Consultivo’s Impactful Safety Audit in a large Refinery & Petrochem Complex

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Conducting a comprehensive Safety Audit in a sprawling Refinery and Petrochemicals Complex in India, handling an annual crude throughput of 18 MMTPA, posed a significant challenge. With multiple units and diverse departments, including a workforce of 2000 regular employees and 3000 contractors, the goal was to evaluate and enhance the existing Safety Management System. The extensive scope covered various critical aspects such as transportation, maintenance, hazardous materials handling, and emergency management.


To address this challenge, Consultivo crafted a detailed scope of work, aligning with IS 14498:2018 and OISD requirements. A multidisciplinary team, including experts in the Chemical Process, and the Mechanical, Electrical, and Fire & Safety disciplines, was deployed. The audit delved into areas like safety interlocks, maintenance procedures, instrumentation systems, and employee safety compliance. The scope also included reviewing audit elements outlined in the IS Code for Occupational Health & Safety Audit (IS 14489:2018).

Audit Methodology

The audit methodology employed by Consultivo in the Safety Audit of the Refinery and Petrochemicals Complex is a systematic and comprehensive approach designed to assess the effectiveness of the existing Safety Management System. The methodology covers various critical aspects of the facility, ensuring a thorough evaluation. Here’s an elaboration on the audit methodology

Scope Definition

  • Clearly defining the scope of the audit, in alignment with IS 14498:2018 and OISD requirements.
  • Encompassing all plant units and departments, including critical areas like transportation, maintenance, hazardous materials handling, and emergency management.

Multidisciplinary Team Deployment

  • Assembling a team of experienced technical experts from diverse disciplines, including Chemical Process, Mechanical, Electrical, and Fire & Safety.
  • Leveraging the team’s in-depth experience in Petrochemical plants and Petroleum Refinery operations.

Document Review and Compliance Check

  • Conducting a meticulous review of relevant documents, including safety policies, training records, maintenance procedures, and previous safety audit reports.
  • Ensuring compliance with statutory requirements, industry standards, and best practices.

Onsite Inspection

  • Performing onsite inspections of critical areas, equipment, piping, supports, structures, and various departments to identify potential hazards and risks.
  • Assessing the movement of vehicles, safety interlocks, maintenance practices, and the adequacy of instrumentation systems.

Audit Elements Evaluation

  • Assessing each audit element outlined in the IS Code for Occupational Health & Safety Audit (IS 14489:2018).
  • Evaluating safety management systems, accident reporting and investigation, occupational health monitoring, electrical installations, fire prevention, hazardous materials handling, emergency management, and more.

Interviews and Employee Participation

  • Conducting interviews with key personnel to gather insights into safety practices and employee participation in safety management.
  • Evaluating motivational and promotional measures for occupational safety and health.

Review of Emergency Response Plans and Drills

  • Assessing the adequacy and effectiveness of onsite emergency plans and conducting a review of emergency response and disaster management plans.
  • Evaluating the performance of mock drills and assessing the preparedness of emergency control centres.

Report Generation

  • Compiling a consolidated report with an executive summary, outlining findings, observations, and recommendations.
  • Providing specific and actionable recommendations based on the scope of work and premises-specific observations.

Continuous Improvement and Lessons Learned

  • Identifying lessons learned during the audit process to refine future safety protocols.
  • Facilitating a culture of continuous improvement by providing insights that contribute to the ongoing enhancement of safety standards.

Consultivo’s audit methodology is dynamic, ensuring a holistic evaluation and the provision of practical recommendations for enhancing safety measures within the Refinery and Petrochemicals Complex.


The safety audit unearthed critical insights, leading to recommendations for the reduction of accidents and loss potential. The findings covered areas such as machine guarding, ventilation, fire prevention, emergency management, and occupational health monitoring. The outcome went beyond compliance, offering a roadmap for a safer and more efficient operation. A consolidated report, including an executive summary, outlined specific observations and recommendations for future actions.


Consultivo adhered to IS 14498:2018, OISD requirements, and IS 14489:2018 throughout the audit. The evaluation encompassed safety management systems, operational practices, electrical installations, fire prevention, and emergency response.

Value Created for the Customer

The audit’s value extended beyond compliance, fostering a culture of safety and risk reduction. By identifying and addressing potential hazards, Consultivo contributed to the refinery’s overall resilience. The insights gained not only enhanced safety protocols but also served as a foundation for continuous improvement, ensuring a safer environment for all personnel.

In conclusion, Consultivo’s Safety Audit played a pivotal role in elevating safety standards within the Refinery and Petrochemicals Complex, creating a lasting impact on operational excellence and risk mitigation.

Disclaimer: This article does not include any confidential information from either the client or the specific project. Consultivo adheres to a strict data privacy and confidentiality policy, and great care has been taken to preserve the confidentiality of any data discussed. Any specific data and information mentioned in this write-up are publicly available.

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Category:  Blog

Tags: Safety, Fire Safety

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