Chennai: The recent ammonia gas leak tragedy has drawn attention to whether factories are adequately equipped to prevent and respond to emergencies. Safety experts say hazardous industries are monitored through a range of safety measures, including on-site safety officers, worker health checks, safety audits and equipment inspections.One of the biggest concerns, auditors say, is the absence of on-site safety personnel. M Abdurrahman, a notified safety auditor with the Union govt’s directorate-general, factory advice and labour institutes, said, “Whether it is chemical manufacturing or a mechanical industry, there should be a person who understands the process and can respond during an emergency.” Factories are required to appoint safety officers based on the number of workers, though not all industries follow the rule consistently.Vishnu M, a safety auditor, said hazardous-process industries generally undergo external safety audits once every two years, during which auditors assess equipment integrity, emergency preparedness, worker safety measures and compliance with prescribed standards. Equipment such as pressure vessels and compressed-gas storage systems undergo periodic inspections, while gas detection and alarm systems are tested and maintained.The audits also review how facilities handling flammable gases identify and manage potential risks. “Zone 0 refers to areas where flammable gases or vapours are continuously present, Zone 1 where they are likely to be present during normal operations, and Zone 2 where they may occur only under abnormal conditions such as equipment failure,” Vishnu said.Auditors verify the accuracy of these classifications, assess whether electrical systems are suitable for the zone, and check if modifications have altered the risk profile.Abdurrahman said audits also examine health risks, including exposure to dust, toxic substances and excessive noise. Workers in hazardous industries are required to undergo periodic medical tests, while health centres must be set up based on workforce strength.However, experts say that audits alone cannot prevent accidents. “They can identify deficiencies, but their effectiveness depends on implementation. The TN Directorate of Industrial Safety and Health has to enforce the recommendations,” he said.
