Home / Applications / Safety Audits

Safety Audits 

Problem

In spite of extensive OSHA Process Safety Management systems in place, a world-class pulp mill experienced a chlorine release affecting the mill and the local community.

The state regulatory authority and the local fire department required the mill to engage a third party to conduct a safety audit of the pulp mill's equipment, operating and maintenance procedures, and emergency plan. The mill was searching for a solution that would allow them to comply with the requirements of the regulatory bodies, while maintaining economical production.

Solution

Universal Dynamics was selected to perform the safety audit. Our engineers' extensive experience in designing, operating, and maintaining similar chlorine systems gave us credibility with the mill and the regulating bodies.

After surveying the operation and comparing the systems with best management practices in the industry, Universal Dynamics developed a set of recommendations for improvement that successfully met the requirements of all parties, including:

• Improve the emergency shutdown system for chlorine rail cars and vaporizers. This could be done by optimizing existing process controls and installing a new shutdown system on the rail car emergency device.
• Reorganize and improve operator training to supplement the actions of the emergency response team.
• Enhance system reliability by changing construction materials on specific system components.

Results

• The extent and depth of the audit was able to assure State and local regulating bodies that the mill's programs for safely handling hazardous material were adequate.
• The changes proposed by Universal Dynamics were supported by the regulators.
• The Universal Dynamics recommendations could be successfully implemented within the mill's plan for capital and maintenance spending.
• As well as satisfying the regulatory requirements, the mill's emergency containment system was improved as a result of the audit.