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 .

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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 ,

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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

see what

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

the

3.

7. All

and

surround

exercise

led

to

the

On

following

next
a

to

good

truck
day,

parking
it

might

recommendations:

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 .

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

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

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

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 .

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 :

41

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 .

42