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I.CHEM.E. SYMPOSIUM SERIES NO. 110 SAFETY AUDITS IN DEVELOPING COUNTRIES

Sami

Atallah*

and

E v e r a r s e n i o Guzman*

The a u t h o r s r e c e n t l y c a r r i e d o u t a s a f e t y a u d i t of an a c r y l i c f i b e r p l a n t in a L a t i n American country. The p l a n t h a n d l e d l a r g e q u a n t i t i e s o f a c r y l o n i t r i l e , v i n y l a c e t a t e , d i m e t h y l formamide and o t h e r h a z a r d o u s c h e m i c a l s . T h i s e x p e r i e n c e will be used to i l l u s t r a t e the p r o b l e m s e n c o u n t e r e d when c a r r y i n g o u t s u c h a u d i t s i n developing c o u n t r i e s .

INTRODUCTION I n t h e wake o f m a j o r w e l l - p u b l i c i z e d c h e m i c a l a c c i d e n t s t h a t h a v e o c c u r r e d i n v a r i o u s p a r t s o f t h e w o r l d o v e r t h e p a s t two d e c a d e s , many p r i v a t e a n d n a t i o n a l c o m p a n i e s o p e r a t i n g i n d e v e l o p i n g countries have recognized their own vulnerability to such disastrous accidents. M o t i v a t e d more b y s e l f - p r e s e r v a t i o n t h a n by r e g u l a t o r y r e q u i r e m e n t s , t h e s e c o m p a n i e s h a v e been seeking help i n a s s e s s i n g t h e i r p o t e n t i a l for s u f f e r i n g c a t a s t r o p h i c accidents similar to those that befell Flixborough, Bhopal, Seveso, Mexico C i t y and the Rhine r i v e r . Lacking local knowledgeable c o n s u l t a n t s i n t h e a r e a s o f c h e m i c a l s a f e t y and r i s k a s s e s s m e n t , t h e y h a v e s o u g h t h e l p from c o n s u l t i n g f i r m s o p e r a t i n g p r i m a r i l y in developed n a t i o n s . T o e d u c a t e t h e i r own s t a f f , and t o f i n d o u t who p r o v i d e s s u c h s e r v i c e s and w h a t t h e d e v e l o p e d n a t i o n s a r e doing t o p r e v e n t t h e r e c u r r e n c e o f such accidents, t h e s e companies have i n c r e a s i n g l y p a r t i c i p a t e d i n international safety meetings. This is evidenced by the a t t e n d a n c e l i s t s and t h e c o u n t r i e s r e p r e s e n t e d b y t h e a t t e n d e e s o f t h i s v e r y m e e t i n g , t h e Symposium o n P r e v e n t i n g Major C h e m i c a l A c c i d e n t s h e l d i n W a s h i n g t o n i n 1 9 8 7 , and t h e L o s s P r e v e n t i o n and S a f e t y Promotion in the P r o c e s s I n d u s t r i e s held in Cannes in 1986. One o f t h e p r o b l e m s f a c i n g c o m p a n i e s t h a t a r e n o t a w a r e o f t h e s e m e e t i n g s has been the identification of i n d u s t r i a l safety c o n s u l t a n t s t o whom t h e y c a n t u r n f o r h e l p . Quite o f t e n , they r e s o r t t o p u b l i s h e d l i s t s o f c o n s u l t i n g c o m p a n i e s , s e l e c t a few * Risk & I n d u s t r i a l Safety Des P l a i n e s , IL 6 0 0 1 8 USA

Consultants,

35

Inc.,

292

Howard

Street,

I.CHEM.E. SYMPOSIUM SERIES NO. 110 at random, and r e q u e s t q u a l i f i c a t i o n s and work r e f e r e n c e s . It is in t h i s context t h a t a privately-owned Latin American company which h a n d l e s several h a z a r d o u s c h e m i c a l s used t h e a n n u a l National F i r e P r o t e c t i o n Association Fire P r o t e c t i o n and Fire S e r v i c e R e f e r e n c e D i r e c t o r y to c o n t a c t a number of US f i r e c o n s u l t i n g c o m p a n i e s s e l e c t e d more o r l e s s a t r a n d o m . We received such a c a l l from the s a f e t y o f f i c e r who spoke a very h a l t i n g English asking if we were able to conduct a s a f e t y a u d i t of an a c r y l i c f i b e r p l a n t which handled l a r g e q u a n t i t i e s of acrylonitrile, vinyl acetate, dimethyl formamide, fuel oil, c a u s t i c soda, s u l f u r i c a c i d , c h l o r i n e and polymer powder. We r e s p o n d e d w i t h a t e l e x d e s c r i b i n g w h a t , i n o u r u n d e r s t a n d i n g , may b e i n v o l v e d i n a s a f e t y a u d i t and r e q u e s t e d a d d i t i o n a l d a t a before a cost proposal could be s u b m i t t e d . The company t o o k i t s time in c o l l e c t i n g the r e q u e s t e d data (flow c h a r t s , plant l a y o u t , inventory of c h e m i c a l s , e t c . ) . Once r e c e i v e d , we promptly sent a formal proposal to conduct a q u a l i t a t i v e s a f e t y a u d i t with an option to c a r r y out a q u a n t i t a t i v e r i s k a s s e s s m e n t . We were asked to v i s i t the p l a n t to d i s c u s s and n e g o t i a t e the c o n t r a c t . At t h a t one-day meeting, a l o t of haggling went o n , i n c l u d i n g t h e a d d i t i o n o f o t h e r a r e a s o f t h e p l a n t not i n c l u d e d in the o r i g i n a l scope of the a u d i t . The c l i e n t p r e f e r r e d to see the f i n a l r e p o r t in Spanish. The d e l i v e r y dates were s e t , a schedule of payment was agreed upon, and a s t a r t d a t e established. Understandably, the c l i e n t did not care to fund a quantitative r i s k assessment. F i r s t , the concept of q u a n t i f y i n g i n d u s t r i a l r i s k s was not f a m i l i a r to management. However, it became p a t e n t l y c l e a r during t h a t one-day v i s i t t h a t t h e r e were simply too many i n f r a c t i o n s of common-sense engineering s a f e t y p r a c t i c e s , and t h a t the c o r r e c t i o n of any of these i n f r a c t i o n s would improve p l a n t s a f e t y s i g n i f i c a n t l y without the need for an elaborate risk analysis. We spent two weeks at the p l a n t , during which we met with key s t a f f members i n p r o d u c t i o n , m a i n t e n a n c e , s a f e t y and s e c u r i t y , e n g i n e e r i n g , c h e m i c a l and p h y s i c a l p r o c e s s i n g , and training. We observed key o p e r a t i o n s , examined r e c o r d s , standard o p e r a t i n g procedures and t r a i n i n g c u r r i c u l a , and p a r t i c i p a t e d in a night s h i f t s e c u r i t y tour of the p l a n t . At the conclusion of our s t a y , we met with the s u p e r i n t e n d e n t s , who are the second t i e r of plant management, and presented them with a p r e l i m i n a r y l i s t of f i n d i n g s . We a l s o played the game of "what if" with them. Several p o t e n t i a l a c c i d e n t - i n i t i a t i n g s c e n a r i o s were presented to them and t h e i r responses s o l i c i t e d . Back in the home o f f i c e , we reviewed the data we c o l l e c t e d and our own o b s e r v a t i o n s , compared the company p r a c t i c e s with those e s t a b l i s h e d in the US and other developed c o u n t r i e s , and prepared a d r a f t r e p o r t . A third t r i p was made to r e c e i v e the company's comments and to make a f i n a l o r a l p r e s e n t a t i o n to departmental managers and the d i r e c t o r . The f i n a l r e p o r t contained 119 recommendations. In a d d i t i o n to t h e r e p o r t , we s u p p l i e d t h e c l i e n t with two s u p p l e m e n t a r y volumes: one c o n s i s t i n g of c o p i e s of r e f e r e n c e s not r e a d i l y a c c e s s i b l e t o t h e c o m p a n y , and a n o t h e r c o n s i s t i n g of a c o l l e c t i o n of c a t a l o g s of s p e c i f i c equipment and s u p p l i e r s of s e r v i c e s t h a t we f e l t were r e q u i r e d if the company were to adopt

36

I.CHEM.E. SYMPOSIUM SERIES NO. 110 our

recommendations.

I n t h e r e m a i n d e r o f t h i s p a p e r , w e want t o r e v i e w some o f t h e c h a r a c t e r i s t i c s o f t h i s a s s i g n m e n t t h a t made i t q u i t e d i f f e r e n t from o t h e r a s s i g n m e n t s w e h a v e c a r r i e d o u t i n d e v e l o p e d nat ions. GENERAL PLANT DESCRIPTION The p l a n t was l o c a t e d a l o n g a w e l l - t r a v e l e d , p o o r l y - k e p t r o a d i n a p r e d o m i n a n t l y i n d u s t r i a l a r e a a b o u t 15 km from a m a j o r c i t y in Latin America. The p l a n t r e c e i v e d a c r y l o n i t r i l e b y r a i l r o a d t a n k c a r s and t a n k t r u c k s , and v i n y l a c e t a t e , d i m e t h y l f o r m a m i d e , f u e l o i l , and s e v e r a l o t h e r c o r r o s i v e a n d h a z a r d o u s c h e m i c a l s b y t a n k truck. A c r y l i c p o l y m e r was p r e p a r e d u s i n g a r e l a t i v e l y l o w temperature reaction. The p o l y m e r was d r i e d i n s t e a m d r y e r s a n d p n e u m a t i c a l l y t r a n s p o r t e d as a powder to s t o r a g e b i n s . From t h e r e , t h e powder was d i s s o l v e d and e x t r u d e d i n t o a c r y l i c f i b e r . The p r o c e s s r e q u i r e d l a r g e q u a n t i t i e s o f s t e a m w h i c h was g e n e r a t e d o n t h e p r e m i s e s u s i n g f u e l o i l and g a s - f i r e d b o i l e r s . T h e p l a n t h a d b e e n b u i l t some t w e n t y y e a r s e a r l i e r i n accordance with no s p e c i f i c s t a n d a r d s or r e g u l a t i o n s . Secondhand s t o r a g e t a n k s , b o i l e r s and o t h e r p r o c e s s v e s s e l s o f unknown v i n t a g e were used in t h e a s s e m b l y of t h e p l a n t . T h e p l a n t w a s s u r r o u n d e d b y a 2-m h i g h f e n c e w i t h a continuous guard s e r v i c e a t t h e main e n t r a n c e . The p l a n t operated 24 hours/day in three s h i f t s . P r i v a t e b u s e s were used t o t r a n s p o r t e m p l o y e e s t o and from t h e l o c a l v i l l a g e s and t h e city. P l a n t m a n a g e m e n t c o n s i s t e d o f a d i r e c t o r , t o whom r e p o r t e d a t i e r of departmental managers of manufacturing, e n g i n e e r i n g , p e r s o n n e l ( i n c l u d i n g t r a i n i n g and s a f e t y ) , and m a i n t e n a n c e . R e p o r t i n g t o t h e d e p a r t m e n t a l managers were s u p e r i n t e n d e n t s t o whom t h e s u p e r v i s o r s o r f o r e m e n r e p o r t e d . The p l a n t was one of s e v e r a l owned by the parent corporation. The p l a n t was v i s i t e d t w i c e a y e a r b y t h e c o r p o r a t e s a f e t y e n g i n e e r who e v a l u a t e d t h e s a f e t y p e r f o r m a n c e o f t h e p l a n t and i t s c o m p l i a n c e w i t h p r e v i o u s r e c o m m e n d a t i o n s , and i s s u e d a r e p o r t w i t h new r e c o m m e n d a t i o n s . Management had a d o p t e d a p l a n t m o t t o of " c e r o a c c i d e n t e s " or " z e r o a c c i d e n t s " and t h i s m o t t o was e m b l a z o n e d o n t h e w a l l s o f v a r i o u s p a r t s o f t h e f a c i l i t y and p u b l i c i z e d i n i t s m o n t h l y employee magazine. T o i t s c r e d i t , t h e f a c i l i t y had n o t s u f f e r e d a major a c c i d e n t s i n c e i t s i n c e p t i o n . On the s u r f a c e , the plant appeared to be in e x c e l l e n t , w e l l kept condition. I t was n o t u n t i l w e g o t t o o b s e r v e t h e d e t a i l s o f t h e c o m p a n y ' s a c t u a l o p e r a t i n g and m a i n t e n a n c e p r o c e d u r e s and t o i n s p e c t t h e c o n d i t i o n s o f i t s s t o r a g e t a n k s and m a t e r i a l h a n d l i n g and t r a n s f e r e q u i p m e n t , b o i l e r s , and i n s t r u m e n t a t i o n a n d c o n t r o l s y s t e m s , t h a t p o t e n t i a l s e r i o u s problem a r e a s became evident. Some o f t h e s e p r o b l e m s a r e d i s c u s s e d b e l o w .

37

I.CHEM.E. SYMPOSIUM SERIES NO. 110

SELECTED PROBLEM AREAS "Machismoism"

One of the major problems t h a t the a u t h o r s have p e r s o n a l l y e x p e r i e n c e d in t h e i r r e s p e c t i v e homelands (Middle East and L a t i n A m e r i c a ) is t h e syndrome of what might be r e f e r r e d to as "machismoism". We d e f i n e machismoism as t h e " i t - c a n ' t - h a p p e n t o - m e " b e l i e f , o r the d e l u s i o n t h a t i t i s " s i s s y " t o wear s e a t b e l t s i n c a r s and p l a n e s . Machismoism c a r r i e s through t o t h e p l a n t where w o r k e r s f e e l s i l l y w e a r i n g h a r d h a t s and s a f e t y g l a s s e s , l e t alone a s e l f - c o n t a i n e d breathing a p p a r a t u s . A l t h o u g h t h e t r a i n i n g p r o g r a m o f t h i s company s t r e s s e d v a r i o u s h e a l t h a s p e c t s o f t h e t o x i c and f l a m m a b l e m a t e r i a l s h a n d l e d and t h e i m p o r t a n c e o f u t i l i z i n g p e r s o n a l p r o t e c t i v e e q u i p m e n t , t h e s e i n s t r u c t i o n s were not e n f o r c e d and s u p e r v i s o r s s e t a poor example to new t r a i n e e s . A c r y l o n i t r i l e , for example, was handled as if it were w a t e r . T r a n s f e r c o n n e c t i o n s were made u s i n g b a r e h a n d s , w i t h o u t any s p e c i a l c l o t h i n g o r b o o t s , and without a s e l f - c o n t a i n e d b r e a t h i n g a p p a r a t u s . A continuous stream o f l i q u i d l e a k e d from t h e c o n n e c t i o n s i n t o a b u c k e t . The o p e r a t o r would c o n n e c t t h e t r u c k , t u r n the pump on, and l e a v e to a t t e n d t o o t h e r d u t i e s . The d r i v e r u s u a l l y r e m a i n e d i n t h e t r a n s f e r a r e a , s l e p t i n t h e cab o f h i s t r u c k , o r went t o t h e guard house to smoke. O c c a s i o n a l l y , he would climb on top of the t r u c k to peer down i n t o the open a i r vent to see how much l o n g e r he had to w a i t , or he would t a k e a d v a n t a g e of a nearby water hose to wash t h e grime off h i s t r u c k . Safety Emphasis

The major s a f e t y concern of both the p a r e n t c o r p o r a t i o n and t h e company had been to minimize t h e e a s i l y c o u n t a b l e numbers of w o r k e r ' s i n j u r i e s , p a r t i c u l a r l y t h o s e a s s o c i a t e d with r o t a t i n g m a c h i n e r y u s e d t o d r a w and w i n d t h e a c r y l i c f i b e r s . The c o r p o r a t e s a f e t y review of the p l a n t had numerous t a b l e s showing s u c h d a t a a s f i n g e r and back i n j u r i e s and t h e t i m e l o s t , and comparing the plant performance a g a i n s t that of the other subsidiaries. Very l i t t l e a t t e n t i o n was given t o p o t e n t i a l l y c a t a s t r o p h i c a c c i d e n t s t h a t could lead to a t o t a l or p a r t i a l d i s r u p t i o n o f o p e r a t i o n s , damage t o p r o p e r t y , and i n j u r y t o employees and people l i v i n g in nearby h a m l e t s . It was not u n t i l we met with t h e s u p e r v i s o r s and managers and played t h e game of "what i f " t h a t t h e y r e a l i z e d t h e p o t e n t i a l s e r i o u s n e s s and r e a l i t y of the v a r i o u s c a t a s t r o p h i c s c e n a r i o s we p r e s e n t e d . For e x a m p l e , we p o s e d t h e f o l l o w i n g s e q u e n c e of e v e n t s which was b a s e d on an a c t u a l o b s e r v a t i o n . On a F r i d a y e v e n i n g , d u r i n g s h i f t change, as we were w a i t i n g along with some s e v e n t y workers for our r e s p e c t i v e r i d e s near t h e guard h o u s e , we o b s e r v e d a fuel o i l t r u c k d r i v e i n t o the f a c i l i t y and back up i n t o an unpaved d e l i v e r y t r u c k p a r k i n g a r e a between an a c r y l o n i t r i l e t r u c k and a v i n y l a c e t a t e t r u c k with a few i n c h e s to s p a r e on e i t h e r s i d e . Two o t h e r a c r y l o n i t r i l e t r u c k s were a l s o backed up and parked h a p h a z a r d l y i n t h e same p a r k i n g a r e a . A d m i t t e d l y , the fuel o i l t r u c k d r i v e r performed an amazingly b e a u t i f u l p a r k i n g maneuver on that p a r t i c u l a r day. But what if he did n o t ? What if he h i t ,

38

I.CHEM.E. SYMPOSIUM SERIES NO. 110 s a y , t h e v i n y l a c e t a t e t r u c k and r e l e a s e d a s m a l l s t r e a m o f v i n y l a c e t a t e near the rear of the fuel o i l truck with i t s engine r u n n i n g . None o f t h e d r i v e r s i s a company e m p l o y e e . They travel from v a r i o u s p a r t s o f t h e c o u n t r y o v e r r u g g e d t e r r a i n a n d p o o r l y p a v e d h i g h w a y s f o r many h o u r s . They c o u l d b e t i r e d . They c o u l d be on d r u g s or a l c o h o l . Or t h e y c o u l d s i m p l y make a j u d g m e n t a l error. I t did not t a k e the p l a n t managers too long t o a r r i v e a t the following sequence of e v e n t s : 1. A

quarrel

starts

between

2. Employees a w a i t i n g the q u a r r e l is a l l

the

drivers.

bus r i d e s about.

5.

V e n d o r s o n t h e p u b l i c h i g h w a y n e a r t h e p a r k i n g l o t and some employees stay near the t r u c k s to gape at the f i r e . .The t w e l v e e m p l o y e e s w o r k i n g i n t h e p l a n t and who a r e d e s i g n a t e d as a f i r e b r i g a d e a r r i v e a f t e r 2 m i n u t e s from t h e time of s o u n d i n g t h e a l a r m d r e s s e d i n f i r e c o a t s and h a t s . The a l a r m s y s t e m d o e s n o t i n f o r m them o f t h e n a t u r e o f t h e e m e r g e n c y . Fire now i s i n t h e t i r e s o f b o t h f u e l o i l and v i n y l a c e t a t e t r u c k s and p r e s s u r e i s b u i l d i n g u p i n t h e v i n y l a c e t a t e t a n k .

6.

The f i r e b r i g a d e u n r o l l s a w a t e r h o s e l o c a t e d a b o u t 5 0 m a w a y . N o foam i s a v a i l a b l e a t t h a t l o c a t i o n . The f i r e i s g e t t i n g larger. The v i n y l a c e t a t e t a n k " b l e v e s " . The f i r e b r i g a d e and many o b s e r v e r s a r e i n j u r e d .

sound

parked

The c i t y f i r e d e p a r t m e n t i s c a l l e d . a r r i v e twenty minutes l a t e r . Such

an

the

near

fire

the

alarm

rear (four

now i n v o l v e d .

8 . The a m b u l a n c e , w h i c h i s n o r m a l l y a r e a , cannot be reached. 9.

starts

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Someone a l e r t s t h e g u a r d h o u s e l o n g b l a s t s and one s h o r t ) .

to

fire

to

4.

are

small

drivers

Vinyl a c e t a t e i g n i t e s , of the fuel o i l truck.

trucks

a

the

3.

7. All

and

surround

exercise

led

to

the

On

following

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to

good

truck day,

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recommendations:

o

C h a n g e t h e p a r k i n g s y s t e m s o t h a t t r u c k s e n t e r o n e way a n d e x i t the o t h e r . The p a r k i n g a r e a must b e p a v e d and p r o v i d e d with r a i s e d c o n c r e t e d i v i d e r s between t r u c k s to prevent sideswiping or c o l l i s i o n s .

o

Change the a l a r m system by i n t r o d u c i n g a p u b l i c a d d r e s s system t o i n f o r m t h e f i r e b r i g a d e and a l l e m p l o y e e s o f t h e n a t u r e o f t h e h a z a r d and t h e a p p r o p r i a t e r e s p o n s e . The f i r e b r i g a d e w i l l t h u s come p r e p a r e d w i t h f o a m c o n c e n t r a t e a n d p r o p e r protective clothing. The p u b l i c a d d r e s s s y s t e m w i l l a l s o d i r e c t e m p l o y e e s away from t h e a r e a and t o a s a f e r e f u g e .

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I.CHEM.E. SYMPOSIUM SERIES NO. 110

A second example t h a t was used in t h e "what if" game was the c a s e of the lone o p e r a t o r e f f e c t i n g an a c r y l o n i t r i l e tank t r u c k t r a n s f e r at n i g h t . W e had o b s e r v e d t h e o p e r a t o r c o n n e c t t h e leaky hose with s t e e l bands t h a t were t i g h t e n e d with a s c r e w d r i v e r . He opened the v a l v e s and then s t e p p e d over the hose to get the bucket to c a t c h t h e l e a k . W e posed t h e q u e s t i o n : "What i f h e t r i p p e d and f e l l o n t h e h o s e ? " . The f o l l o w i n g sequence of e v e n t s was d e v e l o p e d : 1. The hose w i l l p u l l off and a c r y l o n i t r i l e w i l l pour o u t . 2. O p e r a t o r w i l l be overcome with fumes. No one w i l l a c c i d e n t at n i g h t for a long p e r i o d of t i m e . 3. Some of t h e a c r y l o n i t r i l e w i l l run i n t o a r a i n i n t o the sewer which l e a d s to a major r i v e r .

notice the

catchment

and

4 . A c r y l o n i t r i l e v a p o r s w i l l t r a v e l towards the b o i l e r s some 3 0 m e t e r s away and i g n i t e . The f l a s h b a c k s t a r t s a f i r e in and around t h e t r u c k , which i s l o c a t e d i m m e d i a t e l y below t h e pipe rack c a r r y i n g p r o c e s s c h e m i c a l s ( v i n y l a c e t a t e , a c r y l o n i t r i l e , and d i m e t h y l formamide) to t h e p l a n t . 5. The pipe rack c o l l a p s e s . This a c c i d e n t s c e n a r i o included the following:

More c o m b u s t i b l e s a r e r e l e a s e d . led

connections

to s e v e r a l

recommendations

which

o

Change the hose hoses.

to q u i c k - c o n n e c t d r i p - p r o o f metal

o

Stop o p e r a t i o n s in case of a l e a k .

o

Wear f u l l p r o t e c t i v e c l o t h i n g and s e l f - c o n t a i n e d a p p a r a t u s while e f f e c t i n g t h e t r a n s f e r c o n n e c t i o n s .

o

C l o s e the sewer immediately under t h e t r a n s f e r a r e a , and s l o p e t h e t r a n s f e r a r e a t o a sump l o c a t e d away from t h e o v e r h e a d pipe r a c k .

breathing

Language The language problem presented itself in different forms. First of all, we do not believe that we could have accomplished our assignment as successfully had we not had a Spanish-speaking engineer on the team. Although many of the upper-level managers knew some English, they were not able to understand technical questions fully, let alone respond to them. Furthermore, all the data that were needed for the safety audit, such as standard operating procedures, accident records, training materials, and warning signs were in Spanish. Plant operators spoke no English at all. Another language problem was the fact that many products arriving at the plant from other countries, and especially the US, were labeled in English. The acrylonitrile railroad tank cars, for example, had all types of warnings and instructions

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I.CHEM.E. SYMPOSIUM SERIES NO. 110

p r i n t e d on t h e i r o u t s i d e s u r f a c e in E n g l i s h , r e a d b y any o f t h e t r a n s f e r o p e r a t o r s .

which

could

not

be

A m a j o r d e f i c i e n c y was t h e n e a r a b s e n c e o f u p - t o - d a t e industrial safety and fire protection books, journals, films, v i d e o s , and t r a i n i n g c o u r s e s i n S p a n i s h . The s a f e t y d e p a r t m e n t a t t h e p l a n t was n o t a w a r e o f w h e r e and when s a f e t y c o n f e r e n c e s w e r e b e i n g h e l d . I f i t d i d , i t was h e s i t a n t a b o u t s e n d i n g i t s s t a f f t o m e e t i n g s i n t h e U S o r E u r o p e b e c a u s e o f l a n g u a g e p r o b l e m s and t h e high cost to c o u n t r i e s which have a monetary exchange disadvantage. Standards

and

Regulations

Another problem f a c i n g many developing nations is the absence or inadequacy of local and/or n a t i o n a l safety standards and r e g u l a t i o n s b y w h i c h p l a n t s a r e b u i l t , o p e r a t e d , and maintained. I n some d e v e l o p i n g c o u n t r i e s , p l a n t s a r e c o n s t r u c t e d i n a c c o r d a n c e w i t h t h e s t a n d a r d s o f t h e c o u n t r y from w h i c h t h e c o n s t r u c t i o n company o r i g i n a t e d . I t i s n o t uncommon t o f i n d p l a n t s c o n s t r u c t e d in a Middle E a s t e r n c o u n t r y with equipment t h a t meets B r i t i s h , American, Korean, and J a p a n e s e standards. B i d d e r s o n c o n s t r u c t i o n j o b s i n a d e v e l o p i n g n a t i o n w h i c h may h a v e m i n i m a l s a f e t y s t a n d a r d s may c o m p r o m i s e s a f e t y i n o r d e r t o r e d u c e t h e b i d p r i c e and win t h e c o n t r a c t . I n some c a s e s , European, J a p a n e s e , o r American s t a n d a r d s a r e b l i n d l y s p e c i f i e d w i t h o u t r e c o g n i z i n g t h e f a c t t h a t what might work i n E u r o p e , J a p a n , o r t h e U S may n o t b e t o t a l l y a p p l i c a b l e i n a d e v e l o p i n g nation. A h y d r a n t loop i n s t a l l e d at a major c h e m i c a l complex in K u w a i t , f o r e x a m p l e , was i n o p e r a b l e w i t h i n a y e a r . Not o n l y was the water supply inadequate and undependable, underground c o r r o s i o n and l a c k o f m a i n t e n a n c e l e d t o i t s a b a n d o n m e n t . The s t a n d a r d s t h a t industrially-developed n a t i o n s use for s a f e t y equipment and c o n t r o l d e v i c e s t a c i t l y assume s c h e d u l e d m a i n t e n a n c e and c a l i b r a t i o n b y t r a i n e d p e r s o n n e l , r e p l a c e m e n t o f d e f e c t i v e c o m p o n e n t s w i t h a p p r o p r i a t e p a r t s , and m i n i m a l power interruption. It is d i f f i c u l t to find replacement p a r t s in developing nations. I t i s e q u a l l y d i f f i c u l t for a n o p e r a t o r t o c o n v i n c e h i s u p p e r m a n a g e m e n t o f t h e n e e d t o k e e p a number o f spare p a r t s on hand. Quite o f t e n , the l o c a l m a c h i n i s t might j u r y r i g a r e p l a c e m e n t or a t t e m p t to r e p a i r the f a u l t y component h i m s e l f w i t h r e a d i l y a v a i l a b l e m a t e r i a l s , w h i c h may o r may n o t b e c o m p a t i b l e w i t h t h e s y s t e m and t h e c h e m i c a l s i t c o n t a c t s . Furthermore, prolonged power interruptions, which are not uncommon o c c u r r e n c e s i n t h e s e c o u n t r i e s , r e n d e r u s e l e s s any s a f e t y c o m p o n e n t s and c o n t r o l d e v i c e s s u c h a s g a s and f i r e d e t e c t o r s , l e v e l a l a r m s , h i g h p r e s s u r e and t e m p e r a t u r e s e n s o r s , etc. T h u s , any r e c o m m e n d a t i o n s f o r t h e i n s t a l l a t i o n o f a u t o m a t e d s a f e t y s y s t e m s must b e made w i t h t h e s e l i m i t a t i o n s i n m i n d . RECOMMENDATIONS Based o n t h i s and o t h e r e x p e r i e n c e s i n p r o v i d i n g s a f e t y c o n s u l t i n g s e r v i c e s in d e v e l o p i n g c o u n t r i e s , we wish to provide t h e f o l l o w i n g r e c o m m e n d a t i o n s and a d v i c e t o f e l l o w c o n s u l t a n t s :

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I.CHEM.E. SYMPOSIUM SERIES NO. 110 1.

Be p a t i e n t and a c c e p t l e n g t h y d e l a y s by t h e c l i e n t in p r o v i d i n g you w i t h t h e n e c e s s a r y d a t a . Quite often, the data you n e e d may n o t b e r e a d i l y a v a i l a b l e . However, be prompt in r e s p o n d i n g t o h i s n e e d s and i n m e e t i n g t h e d e a d l i n e s f o r a l l deliverables.

2.

The s u c c e s s o f a s a f e t y a u d i t i n any c o u n t r y , i s h i g h l y d e p e n d e n t on a m u t u a l and t h o r o u g h u n d e r s t a n d i n g of what n e e d s to be d o n e . S e v e r a l p r o b l e m s can b e a v o i d e d b y h a v i n g o n t h e r e v i e w t e a m a n e n g i n e e r who s p e a k s t h e c l i e n t ' s language.

3.

A l o n g t h e same v e i n , b e p r e p a r e d t o s u b m i t t h e d r a f t and f i n a l r e p o r t s in the c l i e n t ' s language so that a l l l e v e l s of p l a n t m a n a g e m e n t and s u p e r v i s i o n may u n d e r s t a n d a n d comment o n your r e p o r t . I t i s a l s o i m p o r t a n t f o r them t o l e a r n t h e b a s i s f o r y o u r c r i t i c i s m o f t h e i r o p e r a t i o n s and the j u s t i f i c a t i o n for your recommendations.

4.

B e s u r e t o t a k e p h o t o g r a p h s ( o r r e q u e s t t h a t t h e company p h o t o g r a p h e r a c c o m p a n y you t o t a k e p h o t o g r a p h s ) t o i l l u s t r a t e t h e p r o b l e m a r e a s t h a t you o b s e r v e d i n y o u r o r a l r e p o r t t o upper management, and, if a p p r o p r i a t e , in the f i n a l r e p o r t .

5.

Be sure including

6.

Set a good e x a m p l e by w e a r i n g t h e n e c e s s a r y p e r s o n a l p r o t e c t i v e c l o t h i n g and s a f e t y g e a r and o b e y i n g a l l p l a n t safety regulations.

7.

Expect to have your b r a i n s picked on s u b j e c t s included in the a u d i t . B e c o u r t e o u s and extent possible.

8.

Provide the c l i e n t with copies of referenced p u b l i c a t i o n s , c o d e s a n d s t a n d a r d s , and c a t a l o g s o f e q u i p m e n t n o t r e a d i l y a v a i l a b l e t o him.

9.

Involve the he is eager

10.

P r e p a r e y o u r s e l f for t h e p o t e n t i a l c u l t u r a l shock b y l e a r n i n g a s much a s you c a n a b o u t t h e c o u n t r y , i t s h i s t o r y , c u s t o m s , p o l i t i c s and c u l t u r e . Needless to say, respect the c l i e n t ' s c o d e o f e t h i c s , r e l i g i o u s c u s t o m s , and p o l i t i c a l v i e w s a n d a v o i d arguments r e l a t i n g t o such s u b j e c t s .

to observe plant the night s h i f t .

operations

c l i e n t in your s a f e t y t o h e l p and l e a r n .

audit.

during

You

all

shifts,

t h a t may n o t b e helpful to the

will

find

that

In c o n c l u s i o n , it should be c l e a r l y s t a t e d t h a t what we o b s e r v e d a t t h i s L a t i n American company i s not n e c e s s a r i l y r e p r e s e n t a t i v e of a l l companies o p e r a t i n g in a l l developing nations. Many m u l t i n a t i o n a l c o m p a n i e s g a i n b y t h e i r c o n t a c t s w i t h t h e i r p a r e n t c o m p a n i e s and t h e i r c o r p o r a t e s a f e t y d i v i s i o n s .

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