Professional Documents
Culture Documents
Identification
GI-18.201
October 2008
Copyright The content of this document is a trade secret. It may not be reproduced, distributed or disclosed to third
parties without proper authorisation. All rights belong to Nestec Ltd., CH-1800 Vevey, Switzerland.
©Nestec Ltd. 2007
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Table of Contents
Introduction............................................................................................................................... 3
Purpose of the Audit Guide...................................................................................................3
Objectives of the Safety Audit...............................................................................................3
Why do we need a Guide for CO2 R-Plants?.......................................................................3
Target.................................................................................................................................... 4
Auditing CO2 and NH3 R-Plants..........................................................................................4
Distribution and download.....................................................................................................4
Support and feedback........................................................................................................... 4
Audit Guidelines........................................................................................................................ 5
Coordination and follow up....................................................................................................5
Audit frequency..................................................................................................................... 5
Pre-Audits for Project Phase.................................................................................................5
Periodic Safety Checkups.....................................................................................................6
Audit preparation................................................................................................................... 6
Audit team composition......................................................................................................... 7
Audit sequence...................................................................................................................... 7
Safety Index Rating............................................................................................................... 8
Completed and planned safety audits...................................................................................8
The N-CSA Package................................................................................................................. 9
Content.................................................................................................................................. 9
N-CSA Package.................................................................................................................... 9
Package installation.............................................................................................................. 9
The N-CSA Package Workbook..............................................................................................10
Worksheets......................................................................................................................... 10
Access to Worksheets......................................................................................................... 10
Rooms & Equipment Worksheets........................................................................................10
Summary Worksheets......................................................................................................... 11
General Worksheets............................................................................................................11
Action Plan Worksheet........................................................................................................12
N-CSA Cover Sheet............................................................................................................ 12
Guidance Notes................................................................................................................... 13
Drop-down Lists.................................................................................................................. 13
Worksheets Protection........................................................................................................14
Macros................................................................................................................................ 15
How to run the N-CSA Workbook............................................................................................16
Starting the Workbook.........................................................................................................16
Filling in the Cover Sheet....................................................................................................16
Preparing the Worksheets...................................................................................................17
Adding, Deleting and Exchanging Worksheets....................................................................17
Updating a Summary Worksheet.........................................................................................18
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Introduction
Purpose of The purpose of the Audit Guide is to ensure that all Nestlé refrigeration plants
the Audit operating with carbon dioxide (CO2) are designed, built, operated and
Guide maintained in a safe manner, minimising risks to persons, environment,
production and goods.
Objectives of By combining the expertise of a safety audit team and a structured reviewing
the Safety tool, which also includes specific Guidance Notes, the Safety Audit will:
Audit
Provide a means to assess and document the safety of CO2 R-Plants.
Identify actual and potential safety hazards due to design, modifications,
operation and maintenance.
Provide a means of defining the needs for upgrading and modification of
plants and operations.
Provide feedback on safety issues that may be incorporated into new plant
design.
Promote safety understanding.
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Introduction, Continued
Target Carbon dioxide refrigeration plants serving Nestlé operations and operated by
third parties must be audited to make sure that:
Auditing CO2 Systems operating with distributed CO2, as primary or secondary refrigerant,
and NH3 usually operate with NH3 confined in a plant room. However in some cases,
R-Plants CO2 and NH3 might be found in production areas e.g. after a partial existing
NH3 to CO2 system conversion; for example, in an ice cream facility we might
find continuous IC freezers still operating with NH3 and hardening tunnels
operating with CO2.
The auditors shall make sure that the safety audit is performed according to
the GI appropriate for each type of refrigerant (for NH3: GI-18.200).
Obviously, and typically for a refrigeration plant room, a certain number of
questions might repeat. Auditors shall use their judgment to simplify the
auditing procedure whenever possible.
Distribution The Audit Guide and its embedded N-CSA Package (page 9) will be
and download distributed to:
The Audit Guide can be downloaded from Nestec Intranet site "Technical
Instructions" based at the "Technical & Production" site.
Support and Nestec CO-Eng/Serv will provide support for the use of the N-CSA Guide.
feedback
Please contact:
Michel Pirard (e-mail: Michel.Pirard@nestle.com)
or
Any member of CO-ENG/Serv team:
http://intranet.nestle.com/EngServ/
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Audit Guidelines
Coordination Market corporate engineering will coordinate and follow up the safety audits. The
and follow up coordinator has the responsibility to ensure that audits are carried out effectively
and efficiently and must:
Audit As a minimum CO2 R-plants safety audits shall be conducted every 5 years or
frequency less.
The actual audit frequency shall primarily be risk based in function of local
conditions such as factory location, plant age and condition, climate, e.g.
increased risk of corrosion in warm/humid areas, availability of external
support, action plan and Safety Index Ratings (SIR) from previous audits.
Pre-Audits for Project Engineers should use the N-CSA Package, especially the embedded
Project Phase Guidance Notes:
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Audit Guidelines, Continued
Periodic In addition to the Safety Audit, Periodic Safety Checkups shall be performed,
Safety preferably on an annual basis, and include, among others, the following items:
Checkups
Review of the progress made on the actions required during the last safety
audit.
Whenever needed the action plan shall be updated with new deadlines and
with the findings made during the safety checkups.
Inspection of calibration, function test records for the safety cut-outs, CO2 leak
detectors and other instruments related to the plant safety.
Inspection of the refrigeration plant: plant room, production, storage areas
Testing of the CO2 refrigeration plant room ventilation.
This should be done in manual and automatic mode.
Testing of the local, remote visual and audible alarms
Inspection of the protective equipment used for interventions in the system.
Periodic Safety Checkup reports shall be part of the documentation that should
be reviewed by the auditors during the safety audit.
Audit Following actions shall be taken to ensure the effectiveness of the audit:
preparation
The N-CSA Guide Package will be sent well in advance to the factory by the
market coordinator for the audit preparation.
Failure to do the audit preparation will result in delays in the completion of the
audit and waste the time of both the audit team and the factory staff.
Following information shall be prepared and made available to the audit team
during the audit. The factory shall ensure that the required documentation is
available and gathered in a single location to simplify reference.
- As-built CO2 Piping & Instrumentation Diagrams (PIDs)
- As-built electrical diagrams + detailed and updated functional description
- Operating and Maintenance manuals
- Certification documents for compressors, pressure vessels and heat
exchangers
- Updated action plan (from last audit) and periodic safety checkup reports.
- Other documents relevant for the assessment of the R-plant safety in the
factory and its environment
The as-built CO2 PIDs shall be sent to the audit team for familiarisation at
least 2 weeks prior the audit start.
This will also be a confirmation that the preparation has been completed.
The factory shall allocate their representatives for the audit team and ensure
that sufficient technical support will be available for the whole duration of the
audit.
Continued on next page
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Audit Guidelines, Continued
Stage Description
1 Review the factory layout, rooms, areas and R-Plant PIDs
2 Perform a brief inspection to gain an overview of the main areas and
R-Plant components.
3
Audit in detail the R-Plant components such as compressors, vessels, heat
exchangers, pipe work.
It is recommended to audit, i.e. inspect, answer the questionnaire and assign
SIRs for each type of equipment, e.g. compressors, after performing a visual
inspection of all similar units.
In some cases the audit team may be divided in groups to perform the detailed
inspection of a given type of equipment.
4 Audit the various areas such as plant rooms, production areas,
and cold rooms.
In some cases the audit team may be divided in groups to perform the detailed
inspection of a given area
5 Audit of the organisational aspects like documentation, staff competence,
training etc. Recommended after the detailed hardware inspection to allow
the audit team to first become familiar with the plant.
6 Consolidate the Action Plan and add the name(s) of the responsible in charge
of the action and expected completion dates.
7 Based on the content of the Action Plan, recommend a schedule for the next
audit and periodic safety checkups.
8 Present and discuss the audit results and required actions to the factory
management, including whenever possible a cost estimate for the main
required actions.
Note Sufficient resources and time should be allocated to perform safety audits!
For instance, 3 to 4 weeks could be needed to complete the first safety audit
(ammonia + carbon dioxide systems) for a very large plant.
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Audit Guidelines, Continued
SIR Definition
"E" = Emergency The defect is so severe that there is immediate danger to
the plant e.g. extended corrosion or organisational defects
that will lead to rapid deterioration of the plant. Or the
inability to safely deal with an incident e.g. lack of
competent staff, inadequate safety equipment etc.
The audit team should ensure that an action is
committed to rectify the defect before leaving the site.
"U" = Urgent The deficiency represents a serious hazard, which may not
be immediately dangerous to life or property and would not
expose the company to any immediate legal action.
A firm deadline should be set to correct the deficiency.
"I" = Improvement Improvement is required, and can be achieved by the factory
through regular channels of maintenance and capital
investment.
Improvements should not be underestimated. It is good
practice to undertake the required corrective actions
latest till the end of the calendar year following the safety
audit.
"N" = Normal No action considered necessary. Where appropriate, the
audit team should include notes explaining why no action is
considered necessary.
No action is required. The audited section is of
acceptable or above normal standard.
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The N-CSA Package
Content The original N-CSA Package (Nestlé-CO2 Safety Audit) comes as a zipped file
and includes:
N-CSA
Package N-CSA Package
(V1.0-2008) .zip
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The N-CSA Package Workbook
Access to Each Worksheet can be accessed by clicking on the bottom tab in the Workbook.
Worksheets
For more details see "How to start the Audit Guide ==> Adding and Deleting
Worksheets".
Continued on next page
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The N-CSA Package Workbook, Continued
Summary Content
Worksheets The Summary Worksheets shows key data that may be helpful to the factory.
The illustrations below show the total number of "I", "U", "E" SIRs assigned to a
given plant item.
Number of Worksheets
The macros for the Summary Worksheets allow for the consolidation of a
predefined number of Worksheets as listed below.
General General Worksheets refer mainly those that do not need to be multiplied as a
Worksheets function of the number of plant items, like rooms and equipment.
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The N-CSA Package Workbook, Continued
If a SIR different than "N" has been assigned, the Plant Reference, Question
and SIR will be shown even if no specific action has been required; sometimes
the action required can be obvious without the need for additional comments.
N-CSA Cover The Audit Cover Sheet provides an overview of key data such as:
Sheet Factory reference
Audit number and date
Audit Team
Periodic Safety Checkups summary
Safety Index Ratings for the current audit and the previous one.
Incidents summary
Refrigerant charge modifications and average losses % calculation
System alterations such as major plant extensions, plant items replacement etc.
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The N-CSA Package Workbook, Continued
Guidance Guidance Notes have been developed to help the auditors answering the
Notes questionnaires. In many cases recommendations, suggestions or examples,
often based on EU Regulations, are provided.
CSA GNs can be modified or updated to reflect the local Regulations, Codes
and best practices, but the essence of the GNs must be maintained.
The relevant GN can be open through a "blue link" in the Worksheet:
Drop-down Many questions can be answered with the help of a drop-down list.
Lists To display the drop-down list, click on the grey button that appears after having
selected the light blue coloured cell.
Example:
Annex 3: Question A3.1.5: Compressor type?
A list of the most of the most commonly used compressor types, such as "Open
reciprocating" will appear.
Safety Index Ratings (SIRs) and YES/NO answers are selected the same way.
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The N-CSA Package Workbook, Continued
Formatting of cells
Cells where text can be written (=not locked) have a light yellow background.
These cells are formatted for "wrap text". This means that at the end of a line the
text will continue on the next line, and the row height will automatically be
adjusted to make the whole text visible.
If this should not work, Unprotect the Worksheet, select the whole Worksheet
and go to: Format ==> Row ==> AutoFit
After that Protect again the Worksheet.
Important:
Do not modify row heights manually in unprotected mode. This may lock the
automatic row height adjustment!
In all Worksheets write information in cells with a light yellow background only!
Continued on next page
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The N-CSA Package Workbook, Continued
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How to run the N-CSA Workbook
Starting the Open the Excel N-CSA Workbook and "Enable Macros" from the message:
Workbook
To be able to choose whether or not to run macros while starting the Workbook,
change the Security level from High to Medium as follows:
Go to: Tools ==> Macro ==> Security ==> Security Level = Medium
Filling in the Fill in the information required in the N-CSA Cover Sheet such as participants,
Cover Sheet refrigerant charge, SIRs from previous audits etc.
Besides the total number of Is and Us assigned to the system, auditors can
define (optionally) a number of typical findings affected to identical components
(items) for the same reason(s).
Example:
Missing "Auto-Start" at 05 compressors might be defined as 01 typical finding.
Some cells, marked with a red triangle in the corner, have built-in comments:
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How to run the N-CSA Workbook, Continued
Preparing the As mentioned previously the preparation work is a very important step for the
Worksheets successful completion of a safety audit.
When a Worksheet is added, the tab name will automatically have the next
Index Number. This Index Number is a mere sequence number! It is not the
"Plant Reference", which is an information added in the Worksheet
(As explained in the "Guidance Notes" linked to the Workbook)
Deleting Worksheets
Worksheets should be deleted starting with the one with the last Index Number. If
this is not respected, the Index Number given automatically to Worksheets added
subsequently will not follow the sequence anymore and will have to be corrected
manually. (Also the Index Number in Cell B2 of each Worksheet)
Exchange of Worksheets
Worksheets should not be exchanged between Workbooks unless the correct
link to the macros is restored.
Example: Copy "A3 Compressor 1" or "Compressors Summary" from Workbook
"Factory A" to Workbook "Factory B".
Continued on next page
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How to run the N-CSA Workbook, Continued
Updating a Once all Worksheets for a given Annex, have been completed with the required
Summary data, the Summary Worksheets is updated using the button "Update Plant
Worksheet items Summary" in the corresponding "Plant Items Summary" Worksheet.
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