Kazakhstan Industrial Safety Examination cheat sheet

Core statute: Law of the Republic of Kazakhstan 'On Civil Protection' (2014) governs industrial safety obligations; hazardous production facilities are covered by the Law 'On Industrial Safety at Hazardous Production Facilities' and subordinate acts of the authorised body.

The authorised state body for industrial safety is the Committee for Industrial Safety and State Inspection in the Field of Ecology and Technical Supervision under the Ministry of Ecology and Natural Resources; it registers HPF declarations and issues permits and attestations.

Key subordinate acts: Rules for Identification of Hazardous Production Facilities; Rules for Development of Industrial Safety Declarations; Rules for Industrial Safety Expertise; Technical Regulation on Requirements for Safety of Machinery and Equipment.

Legal entities operating HPFs must be registered, hold a permit (attestation) for operation, and have mandatory civil liability insurance for harm caused by accidents at the HPF.

Accidents and incidents at HPFs are subject to mandatory investigation and recording under the Rules for Technical Investigation of Accidents; the investigation commission includes the employer, the territorial inspection and, where relevant, the local executive body.

Violations of industrial safety requirements are administrative offences under the Code of Administrative Offences (fines, suspension of operations) and may be criminal under the Criminal Code where harm to life or health results.

State control is exercised through inspections (scheduled and unscheduled) under the Entrepreneurial Code; scheduled inspections are conducted according to risk-based frequency, and unscheduled ones require a legal ground (complaint, accident, order of the prosecutor).

Normative technical documents (GOST, ST RK, technical regulations of the EAEU) apply where referenced by the industrial safety rules; the employer must maintain a register of applicable normative documents and review them on revision.

Supervision model: state control over HPFs is risk-based; objects are assigned to risk categories, and inspection frequency depends on the category (high risk - more frequent, low risk - rarely or not inspected).

Permitting: operation of an HPF requires an attestation/permit issued by the territorial department of the authorised body; the permit is tied to the specific facility, the types of activity and the technical devices declared.

Declaration of industrial safety is mandatory for HPFs of hazard class I and II, and for facilities where the legislation expressly requires it; the declaration is submitted to the authorised body and entered in the register.

The industrial safety declaration is developed by the operating organisation (or a licensed/attested developer) and includes: facility identification data, accident risk analysis, conditions of operation, and a mitigation/emergency plan.

The declaration is subject to industrial safety expertise (expert review) by an accredited expert organisation before approval; the conclusion is an integral part of the declaration package.

Re-declaration is required when the technological scheme, equipment or hazard class changes, or when the normative requirements change; the declaration is reviewed periodically and updated on the basis of accident analysis.

The authorised body may suspend or revoke a permit where the operator fails to comply with industrial safety requirements, fails to conduct mandatory expertise, or fails to insure liability.

Self-check decision rule: if a facility handles a hazardous substance at or above the threshold quantity in the identification rules, or operates equipment under pressure or lifting structures above the stated parameters, it is an HPF and must be declared and permitted.

Identification is the operator's obligation: the operator determines whether the facility meets any HPF criterion and assigns the hazard class; the result is documented in an identification act.

HPF criteria include: presence of hazardous substances (flammable, oxidising, combustible, explosive, toxic, highly toxic) at or above threshold quantities; equipment operating under pressure above 0.07 MPa or at water temperature above 115 °C; permanently installed lifting structures; and mining operations.

Classification into hazard classes I–IV depends on the type and quantity of hazardous substance, the pressure/temperature parameters, the number of people in the danger zone, and the potential scale of the accident.

Class I is the highest hazard (largest quantities of hazardous substances, greatest potential for a major accident); class IV is the lowest among declared facilities.

Threshold quantities are specified per substance in the identification rules; mixtures and combinations require summation of the contributions of the individual hazardous components.

The identification act, together with the declaration, is submitted for registration; the hazard class determines the frequency of inspections, the type of expertise and the insurance tariff.

Re-identification is required when the process technology, the quantity of hazardous substances, the equipment or the boundaries of the facility change.

Decision rule: if a facility falls below all thresholds and operates no pressure equipment or lifting structures above the stated parameters, it is not an HPF and is regulated by general labour safety rules instead.

The employer must establish and maintain an industrial safety management system (ISMS) covering: policy, planning, implementation, performance evaluation and management review, aligned with the PDCA cycle.

Mandatory elements of the ISMS: identification of hazards and risk assessment, development of measures to reduce risk, appointment of responsible persons, training and certification of personnel, and internal control (production control).

Production control is a documented system of the operator's own inspections of compliance with industrial safety requirements; results are recorded and reported to management, and the authorised body may request them.

The employer must develop and approve instructions, technological regulations, schemes and plans for accident elimination (PAE/PLAS) for each HPF; the plan is coordinated with emergency services and the local executive body.

The employer must ensure that technical devices are certified (EAEU technical regulations or GOST), registered where required, and maintained and repaired according to manufacturer's documentation.

Mandatory civil liability insurance of the HPF operator covers harm to life, health and property of third parties and the environment caused by an accident at the facility.

Personnel requirements: workers at HPFs must be trained and certified in industrial safety; the certification is periodic (at least once every 5 years, and on transfer or after a break in work).

The employer must investigate and record accidents and incidents, analyse their causes, and implement corrective measures; failure to do so is a ground for administrative liability and permit suspension.

Risk is defined as the combination of the probability of an accident and the severity of its consequences; the declaration must contain a quantitative or qualitative risk assessment.

Common methods: qualitative (checklists, HAZOP, What-If), semi-quantitative (risk matrices), and quantitative (fault tree analysis, event tree analysis, consequence modelling).

HAZOP uses guide words (no, more, less, reverse, part of, as well as, other than) applied to process parameters at nodes to identify deviations and their causes and consequences.

Fault tree analysis is deductive: it starts from the top event (accident) and works down through AND/OR gates to basic events; event tree analysis is inductive and models the sequence of responses after an initiating event.

Consequence modelling estimates the affected zone for fire (pool fire, jet fire, flash fire), explosion (overpressure) and toxic release (dispersion); the results define the danger zone and the emergency planning distances.

Acceptable risk criteria are set by the legislation and normative documents; if the calculated risk exceeds the criterion, the operator must develop and implement additional mitigation measures.

Accident analysis must identify root causes (technical, organisational, human), not only immediate causes; the results feed back into the risk assessment and the emergency plan.

Risk assessment is reviewed when technology, equipment, substances or staffing change, and after every accident or incident at the facility or at a comparable facility.

Pressure equipment: vessels, boilers and pipelines operating above 0.07 MPa or at water temperature above 115 °C are subject to industrial safety rules, registration and technical examination.

Technical examination of pressure equipment includes external and internal inspection and hydraulic (or pneumatic) pressure test; the periodicity is set by the rules and the manufacturer's documentation.

Safety devices required on pressure equipment: safety valves (or safety devices), pressure gauges with a red line at the working pressure, level indicators, and interlock and alarm systems.

Lifting structures (cranes, hoists, lifts) require: registration with the authorised body, technical examination before commissioning and periodically, and inspection by a responsible person for safe operation of lifting structures.

Crane operation requires an appointed responsible person for safe operation, a person responsible for the good condition of the crane, and certified slingers and crane operators.

Lifting operations are prohibited when the load exceeds the rated capacity, when the load is not slung correctly, when people are in the danger zone, or when the wind speed exceeds the limit stated in the crane's operating manual.

Registration is not required for certain lifting structures below the parameters stated in the rules; the operator must verify the exemption before deciding not to register.

Pipelines and gas equipment require periodic pressure testing, leak testing and inspection of safety shut-off valves; the results are recorded in the equipment passport and repair log.

Oil and gas facilities are HPFs of the highest hazard classes where they handle flammable and explosive hydrocarbons above threshold quantities; they require a declaration, a permit and an emergency plan.

Fire and explosion protection: explosion-proof electrical equipment in hazardous zones, lightning protection, grounding, gas detection and automatic shutdown systems.

Well operations (drilling, workover, well killing) require a plan approved by the technical supervisor, blowout prevention equipment (BOP), and control of the well kick indicators.

Tank farms and loading racks require: bunding (dikes) with capacity for the largest tank, breathing valves, foam or inerting fire suppression, and strict control of hot work.

Hot work in explosive zones requires a hot work permit, gas-air testing before and during the work, and fire watch with extinguishing means.

Pipeline operation requires periodic pressure testing, corrosion monitoring, inspection of shut-off valves, and a leak detection and emergency shutdown system.

Petrochemical process units require interlocks, relief systems, flare systems and a documented process regulation; deviations from the regulation require a formal management-of-change procedure.

Personnel at oil and gas facilities must be trained in gas safety, use of breathing apparatus and first aid; the emergency plan is drilled periodically.

Mining operations are an HPF criterion; mines and pits require a permit, a declaration, a mine ventilation and emergency plan, and a rescue service agreement.

Underground mining requires: two independent exits to the surface, a ventilation system with continuous monitoring of airflow and gas composition, and a gas protection service.

Blasting operations require a permit, a project for the blast, a danger zone calculation, and a responsible blasting supervisor; blasting is prohibited without warning signals and guarding of the danger zone.

Mine hoisting installations are lifting structures and are subject to the lifting structure rules: registration, technical examination and certified operators.

Metallurgical facilities: blast furnaces, converters, coke ovens and molten metal handling require protection against contact with water, control of molten metal transport, and protective equipment for workers.

Mining and metallurgical equipment requires guarding of moving parts, lockout/tagout during repair, and control of entry into confined spaces (silos, bunkers, furnaces).

Dust and gas control: ventilation, dust suppression, and monitoring of harmful substances in the working area against the maximum allowable concentrations (MAC).

Emergency response at mines is organised through the mine rescue service (paramilitary mine rescue units); the plan for accident elimination is coordinated with that service.

Each HPF must have a plan for the elimination of accidents (PLAS/PAE) approved by the management and coordinated with the emergency services; the plan defines the notification scheme, responsibilities and resources.

Emergency response drills are conducted periodically; the results are recorded and used to revise the plan.

Notification scheme: worker who detects the accident notifies the shift supervisor, who notifies the facility management, the emergency services (112) and the local executive body.

First aid at HPFs: stop the exposure, ensure scene safety, call for help, assess consciousness and breathing, start CPR (30 compressions to 2 breaths) if not breathing, and control bleeding with direct pressure or a tourniquet.

Chemical exposure: remove the casualty from the contaminated area, remove contaminated clothing, flush the affected area with plenty of water, and provide the safety data sheet to the medical team.

Fire safety: fire extinguishers are selected by fire class (A - solids, B - flammable liquids, C - gases, E - electrical); water is prohibited on live electrical equipment and on burning metals.

Fire evacuation routes must be kept clear, marked with signs and illuminated; fire drills are conducted at the frequency set by the fire safety rules.

Burns: cool the burn with clean water for at least 10–15 minutes, do not open blisters, cover with a sterile dressing; electrical injury requires separating the casualty from the source before touching them.

Employers must conduct induction training (on hiring) and periodic workplace training on labour safety, with records in the training log and the worker's personal card.

Workers in harmful and hazardous conditions are entitled to: reduced working hours, additional leave, free special clothing and personal protective equipment (PPE), and periodic medical examinations.

PPE is issued according to the norms for the worker's profession and the results of the special assessment of working conditions (SOUT/SAWC); the employer bears the cost and must not charge the worker.

Industrial safety certification of managers and specialists at HPFs is periodic - at least once every 5 years - and is required before appointment and after a break in work in the relevant role.

Workers in high-risk jobs (working at height, confined space, electrical work, slinging) require additional certification and annual refresher training.

The special assessment of working conditions classifies conditions into optimal, acceptable, harmful (degrees 1–4) and dangerous classes; the class determines guarantees, compensation and medical examination frequency.

Workers must be instructed on the safe methods of work before being allowed to work independently, and the employer must not allow untrained or uncertified workers to perform work.

Recording and reporting: accidents at work are investigated by a commission with employer and worker representatives; the results are documented and reported to the authorised body within the established time limits.