4.3 - Walkways adequately and clearly marked?

  Yes

  No

  N/A

• 4.4 - Intersections kept clear of boxes etc?

  Yes

  No

  N/A

• 4.5 - Stair and risers kept clear?

  Yes

  No

  N/A

• 4.6 - Are liquid spills removed quickly?

  Yes

  No

  N/A

• 4.7 - Are railings in good condition?

  Yes

  No

  N/A

• 4.8 - Are fall preventive measures in place and used ?

  Yes

  No

  N/A

• 4.9 - Are footpaths in good condition?

  Yes

  No

  N/A

• 4.10 - Is there access control to the factory?

  Yes

  No

  N/A

• 4.11 - Does a plant rules/ hazard board exist on entry to site?

  Yes

  No

  N/A

5.0 - Maintenance Work Benches

• 5.1 - Clear of rubbish?

  Yes

  No

  N/A

• 5.3 - No damaged hand tools in use?

  Yes

  No

  N/A

• 5.4 - No damaged power tools in use?

  Yes

  No

  N/A

• 5.6 - No sharp edges?

  Yes

  No

  N/A

6.0 - Rubbish Removal

• 6.1 - Bins located at suitable points around site?

  Yes

  No

  N/A

• 6.2 - Bins emptied regularly?

  Yes

  No

  N/A

7.0 - Storage Design and Use

• 7.1 - Materials stored in racks and bins wherever possible?

  Yes

  No

  N/A

• 7.2 - Storage designed to minimise lifting problems?

  Yes

  No

  N/A

• 7.3 - Chemical Cabinets Compliant? ( Check for incompatible chemicals, maximum storage, labeling ..etc)

  Yes

  No

  N/A

8.0 - Machines and Plant

• 8.1 - Are they kept clean?

  Yes

  No

  N/A

• 8.2 - Are the floors around the machines kept clean?

  Yes

  No

  N/A

• 8.3 - Guards in good condition?

  Yes

  No

  N/A

• 8.4 - Starting and stopping devices within easy reach of operator?

  Yes

  No

  N/A

• 8.6 - Drip pans on floor to prevent spillage, where applicable?

  Yes

  No

  N/A

• 8.7 - Adequate work space?

  Yes

  No

  N/A

• 8.8 - Is lighting adequate?

  Yes

  No

  N/A

• 8.9 - Noise levels controlled?

  Yes

  No

  N/A

• 8.10 - No bending or stooping required?

  Yes

  No

  N/A

• 8.12 - Operators trained/inducted into the operation of the machines/ Equipment?

  Yes

  No

  N/A

• 8.13 - Is the training recorded?

  Yes

  No

  N/A

• 8.14 - Do operators comply with the training?

  Yes

  No

  N/A

• 8.15 - Are lockout procedures implemented and followed where applicable?

  Yes

  No

  N/A

• 8.16 - Are gas bottles secured?

  Yes

  No

  N/A

• 8.17 - Is plant signage adequate?

  Yes

  No

  N/A

• 8.18 - Are there any process safety concerns?

  Yes

  No

  N/A

8.2 - Maintenance and Preventative Maintenance

• 8.2.1 - Are the six weekly condition monitoring checks for the warehouse racking been completed? Are any damage records noted on FOCUS?

  Yes

  No

  N/A

• 8.2.2 - Are the six weekly condition monitoring checks for Plant Bunds completed? - No damage or liquid within the bunds?

  Yes

  No

  N/A

• 8.2.3 - Have the six weekly checks of the Nitric Acid scrubber NO2 analyser (weekly calibrations) been completed? See log book. Check with the production manager.

  Yes

  No

  N/A

• 8.2.4 - Are chemical hoses tested and tagged?

  Yes

  No

  N/A

• 8.2.5 - Has the six weekly condition monitoring of Safety Critical Elements(SCEs) been completed? (Vibration in pumps/motors/couplings/ observed)

  Yes

  No

  N/A

• 8.2.6 - Arsenic Plant Backup gas fan test completed on schedule?

  Yes

  No

  N/A

9.0 - Electrical Safety

• 9.4 - Portable equipment tested and tagged?

  Yes

  No

  N/A

• 9.5 - No broken plugs, sockets or switches?

  Yes

  No

  N/A

• 9.6 - No power leads across walkways?

  Yes

  No

  N/A

• 9.7 - No frayed or damaged leads?

  Yes

  No

  N/A

• 9.8 - No strained leads?

  Yes

  No

  N/A

• 9.9 - Portable power tools in good condition?

  Yes

  No

  N/A

• 9.10 - Where required, are emergency shut-down procedures in place?

  Yes

  No

  N/A

• 9.11 - Are controls properly labeled?

  Yes

  No

  N/A

10.0 - Chemical Safety

• 10.1 - Hazardous Substance Register complete and up to date? Check Register (KPCNZ-SHE-REG-004)

  Yes

  No

  N/A

• 10.2 -Safety Data Sheets available for all chemicals?

  Yes

  No

  N/A

• 10.3 - Risk assessments completed for any new hazardous substances? Check MOC records.

  Yes

  No

  N/A

• 10.5 - Unused substances disposed of?

  Yes

  No

  N/A

• 10.4 - All containers labelled correctly?

  Yes

  No

  N/A

• 10.6 - Do special storage conditions apply?

  Yes

  No

  N/A

• 10.7 - If applicable are special storage conditions followed?

  Yes

  No

  N/A

• 10.8 - Workers trained in the use of hazardous substances?

  Yes

  No

  N/A

• 10.9 - If required is PPE available?

  Yes

  No

  N/A

• 10.10 - Is adequate ventilation provided?

  Yes

  No

  N/A

• 10.11 - Are eye washes and showers easily accessed?

  Yes

  No

  N/A

• 10.12 - Are spill kits available?

  Yes

  No

  N/A

• 10.13 - Are used Arsenic Trioxide and Chrome drums free from residual chemicals after drum washing? Check drums for any solids after washing.

  Yes

  No

  N/A

11.0 Ladders

• 11.1 - Are all ladders Industrial strength? (Non Household rated, check label.)

  Yes

  No

  N/A

• 11.2 - Are ladders in good condition?

  Yes

  No

  N/A

• 11.4 - Used according to instructions?

  Yes

  No

  N/A

12.0 - First Aid Facilities

• 12.1 - Are cabinets and contents clean and orderly?

  Yes

  No

  N/A

• 12.2 - Are contents regularly checked?

  Yes

  No

  N/A

• 12.3 - No contents past their expiry date?

  Yes

  No

  N/A

• 12.4 - Cabinets clearly labelled?

  Yes

  No

  N/A

• 12.5 - Is there easy access to cabinets?

  Yes

  No

  N/A

• 12.6 - Employees aware of location of first aid cabinet?

  Yes

  No

  N/A

• 12.7 - Are first aid officers accessible?

  Yes

  No

  N/A

• 12.8 - Are emergency numbers displayed?

  Yes

  No

  N/A

13.0 - Office Hazards

• 13.1 - Desks in good condition? (No damage.)

  Yes

  No

  N/A

• 13.2 - Tasks designed to prevent Occupational Overuse Syndrome? (Breaks included.)

  Yes

  No

  N/A

14.0 - Emergency Response and Preparedness

• 14.1 - Is the emergency response plan up to date and has it been tested.

  Yes

  No

  N/A

• 14.2- Does the Emergency Response Plan cover all possible emergency scenarios ?

  Yes

  No

  N/A

15.0 - Training and Inductions

• 15.1 - Are staff and contractor induction records up to date? Check the site Induction Register.

  Yes

  No

  N/A

• 15.2 - Is the staff Skills and Training up to date? Check the site Skills and Training Matrix (KPCNZ-SHE-REG-002)

  Yes

  No

  N/A

16.0 - Incident Management and Safety Observations

• 16.1 - is the incident management system functional?

  Yes

  No

  N/A

• 16.2 - Are incidents and Near Misses communicated at team meetings?

  Yes

  No

  N/A

17.0 - Management of Change

• 17.1 - Is the management of change system for new chemicals, equipment, processes & procedures operational? (Check the MOC register - KPCNZ-MOC-REG-009) on the network and list at least two recent change documents)

  Yes

  No

  N/A

18.0 - General Work Station or Plant Compliance (Choose 3 workstations or Plant Areas at Random)

• 18.1 - Is Work Station 1 compliant? Log the Name/ID of the work station below together with any non- conformance's.<br>Check the following: Adequate risk assessment, Housekeeping, Documentation.<br>

  Yes

  No

  N/A

• 18.2 - Is Work Station 2 compliant? Log the Name/ID of the work station below together with any non- conformance's.<br>Check the following: Adequate risk assessment, Housekeeping, Documentation.<br>

  Yes

  No

  N/A

• 18.3 - Is Work Station 3 compliant? Log the Name/ID of the work station below together with any non- conformance's.<br>Check the following: Adequate risk assessment, Housekeeping, Documentation.

  Yes

  No

  N/A

Emissions Control - Air Discharge Consent - Permit Number: 37264 - Resource Management Act 1991

• Has a check been conducted at 3 points outside the boundary(10 m) to check for odour or airborne particulate matter? Compliance with the air discharge consent, Conditions 5-7.

  Yes

  No

  N/A

• Has the 6 monthly stack testing of arsenic trioxide on the arsenic acid plant bag filter been scheduled or completed?

  Yes

  No

  N/A

• Has the 3 monthly combustion checks of the boiler been scheduled or completed?

  Yes

  No

  N/A

• Have the annual calibrations of the temperature, density and flow meters been scheduled or completed?

  Yes

  No

  N/A

• Are the bi-monthly emergency power system (generator) checks been completed?

  Yes

  No

  N/A

Major Hazard Facilities

• Are the six weekly Safety Critical Element monitoring checks completed? This would be a part of the site six - weekly inspections.

  Yes

  No

  N/A

• Has the management of change register been checked to identify if updates to the Safety Case are required?

  Yes

  No

  N/A

Compliance

• Is the Facility compliant to local standards, laws & regulations? Check Compliance Register (KPCNZ-SHE-REG -006) for any outstanding items. Check the H&S at Work Act Obligations Register (KPCNZ-SHE-REG-008).

  Yes

  No

  N/A

• Does any of the following exist , HAZOP's, PHA 's, or Third party safety assessments. If yes please list.

  Yes

  No

  N/A

• Is the Bio-security Internal Audit Complete? Are there any follow-up audit actions still outstanding? Check the following:<br>Does the facility have dedicated and labelled equipment? e.g.<br>• Broom and dustpan (or vacuum)<br>• Biosecurity bin (lined if appropriate)<br>• Torch<br>• Dual-action insecticide<br>• Any other equipment required in the TF Approval.<br>

  Yes

  No

  N/A

Documentation

• Are safety documents like the SHE management plan, Emergency Response, policies and procedures , etc. available?

  Yes

  No

  N/A

• Are operations and maintenance manuals, sops's, etc. available?

  Yes

  No

  N/A

Recommendations and Comments

• undefined

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