Safety Audit Ppt Representation

SAFETY AUDITSAFETY AUDIT

IS 14489 : 1998DO INSPECTION – AUDIT YOURSELF

INTRODUCTIONINTRODUCTION

Safety Audit is management tool comprising of a systematic ,periodic and objective evaluation of how well the safety organization, management and equipment are performing, with the aim of helps to safeguard a company’s assets by facilitating management control of safety, health and environmental practices and assessing compliance with established standards

TYPES OF AUDITS

External External :: These are conducted by a third These are conducted by a third partyparty

Internal Internal :: CorporateCorporate : : By headquarters

or

personnel from other units of the same company. Self : In –house – by the plant personnel themselves.

AUDITS OBJECTIVESAUDITS OBJECTIVES

Verify compliance with established standards Verify compliance with established standards (regulations, internal policies and industry wise (regulations, internal policies and industry wise standards of practice )standards of practice )

Identify deviation from designed and planned Identify deviation from designed and planned operating and maintenance procedure and operating and maintenance procedure and standardsstandards

Identify plant condition or operating procedures Identify plant condition or operating procedures that could lead to an accident and significant that could lead to an accident and significant losses to life or propertylosses to life or property

Ensure that the plan and operating and Ensure that the plan and operating and maintenance procedures match the design intent maintenance procedures match the design intent and standardsand standards

Keep the operating personnel alert to the process hazards

Review operating procedures for necessary revisions

Seek to identify equipment or process changes that could have introduced new hazards

Ultimate application of new technology to existing hazards

Review adequacy of safety inspections Look for major risk situations recommend

measures to improve overall safety performance of the plant

Methodology in Conducting a Safety Audits

The following activities are carried out in conducting a

safety audit and implementing the audit recommendation Pre-audit activities

Key on-sites activities

Post-audit activities

Pre-audit Activities

The safety audit process being with the following activitiesThe safety audit process being with the following activities before the actual onsite audit takes place : before the actual onsite audit takes place :

Request by management / identification of industry according to high hazards/high rate of accidents

Scheduling of the audits

Selection of the audit team

Development of an audit plan which includes -Defining the scope of the audit -Selecting priority topics -Modifying the audit protocols -Allocating audit team resources

Advance visit to the factory to gather background information and data, administering a questionnaire.

Background information to be gathered :

1. List of products

2. Brief description of the manufacturing process with process flow diagram/block diagram

3. Built-up area and site plan/names of departments

4. Number of company employees ( managers, supervisors and workmen ) and contractor’s employees

5. Organization structure, including SHE function

6. List of chemicals handled: - Raw materials - Products - Intermediates - By-products

Date to be gathered :Date to be gathered :

1 Brief description of major accidents in the past 1 Brief description of major accidents in the past ten yearsten years

2 Accident statistics for the last five years – 2 Accident statistics for the last five years – types / cause of accidents and analysistypes / cause of accidents and analysis

3 Details of fires / explosions / toxic releases in 3 Details of fires / explosions / toxic releases in the last five yearsthe last five years

Key On-site Activities

Understanding Management Systems:

First of all a working understanding of the industry’s internal safety management system, i.e. the set of

formal and normal actions taken by the industry is required to be developed. This step usually includes

developing a understanding of :

Factory processesFactory processes Internal controls ( both management and engineering)Internal controls ( both management and engineering)

Plant organization and responsibilitiesPlant organization and responsibilities Compliance parameters and other applicable requirementsCompliance parameters and other applicable requirements Any current or past problemsAny current or past problems The picture of internal management systems is usually drawn The picture of internal management systems is usually drawn

from the following sources:from the following sources: Discussions with management personnel, supervisors and Discussions with management personnel, supervisors and

worksworks Specially designed internal controls questionnaireSpecially designed internal controls questionnaire Plant visitsPlant visits In some cases, a limited amount of verification testing In some cases, a limited amount of verification testing

conducted to help confirm the auditor’s initial understandingconducted to help confirm the auditor’s initial understanding The auditor records his or her understanding in a flow chart-The auditor records his or her understanding in a flow chart-

narrative, description, or some combination of the two-in narrative, description, or some combination of the two-in order to have a written description against which audit is to be order to have a written description against which audit is to be done. done.

Assessing Strengths and Weaknesses :

In assessing strengths of internal controls, auditors look for the following indications.

Whether factory personnel are trained and experienced Whether responsibilities at various levels are clearly

defined and carefully assigned

Whether duties are so divided that these minimize conflicts of Whether duties are so divided that these minimize conflicts of interestinterest

Whether authorization systems are in existenceWhether authorization systems are in existence Whether internal verification procedures are in placeWhether internal verification procedures are in place Whether protective measures-security systems and alarms Whether protective measures-security systems and alarms

are takenare taken Whether procedures and compliance / exception results are in Whether procedures and compliance / exception results are in

place place

For each of the areas assigned, the auditor should ask himself For each of the areas assigned, the auditor should ask himself the following questions :the following questions :

* If the facility is doing everything the way they say it * If the facility is doing everything the way they say it happens, is that acceptable ? happens, is that acceptable ? * Is the facility incompliance * Is the facility incompliance with applicable requirements and is the factory adequately with applicable requirements and is the factory adequately protected ? protected ?

Assessing strengths and weakness is especially important Assessing strengths and weakness is especially important because it determines, to a great extend, how the balance because it determines, to a great extend, how the balance of the audit is to be conducted. In addition to assessing of the audit is to be conducted. In addition to assessing the soundness of the internal controls, the auditor also the soundness of the internal controls, the auditor also makes a judgment about the severity of the risk makes a judgment about the severity of the risk associated with a particular activity being reviewed. In associated with a particular activity being reviewed. In areas of high risk, and with weak internal controls, the areas of high risk, and with weak internal controls, the auditor should speed a significant time in verifying the auditor should speed a significant time in verifying the actual performance of the facility. Similarly in areas of actual performance of the facility. Similarly in areas of high risk and with strong controls, the auditor should high risk and with strong controls, the auditor should conform whether those controls functions effectively. In conform whether those controls functions effectively. In case of high risk and weak controls, the auditor should case of high risk and weak controls, the auditor should verify that the actual performance complies with the verify that the actual performance complies with the requirements. The auditor should relatively put less requirements. The auditor should relatively put less effort during the following step in areas of low risk but effort during the following step in areas of low risk but having strong internal control. having strong internal control.

Collecting Audit Evidence :

Audit evidence forms the basis on which the team determines compliance with laws, regulations, corporate policies and / or other standards. Suspected weaknesses in the management system are confirmed in this step. Also management systems that appear sound are tested to verify that they work as planned and are consistently effective. Various work such as record reviews, examination of available data, observation and interviews with factory personnel are used to gather audit evidence.

Record reviews and examination of available data with audit team needs access to applicable codes and standards, detailed plant descriptions, such as piping and instrumentation drawings and flow charts: plant procedures for start-up, shut-down, normal operation and emergencies, personnel injury reports, hazardous incidence report maintenance records such as critical instrumental pressure relief valve tests and pressure vessel inspection and process material characteristics i.e. toxicity and reactivity information. The following points should be examined during review of records:

Completeness and authenticity of records Purpose and effectiveness of the format and their

satisfactory filling-up. Checking of records and show-up action by never

authorities. Method of maintaining records

Interview with factory personnel :

The auditor asks questions, both formally and informally. The following points should be kept in mind while interviewing a person.

Interviewing persons is a difficult matter and should be handled properly.

Sometimes due to various reasons, the person is reluctant to provide the required information.

During interviews, unnecessary / irrelevant questions should be avoided.

The person being interviewed should be kept at ease The interviewer should create a feeling of trust in the person

being interviewed. Information should be collected by interviewing, persons at

the appropriate level. Verify statements by interviewing persons of the same /

different levels. The person should be interviewed at his normal working

location. Proper judgments should be used to select a sample of the

work force for the interview.

Observation :

Plant visit, observation is a significant aspect of safety audit. The auditor collect evidence through what can be seen, heard, touched or smell. The following points should be kept in mind during a plant visit :

Visit to the plant must be during the normal working condition.

Observation on relevant audit elements should be recorded on the spot.

The auditor should develop skills ( keep eyes open ) to make observation of several elements at each location.

Once sufficient deficiencies relating to a particular item are detected, checking of that item at other locations may be stopped.

When sufficient observations ( particularly about acceptable systems ) are made on a particular element during plant visit the auditor should spent less time in document verification of that item.

Safe operating procedures should also be checked. The auditor should try to visit some locations under

shut down maintenance, construction, etc. The auditor must make one visit during second shift

/ holiday to assess conditions and functioning of systems apart from in the general shift.

The auditor must check the availability of operating procedures in the plant.

Evaluating audit evidence :

After the evidence is gathered, the audit findings and observations are evaluated. The audit team sets aside a few hours at the end of the audit to discuss, evaluate and finalize the tentative audit findings. The team confirms if there is sufficient evidence to support all findings. Findings that may be more significant than individual deficiencies are identified and each finding is summarized in a way that most clearly conveys its significance.

Reporting Audit Findings :

During the audit deficiencies or “ findings “ are reported continuously as the auditors and factory personnel interact. Findings are summarized in daily “ warp-up “ meetings. The audit team formally communicates all observations and findings during an ‘ exit ‘ or ‘ close out ‘ meeting between the audit team and the factory personnel. Any ambiguities about the findings are also clarified during the exit meeting. Then, the written audit report is prepared. The report should contain objectives, methodology, scope, information about compliance status, findings and corrective measures. Sometime a draft report is prepared, reviewed and commented upon by those directly involved in the audit before a final report is issued. Report reviewers often include the safety department, management of the factory audited and the audit team.

Post-audit Activities

The final audit report is issued to the chief executive of the company. Some companies also distribute the report to various levels of the operating and line management communication and distributed to those with a need to know. A formal procedure for responding to the audit report is established. The action planning process is initiated as audit findings are identified. If assigns responsibilities for corrective action, determines potential solutions and prepares recommendations to correct any deficiencies mentioned in the audit report, and establishes time tables. Companies may also incorporates the action plan in the final report. Action plans are monitored and followed either by the operating management, the safety department. Or the auditors. The follow-up involves a written or oral inquiry to the status of the planned action.

ANNEX – A(Clauses 2.1 and 4.2.4 )(Clauses 2.1 and 4.2.4 )

ELEMENTS OF OCCUPATIONAL SAFETY AND ELEMENTS OF OCCUPATIONAL SAFETY AND HEALTH SYSTEMHEALTH SYSTEM

(OS&H)

1. Occupational safety & health policy

2. OS&H organizational set-up

3. Education and training

4 In Employees participation OS &H management5 Motivation and promotional measures for OS &H6 Safety manual and rules. Compliance with

statutory requirements7 New equipment review / inspection8 Accident reporting analysis investigation and

implementation of recommendations9 Risk assessment including hazard identification10 Safety inspections11 Health and safety improvement plan / targets12 First aid facilities-occupational health centre13 Personal protective equipment14 Good housekeeping15 Machine and general area guarding

16 Material handling equipment17 Electrical and personal safeguarding18 Ventilation, illumination and noise19 Work environment monitoring system20 Prevention of occupational diseases including periodic

medical examination21 Safe operating procedures22 Work permit systems23 Fire prevention, protection and fighting system24 Emergency preparedness plans ( on-site / off-site)25 Process / plant modification procedure26 Transportation of hazardous substances27 Hazardous waste treatment and disposal28 Hazardous waste treatment and disposal29 Safety in storage and warehousing30 Contractor safety systems31 Safety for customers ( including material safety data

sheets )

Audit ElementsThe detailed scope of the audit is listed as a series of

audit elements in two broad categories :

1 Management Systems , and

2 Technical / Hardware Aspects .

Under each element a number of sub- elements have been listed. There may be many instances, particularly in small or medium sized plants, where all elements need not be used. Further, for each type of industry (e.g. fertilizer petrochemical, pesticide ) detailed listings /checklists would need to be prepared. Therefore selection of elements and sub-elements should be done using the professional judgment of the auditor, based on the type and size of the industry and other aspects.

Management System

The essential elements of safety management system to be audited are given below :

1 Safety, Health & Environment ( SHE ) Policy i ) Management’s commitment to SHE ii ) Accountability and Responsibility iii ) Implementation iv ) Policy review

2 Safety and Health Organizational Set-up i ) Safety Department - Structure - Responsibilities ii ) Occupational Health Services iii ) Safety Committee

3 Education and Training

i ) Induction training for new employees -Category -Topics -Duration -Feedback -Methodology

ii ) Periodic Training -Category

-Topics -Duration -Periodicity -Feedback -Methodology

4 ) Communication / Motivation / Promotion in 4 ) Communication / Motivation / Promotion in SafetySafety

i) Safety suggestion scheme ii) Safety competitions - Safety performance - Housekeeping - Safety essay, slogan and poster iii) Display Board information iv) Safety publications v) Safety week / Day celebrations

5 ) Safety Inspections5 ) Safety Inspections i) Periodic inspection

ii) Routine inspection iii) Special inspection

6) Accident Reporting, Investigation and Implementation of Recommendations

i) Reportable

- Fatal - Serious - Others ii) Non-Reportable iii) Dangerous occurrences / Near misses

7) Maintenance of Accident Statistics and its Utilization

i) Accident rate per 1000 workers employed ii) Frequency rate iii) Severity - Type-wise and cause-wise analysis of accidents

8) Safety Audits8) Safety Audits i) External audits ii) Internal audits - Self - Corporate

9) Personal Protective Equipments9) Personal Protective Equipments i) Types and selection ii) Training and motivation iii) Enforcement iv) Maintenance v) Testing

10)10) Process / Plant Modification ProcedureProcess / Plant Modification Procedure ( including Technology Change )( including Technology Change )

11)11) Safe Operating ProcedureSafe Operating Procedure

i) Implementation i) Implementation ii) Review ii) Review

12)12) Work Permit System Work Permit System

i) Line breaking i) Line breaking ii) Confined space entry ii) Confined space entry iii) Hot iii) Hot work work iv) Electrical lockout and tag system iv) Electrical lockout and tag system v) Excavation v) Excavation vi) Working at height vi) Working at height vii) Working on fragile vii) Working on fragile

13) Fire Fighting System13) Fire Fighting System

i) Selection of fire fighting equipment i) Selection of fire fighting equipment ii) Fire fighting procedures ii) Fire fighting procedures iii) Fire fighting team iii) Fire fighting team iv) Communication iv) Communication system v) system v) Drills Drills vi) Inspection and maintenance of fire fighting vi) Inspection and maintenance of fire fighting

equipmentsequipments

14) Health and Safety Improvement Plan / Targets14) Health and Safety Improvement Plan / Targets

i) Accident / Incident rate reduction i) Accident / Incident rate reduction ii) Improvement in environmental standards ii) Improvement in environmental standards

15 Prevention of Occupational Diseases15 Prevention of Occupational Diseases i) Identification of areas with i) Identification of areas with potential for occupational diseases potential for occupational diseases ii) Engineering control measures ii) Engineering control measures iii) Administrative iii) Administrative control measurescontrol measures

16) Work Environment Monitoring System16) Work Environment Monitoring System i) In-plant facilities i) In-plant facilities ii) Assistance ii) Assistance from outside organizationsfrom outside organizations

17) Medical Examination17) Medical Examination i) Pre-employment i) Pre-employment ii) Periodical ii) Periodical

18) Material Safety Data Sheets18) Material Safety Data Sheets i) Preparation i) Preparation ii) Updates ii) Updates iii) Dissemination iii) Dissemination

19) Emergency Preparedness Plan ( On-site / off-19) Emergency Preparedness Plan ( On-site / off-site )site ) i) Emergency response system i) Emergency response system ii) Emergency alarm system ii) Emergency alarm system iii) Mock drills iii) Mock drills iv) Co-ordination with the iv) Co-ordination with the local authorities v) Education of local authorities v) Education of general public general public vi) Communication with the public vi) Communication with the public

20)20) Hazardous Waste Treatment and Hazardous Waste Treatment and DisposalDisposal i) Incineration of solid waste ii) Efficient treatment iii) Disposal iii) Air pollution control measures

21) Transportation of Hazardous Materials 21) Transportation of Hazardous Materials

i) Provision of information i) Provision of information ii) ii) Emergency responseEmergency response

22) Hazard Identification22) Hazard Identification

i) Checklist i) Checklist ii) “What if ?” review of ii) “What if ?” review of operations operations iii) Hazard and operability study iii) Hazard and operability study ( Hazop ) iv) ( Hazop ) iv) Fault Tree Analysis Fault Tree Analysis v) Mond and Dow index v) Mond and Dow index

23) Contractor Safety Systems23) Contractor Safety Systems

24) New Equipment Review / Inspection 24) New Equipment Review / Inspection

Technical Aspects The essential elements of a technical safety audit are based

on the scope of the audit. These may be acted in a particular plant / operation / aspect or may extend to technical safety aspects of the entire factory.

The following technical aspects are to be looked in to in detail while carrying out the safety audit. 1) Building and Structures

i) Location and lay-out ii) Conforming to standards iii) Stability certificate iv) Escape routes and exits v) Fire-proof construction vi) Lighting arrestor

2) Operational Safety and Procedures

i) Availability and compliance of operating and i) Availability and compliance of operating and safety manuals ii) safety manuals ii) Control of operating parameters iii) Control of operating parameters iii) Start-up and shut-down procedures iv) Start-up and shut-down procedures iv) Venting / Scrubbing systems Venting / Scrubbing systems v) Running of emergency v) Running of emergency equipment during power failure equipment during power failure vi) Cleaning and tank entry vi) Cleaning and tank entry procedures vii) Work permit systems procedures vii) Work permit systems viii) Precautions against endothermic / viii) Precautions against endothermic / exothermic run-away reactionsexothermic run-away reactions

3)3) Chemical Process SafetyChemical Process Safety i) Plant lay out i) Plant lay out - Separation and - Separation and isolation, - Drainage, - Enclosed spaces isolation, - Drainage, - Enclosed spaces ii) Material compatibility ii) Material compatibility iii) Contamination iii) Contamination control control iv) Physical facilities iv) Physical facilities v) Inspection and maintenance v) Inspection and maintenance vi) General vi) General containment and controls containment and controls vii) Instrumentation vii) Instrumentation viii) Piping viii) Piping systems systems ix) Protective systems ( not quality control) ix) Protective systems ( not quality control) x) Electrical equipment x) Electrical equipment xi) Pressure vessels xi) Pressure vessels

xii) Pumps and compressors xii) Pumps and compressors xiii) Reactions xiii) Reactions xiv) xiv) Venting Venting xv) Interlock devices for xv) Interlock devices for critical operations and equipments critical operations and equipments xvi) Over-pressure: relief devices xvi) Over-pressure: relief devices xvii) Continuous operation of neutralization system and xvii) Continuous operation of neutralization system and connecting it with diesel generating set in case of power connecting it with diesel generating set in case of power failure failure xviii) Connecting critical equipment with diesel xviii) Connecting critical equipment with diesel generating set in case of total power failure generating set in case of total power failure xix) Alarm warning system in case of emergency xix) Alarm warning system in case of emergency xx) xx) Indication and alarm system for process parameters Indication and alarm system for process parameters control xxi) Installation of control xxi) Installation of fail-safe instruments fail-safe instruments

4 Handling and Storage of Chemicals Chemicalsi) Site selection -Storage area away from buildings or structures , - Distances as per the statutory regulations , - Well ventilated area , - Easy access from the control room

ii) Alarm and indications ii) Alarm and indications - High level alarm , - High pressure & high temperature alarms , - Isolation of the tank , -Remote control valve iii) Fencing iii) Fencing iv) Distance between two iv) Distance between two tank tank

v) Dyke walls with drainage system v) Dyke walls with drainage system vi) Display of caution notice vi) Display of caution notice vii) Support for above vii) Support for above ground tanks viii) Venting ground tanks viii) Venting ix) Valves ix) Valves x) Level measurement x) Level measurement xi) Pumps xi) Pumps xii) Sources of ignition xii) Sources of ignition xiii) xiii) Lighting Lighting xiv) Marking of tanks , xiv) Marking of tanks , connections and fittings connections and fittings xv) Gas leakages and control xv) Gas leakages and control

xvi) Safety valves discharge connection to the xvi) Safety valves discharge connection to the neutralization system / flare neutralization system / flare xvii) Flame proof fittings xvii) Flame proof fittings xviii) Electrical grounding of the vessels xviii) Electrical grounding of the vessels and pipe lines and pipe lines xix) Diesel generating set connected xix) Diesel generating set connected to the emergency power supply to the emergency power supply xx) xx) Minimizing of inventory Minimizing of inventory xxi) Storage of xxi) Storage of chemicals under low pressure chemicals under low pressure xxii) House xxii) House keeping keeping xxiii) Fire fighting arrangement and provision of xxiii) Fire fighting arrangement and provision of static water static water

xxiv) Extension of liquid inlet line to xxiv) Extension of liquid inlet line to avoid static charge avoid static charge xxv) Personal protective equipments xxv) Personal protective equipments xxvi) xxvi) Hydraulic testing and inspection of pipelines Hydraulic testing and inspection of pipelines xxvii) Material xxvii) Material safety data sheet xxviii) safety data sheet xxviii) Trem (Transit Emergency ) card Trem (Transit Emergency ) card xxix) Emergency information panel xxix) Emergency information panel xxx) Labeling of packaging xxx) Labeling of packaging material xxxi) material xxxi) Loading and unloading procedure Loading and unloading procedure xxxii) Transport emergency preparedness xxxii) Transport emergency preparedness xxxiii) Emergency kit / xxxiii) Emergency kit / fire fighting equipment fire fighting equipment

(5) Fire and Explosion hazards

1 Fire prevention1 Fire prevention - - No smoking No smoking restricted area restricted area -Periodic checking & continuity of ear thing -Periodic checking & continuity of ear thing -Prevention of spillages -Prevention of spillages -Accumulation of -Accumulation of waste and combustible in process areas waste and combustible in process areas -Water sprinklers -Water sprinklers -Fire alarms -Fire alarms -Lightning -Lightning arrestor arrestor -Flame proof fittings -Flame proof fittings -Flame arrestor -Flame arrestor -Static charge -Static charge - -Fire exitsFire exits

2- Fire Protection2- Fire Protection -Location and capacity of fire hydrant -Location and capacity of fire hydrant pump -Booster pump and pump -Booster pump and stand – by pump -stand – by pump -Hydrant pump starting system and procedure Hydrant pump starting system and procedure -Static water quantity -Static water quantity Layout of lines Layout of lines Space Space between the hydrants between the hydrants Water jet monitors Water jet monitors Hydrant boxes Hydrant boxes Foam requirement Foam requirement

3- Fire extinguishers : Testing Testing

and certification by competent authoritiesand certification by competent authorities Fire siren systemFire siren system Fire fighting teamFire fighting team Fire fighting trainingFire fighting training Mutual aid schemeMutual aid scheme

(6) Material Handling(6) Material Handlingi) Manual handling :i) Manual handling : Procedures

-Handling aids -Condition of material handling areas

ii) ii) Lifting machinery and tackles :Lifting machinery and tackles : -Selection

-Design criteria -Inspection and testing -Compliance with standards -Periodic checking and maintenance -Storages -Safe working load, identification, markings etc. -Slinging practices

iii) Material Handling procedures :

-Stacking and restacking procedures : -Stacking and restacking procedures : -Compliance with -Compliance with standards standards -Load bearing capacity -Load bearing capacity -Stacking -Stacking stability stability -Safe handling procedure for -Safe handling procedure for chemicals and explosives chemicals and explosives -Storage facilities ( adequacy & suitability ) -Storage facilities ( adequacy & suitability ) including pallets including pallets -Clearance and passages -Clearance and passages -Provision of aisles -Provision of aisles

7) Machine Guarding7) Machine Guarding i) Types of guards ii) Guarding materials iii) Maintenance of guards iv) Periodic inspection

8) Pumps and Compressors8) Pumps and Compressors i) Pressure design of casing ii) Rating of in stream piping iii) Check valves / Control valves iv) Suction piping and over pressure v) Isolation valve vi) Speed control vii) Design temperature control viii) Leakages ix) Lubrication x) Reverse flow / rotation xi) Vibration / Alignment

9) Inspection & Testing of Pressure Vessels

i) Schedule and inspection and testing i) Schedule and inspection and testing ii) Testing and inspection reports ii) Testing and inspection reports iii) Compliance iii) Compliance with standards with standards iv) Inspection and testing of pressure relief valves and iv) Inspection and testing of pressure relief valves and rupture discs rupture discs

10 Personal Protective Equipments10 Personal Protective Equipments - Selection and suitability - Selection and suitability

i) Proper use i) Proper use ii) Display ii) Display iii) Inspection and testing iii) Inspection and testing iv) Maintenance iv) Maintenance v) Proper storage v) Proper storage

11) Electrical Hazards11) Electrical Hazards

i) Area classification i) Area classification ii) Selection and use of electrical appliances ii) Selection and use of electrical appliances iii) iii) Overload and short-circuit devices Overload and short-circuit devices iv) Power isolation procedures v) iv) Power isolation procedures v) Electrical fire-fighting devices Electrical fire-fighting devices vi) Flame proof fittings vii) vi) Flame proof fittings vii) Lightning arrestor Lightning arrestor viii) Ear thing / Earth leakage circuit breaker viii) Ear thing / Earth leakage circuit breaker ix) Lock out and tagging proceduresix) Lock out and tagging procedures

12) Instrumentation i) Provision and suitability of instrument in process / i) Provision and suitability of instrument in process /

equipment ii) equipment ii) Instrument calibration procedures Instrument calibration procedures iii) Tripping devices for control of iii) Tripping devices for control of process parameters process parameters iv) Fail-safe instrumentation procedures iv) Fail-safe instrumentation procedures v) Periodic maintenance v) Periodic maintenance procedures procedures vi) Testing and inspection procedures vi) Testing and inspection procedures vii) Checking against vii) Checking against response time response time viii) Effects of humidity and temperature on viii) Effects of humidity and temperature on instruments instruments ix) Back-up procedures ix) Back-up procedures x) Checking of air ( quality, x) Checking of air ( quality, pressure, etc )pressure, etc )

13) Preventive Maintenance

i) Schedule ii) Maintenance checklist / reports iii) Equipment change-over schedule iv) Review of equipment failures

14) Pollution System i) Effluent treatment plant

ii) Air pollution control and monitoring iii) Hazardous wastes disposal iv) Noise pollution

15) Emergency Preparedness i) Organization

ii) Emergency planning iii) Emergency control center iv) Escape routes v) Assembly points vi) Evacuation procedures vii) Communication within the plant viii) Identification of hazardous areas ix) Key personnel x) Emergency response equipments xi) First aid and medical facility xii) Communication ( authorities and public ) xiii) Dispersion models xiv) Training and drills

16) Boilers / Furnaces

i) Compliance with statutory requirements ii) Feed water piping iii) Steam outlet piping iv) Quality of water v) Drum water level vi) Maintenance of instrument vii) Gas burner control

viii) Interlocks ix) Shut-off valves x) Dampers xi) Low pressure, high pressure alarms xii) Pressure and vacuum relief valves xiii) Flame arrestor on discharge of relief valves xiv) Stack height xv) Emergency relief device xvi) Monitoring of stack emission xvii) Economizer and super heater xviii) Access to control valves xix) Inspection of furnace lining xx) Explosion hazards xxi) Fuel control xxii) Insulations xxiii) Measurement of heat stress

17) Hand Tools and Portable Power Tools i) Selection ii) Maintenance iii) Quality iv) Storage v) Guarding vi) Ear thing of portable power tools

18) Lighting / illumination18) Lighting / illumination

i) Type of lighting ii) Illumination levels iii) Compliance with standards iv) Ratio of contrast v) Glare vi) Maintenance of fixtures and fittings

19) House-keeping 19) House-keeping

i) Floor surface i) Floor surface ii) Cleanliness and ii) Cleanliness and tidiness tidiness iii) Disposal bins iii) Disposal bins iv) iv) Fencing of dangerous spots and ditches Fencing of dangerous spots and ditches v) Covering of v) Covering of trenches and pits trenches and pits vi) Steps, ladders, staircases, vi) Steps, ladders, staircases, ramps, walkways ramps, walkways vii) Passages vii) Passages viii) Drainage viii) Drainage ix) Work platforms ix) Work platforms x) Left x) Left over materials over materials xi) Stacking xi) Stacking

IMPORTANT ASPECT FOR ACCIDENT PREVENTATION

TOPREVENTACCIDENT

HAZARD IDENTIFICATION-HAZOP-HAZAN-FAULT TREE ANALYSIS-EVENT TREE ANALYSIS-DOW INDEX-SAFETY AUDIT-SAFETY INSPECTION

WORK PERMIT SYSTEM-MECH. MAINTENANCE PERMIT-ELEC. MAINTENANCE PERMIT-HOT WORK PERMIT-COLD WORK PERMIT-VESSEL ENTRY PERMIT-WORK AT HEIGHT PERMIT-ESCAVATION PERMIT-E.T.C. PERMIT

JOB SAFETY ANALYSISI

SAFE OPERATING PRACTICEI

TRAINING

ANNEX- B(Clause 4.3.3.1)

TYPES OF RECORDS TO BE EXAMINED DURING THE SAFETY AUDIT

1 OS&H policy

2 Safety organizations chart

3 Training records on safety fire and first-aid

4 Record of plant safety inspections

5 Accident investigations reports6 Accidents and dangerous occurrences-statistics and analysis7 Record of tests and examinations of equipments and

structures as per status8 Safe operating procedure for various operations9 Record of work permits10 Record of monitoring of flammable and explosive

substances at work place11 Maintenance and testing records of fire detections and fire

fighting equipment12 Medical records of employees13 Records of industrial hygiene surveys ( noise, ventilation

and levels, illumination levels, airborne and toxic substances, explosive gases )

14 Material safety data sheets

15 On-site emergency plans and record of Mock Drills

16 Records of waste disposal

17 Records of effluent discharges to the environment

18 Housekeeping inspection records

19 Minutes of safety committee meetings.

20 Approval of layout and other approval from statutory authorities

21 Records of any modifications carried out in plant 21 Records of any modifications carried out in plant or processor process

22 Maintenance procedure records22 Maintenance procedure records23 Calibration and testing records23 Calibration and testing records24 Shut down maintenance procedures24 Shut down maintenance procedures25 In services inspections manuals, records 25 In services inspections manuals, records

including that of materials handlingincluding that of materials handling26 Safety budget26 Safety budget27 Inspection books and other statutory records27 Inspection books and other statutory records28 Records of previous audits28 Records of previous audits29 Safety in transportation of hazardous substances 29 Safety in transportation of hazardous substances

ANNEX- C(Clause 4.3.3.1)

SAFETY AUDIT QUESTIONNAIRE

1) HEALTH AND SAFETY POLICY

1 Does the organization has a health and safety

policy ? ( if yes, please attach one copy )2 Do you have any corporate safety policy ? ( if yes, please attach one copy )

3 Who has signed the health safety policy ?

( indicate his position )

4 Whether it is prepared as per guidelines of the statutory provisions ?

5 When was the safety policy declared and adopted ?

6 How many times it has been updated till now ?

7 Whether the policy is made known to all ?

8 Whether the safety policy was scrutinized by outside expert agency ?

9 What was the last date of updating ?

10 Does it find a place in the annual report ?

2) SAFETY & HEALTH ORGANIZATION(A) Safety Department

11 Does the factory has a safety department ? 12. If yes, furnish the following information : i) Head of the safety department : a) Name (b) Designation (c) Qualification (d)

Experience (e) Status ii) Strength of the safety department including safety

officers and staff.

13. Does the head of safety department / safety officer report to the chief executive ?

14. How often are the safety officers retrained in

the latest techniques of total safety management ? What is the frequency of retraining ?

15. What additional duties the safety officer is

required to do ? 16. What is the power of safety officer vis-à-vis

unsafe condition or unsafe act ?

(B) Safety Committee (s)

17 Does the factory has a safety committee (s) ? Give details of their types, structures and terms of reference.

18. Is the tenure of the safety committee (s) as per the status ?

19. How are the members of safety committee (s)

selected ? ( elected / nominated ) 20. How often are the meetings of safety committee (s) held

?

21 What are the subjects ? Are the problems discussed in the meetings ? ( Attach a copy of agenda and minutes of the last meetings.)

22 How are the recommendations of the committee (s) implemented ?

23 Are the minutes of the safety committee (s)

meetings circulated among the members ?

24 Are the minutes forwarded to the trade union (s)

and chief executive and occupier? 25 How the management and trade union play their

active roles in supporting and accepting the committee (s) recommendations ?

26 How are the safety committee (s) members

apprised of the latest developments in safety, health and environment ?

(c) Safety Budget

27. What is the annual safety budget ?

28 How much percentage is this budget of the total turnover of the company.

29 How much budget has utilized till date ?

30 Is the safety budget adequate ?

31 How is the safety budget arrived at ?

32 What is the pattern of expenditure for the last five years?

33 What are the approved sanctions for the expenditure in this budget ?

34 Does this budget get reflected in the annual report of the company ?

3) ACCIDENT REPORTING, INVESTIGATION AND ANALYSIS

35 Whether the accidents data for the last three years for reportable and non-reportable accident available ?

36 Is there any system of classifying and accidents reported and analyzing the near-miss incidents and accidents ? Give the details.

37. Are all near-miss incidents and accidents reported and investigated ?

38. For how many years are the investigation reports retained?

39. By whom the accident statistics and data are maintained ?

40. How is the top management apprised of these data ?

41. Is the accident statistics effectively utilized ? If yes, how ?

42. What nature of injuries occurred during the last three years?

43 How do you ensure implementation of the recommendations to avoid the recurrence of the incidents and accidents ?

4) SAFETY INSPECTIONS

44 What type of safety inspections are carried out and what are their frequency ?

45 Is there any system of internal inspection ?

46 Who does the inspections ?

47 Are the check-list prepared for these inspections ? ( Specify item-wise, for example, housekeeping, fire protection, etc )

48 To whom the recommendations are submitted ?

5) SAFETY EDUCATION AND TRAINING (A) Training

49 Is there any training department ?

50 Is there any program of induction training ?

51 Mention the duration of induction training for each category of employees.

52 Whether the assessment of the trainee worker is done or not ?

53 What infrastructural facilities with audio-visual support are available for training ?

54 Do the programs cover the plant safety rules, hazard communication and any other special safety rules or procedures unique to the plant or specific departments ?

55 Whether the training programs are conducted in the local language ?

56 Whether visits to safety institution / organizations are arranged ?

(B) Periodic Training / Retraining

57 Are all the employees trained and what is the frequency of such training ?

58 Do the training programs cover safety and health aspects and if so how much ( in terms of numbers of sessions / hours ) ?

59 Do the trained supervisors train their own employees in safety and health aspects?

60 Is the retraining performed whenever new hazards / process changes are followed / introduced ?

61 How are the senior management personnel trained in safety and health ?

62 How many employees have been trained in safety and health in the last five years ? Give break up with details.

63 How many man-days / hours are used in training the employees ?

64 How do you ensure that the training is put to use by the employees trained in safety and health.

65 What is the training plan for the next two years ? Give details.

66 What documentation system has been established regarding safety and health training ?

(C) Safety Communication / Motivation / Promotion

67 Does the factory has safety suggestion scheme ? Give details.

68 Does your factory participate in National Awards / Suggestion schemes ?

69 Has your factory been awarded during last five years ?

70 Are safety contests organized in the factory ?

71 What are the publications of your organization ? Do they include information on safety and health subjects ?

72 Is the literature on safety and health made available to the employees ?

73 How is the safety and health publicized in your factory ?

i) Bulletin boards ?

ii) Post serious accidents ? iii) News letter iv) Others ? Specify.74 Does the organization celebrate safety day / week

or organize safety exhibition ?75 When was the last safety day / week celebrated ?

(6) FIRST AID

76 Are adequate number of first aid boxes provided ? Give location details ?

77 Is there any first aid / ambulance room ?78 Are qualified / trained first aiders available in

each shift ?79 How many qualified / trained first aiders are

available at each plant / department ?80 How many persons are trained / given refreshers

training in first aid in a year ?

(7) OCCUPATIONAL HEALTH CENTRE

81 Whether occupational safety and health center is provided or not ?

82 Does it conform to the provisions of the existing legislation ?

83 Are the medical Attendants / Doctors available in each shift ?

84 Is ambulance van available in each shift ?

85 Any liaison with the nearest hospital (s) ? Give details.

(8) GENERAL WORKING (8) GENERAL WORKING CONDITIONCONDITION

(A) Housekeeping

86 Are all the passages, floors and the stairways in good condition ?

87 Do you have the system to deal with the spillage ?

88 Do you have sufficient disposable bins clearly marked and whether these are suitably located ?

89 Are drip trays positioned wherever necessary ?

90 Do you have adequate localized extraction and scrubbing facilities for dust, fumes and gases ? Please specify.

91 Whether walkways are clearly marked and free from obstruction ?

92 Do you have any inter-departmental competition for good housekeeping ?

93 Has your organization elaborated good housekeeping practices and standards and made them known to the employees ?

94 Are there any working conditions which make the floors slippery ? If so, what measures are taken to make them safe ?

95 Does company have adequate measures to suppress polluting dust arising out from road transport ?

(B) Noise(B) Noise96 Are there any machines / processes generating noise ?

Specify

97 Was any noise study conducted ?

98 Which are the areas having high level noise ?

99 Have engineering and administrative controls been implemented to reduce noise exposure below the permissible limits ?

100. Is there a system of subjecting all those employees to periodic audiometric test who work in high level noise areas ?

101. Whether the workers are made aware of the ill-effects of high noise.

102. Whether any personal protective equipment along with ear muffs / plugs are provided and used.

(C) Ventilation

103 Whether natural ventilation is adequate or not ?104 Whether dust / fumes / hot air is generated in the

process ? Give details.105 Is there any exhaust dilution ventilation system in

any section of the plant ?106 Whether any ventilation study has been carried

out in the section (s) to check the record ?107 Are periodic / preventive maintenance of

ventilation system carried out and record is maintained ?

108 Does any ventilation system recirculate the exhausted air in work areas ?

109 Is the work environment assessed and monitored ?110 Whether personal protective equipments are given to

workers exposed to dust / fumes and gases ? Give details.

( D ) Illumination

111 Was any study carried out for the assessment of illumination level ?

112 Is there any system of periodical cleaning and replacing the lighting fitting / lamps in order to ensure that they give the intended illumination level ?

113 Are the workers subjects to periodic optometry tests and records maintained ? Give details.

(9) HAZARD IDENTIFICATION AND CONTROL

114 Are all the hazardous areas identified ?

115 What are type of hazards ( physical- noise, heat, etc and chemical-fire, explosion, toxic release, etc ) ?

116 What steps have been taken to prevent these hazards ? Give details.

117 Are there any safety inter-locks, alarms and trip system ? Give details.

118 Are these tested periodically ? How often ? Please specify.

119 Are there any ambient monitoring devices with alarms fir leakage of hazardous materials ? Give details.

119 Are Safety Audit or HAZOP or any other studies carried out and the recommendations implemented ? Give details.

120 What has been the major modification done in plant / process and has the approval of the competent authority concerned ?

121 What decision and monitoring equipment are available and used for checking the environmental conditions in and around the plant ? Give details.

TECHNICAL ASPECT12) Safe Operating procedures12) Safe Operating procedures

122 Are written safe operating procedures available for all operations ?

123 Whether the written safe operating procedures displayed or made available and explained in the local language to the workers ?

124 Whether the safe operating procedures are prepared jointly by the plant and safety department ?

125 What system is used to ensure that the existing safe operating procedures are updated ? Give details.

126 Have the workers been informed of the consequences of failure to observe the safe operating procedures?

127 Are contractor’s workers educated and trained to observe safety at workplace ?

128 Whether contractor’s workers are permitted on process / operations ?

13) WORK PERMIT SYSTEM

129 What necessary type of work permits exists in your factory ? Give details.

130 What are the hazardous chemicals handled ?

131 Are the keys for individual locks which are used for electrical lock outs with the supervisor concerned ?

14) WASTE DISPOSAL SYSTEM

132 Is identification done for various types of wastes ? Give details.

133 Are these quantities less than those specified by the hazardous wastes.( Management & Handling Rules. 1989 ) ?

134 What are their disposal modes ?135 What are the systems / measures adopted for

controlling air / water / land pollution ?136 What is the system of effluent treatment plant and

whether it is approved by the competent authority?137 How are the treated effluent used ?

15) PERSONAL PROTECTIVE EQUIPMENT ( PPE )

138 Has a list of required PPE for each area / operation been developed and the required PPE is made available to the workers ?

139 Are the safety department and the workers consulted in the selection of PPE ?

140 Have the workers been trained in proper use of PPE ?

141 What is the system of replacement / issue of PPE ?

142 What are the arrangements for safe custody and storage of PPE provider to the workers ?

143 Are the contractor’s workers provided with the required PPE ? Who is responsible ? Give details.

144 Are the PPE conform to any standard ? Give details.

145 Give the details of PPE and also specify the responsibility for their inspection and maintenance ?

20) FIRE PROTECTION

146 Indicate on a plant layout the location number ( quantity ) and types of portable fire extinguishers available.

147 Are the fire fighting system and equipment approved, tested and maintained as per relevant standards ?

148 What is the inspection and maintenance schedule of the above extinguishers ? Who performs these functions ?

149 Which areas of the plant are covered by fire hydrants ? Indicate the locations of the hydrant points and how the required pressure maintained in the system and ensured.

150 What is the capacity of dedicated water reservoir for supply to the hydrants ? What is the source of water ?

151 i) How is the power supply to the fire hydrant pump ensured ?

ii) What is the alternate source of supply in case of supply in case of power failure ? Give details.

152 Are all personnel conversant with the fire prevention and protection measures ? Give details.

153 What percentage of plant personnel and staff and officers have been trained in the use of portable fire extinguishers ? Give details.

154 Do you have fixed or automatic fire fighting installation (s) in any section of your plant ?

155 Are the fire alarms adequate and free from obstructions ?

156 Do you have fire department ? If yes, give details.

157 What is the system for conduction mock drills ? Give details.

158 Do you have any mutual aid scheme with any of your neighboring industry or any local organization (s) ?

159 Give details of the existing fire resistant wall and doors.

160 Do you have any system of color coding for all the pipelines for hazardous chemicals ? Give details including marking of flow directions.

161 Are there any safe containers for the movement of small quantities of hazardous chemical ? Give details.

162 Are all self-closing fire doors in good condition and free from obstructions ?

163 How many major and minor incidents / fires were there in the factory during the last five years ? Give department / plant-wise.

164 Have all the fires / incidents been investigated and

corrective actions taken ? Give break up.

21) EMERGENCY PREPAREDNESS

165 Is there an on-site emergency plan for your factory ? ( attach a copy of the plan )

166 What is the frequency of conducting mock drills of on-site emergency plan ?

167 What are the number and location of emergency control centre, assembly points ?

168 Whether emergency team or the key personnel identified ?

169 Are suitable and adequate protective and rescue equipment available ? How is the emergency rescue team trained to use these equipments ?

170 How is the medical emergency communication with local bodies and other organizations ensured ? Give details.

171 Is any alternate power source identified ? Give details.172 What is the medical emergency response system ? Give

details.173 Are you a member of any MUTUAL-AID-SCHEME of your

area ? If so give details.174 How many emergency alarm system (s) is / are available ?

Give details..22) PLANT LAYOUT AND AREA

CLASSIFICATION175 What is the system of classification of hazardous zones in the plant for 175 What is the system of classification of hazardous zones in the plant for

electrical installations ? Please specify.electrical installations ? Please specify.176 Whether periodic inspection and preventive maintenance of electrical 176 Whether periodic inspection and preventive maintenance of electrical

installations is done by a qualified person and record is maintained ?installations is done by a qualified person and record is maintained ?177 Whether plant layout with area classification has been displayed at 177 Whether plant layout with area classification has been displayed at

appropriate place (s) ? appropriate place (s) ?

22) STATIC ELECTICITY

178 Whether the process (s) and equipment generate and accumulate static charge have been identified ? Give details.

179 Whether all such equipment are properly bonded and earthed ?

179 How is electrical resistance for earthing circuits maintained ? Are periodic inspections done and recorded?

180 Are adequate earthing arrangement made at the terminal points where hazardous chemicals are handled through pipes ?

181 Are anti-static charge devices fitted wherever necessary ?182 Whether these devices are periodically checked and

maintained by a qualified person ?

23) NEW EQUIPMENT REVIEW

183 What is the system for effecting any change in the existing plant, equipment or process ? Whether it is approved by the appropriate competent authority ?

184 Whether the P & I diagrams and other related documents are updated accordingly ?

24) PRESSURE VESSELS ( FIRED AND UNFIRED )

185 Give details of the plants, piping and vessels which are operated at a pressure grater than the atmospheric pressure ?

186 How is it ensured that the working pressure inside the pressure vessels / pressure plants will not exceed their maximum working pressure for which it is designed ?

187 What means of isolating the pressure vessels or means to prevent rise in pressure are installed ?

188 What standards / codes of practice are adopted for design, fabrication, operation and maintenance of the pressure vessels and records maintained ?

189 How are the pressure vessels tested ? Give details.

190 Is there any competent person for testing these pressure vessels ? Give details.

191 How are the recorded results verified ?

192 Give details of safety devices available for these pressure vessels ?

193 Whether log book for pressure vessel and pressure plant has been maintained ?

24) PRESSURE VESSELS ( FIRED AND UNFIRED )

194 Give details of the plants, piping and vessels which are operated at a pressure grater than the atmospheric pressure ?

195 How is it ensured that the working pressure inside the pressure vessels / pressure plants will not exceed their maximum working pressure for which it is designed ?

196 What means of isolating the pressure vessels or means to prevent rise in pressure are installed ?

197 What standards / codes of practice are adopted for design, fabrication, operation and maintenance of the pressure vessels and records maintained ?

198 How are the pressure vessels tested ? Give details.

199 Is there any competent person for testing these pressure vessels ? Give details.

200 How are the recorded results verified ?

201 Give details of safety devices available for these pressure vessels ?

202 Whether log book for pressure vessel and pressure plant has been maintained ?

25) LIFTING MACHINES & TACKLE

203 Whether all the lifting machines are marked with their S.W.L. ?

204 Are all the examinations and testes documented in the prescribed form ?

205 Are all the examinations and tests carried out and certified by competent person (s) ? Give details.

206 Are adequate lifting tackles provided at all the places where it is required ? Give details.

207 Are the trained operators engaged for operating the equipment ? Give details.

208 What is the system of training such operators ?209 Are all the lifting machines and tackles maintained

in good conditions and record maintained ?

26) MOBILE EQUIPMENT AND VEHICULAR TRAFFIC

210 Are all the mobile equipment in good condition ?211 Are trained drivers engaged for fork-lift trucks ?212 What is the system for identifying these drivers

from other drivers ?213 What system do you adopt to assess their

standard of driving as poor / fair / satisfactory / good ?

214 Are there adequate number of warning signs / signals ?

215 Are the hazards associated with transportation within the plant identified and safety measures taken ? Give details.

27) ACESS

216 Is adequate safe access provided to all places where workers need to work ?

217 Are all such access in good condition ?

218 Are portable access platforms necessary ? If yes : i) Are these sufficient ? ii) Are these regularly inspected ? iii) Are these readily available ? iv) Are these provided with toe-boards and railing ?

219 Oiling and greasing points: i)

Are these located and extended to safe place clear of moving parts ? ii) Are these easily accessible ? iii) Are these liable to drip in to walk ways ? iv) Whether such workers wear trained and whether they are provided with fit-tight clothing and register is maintained ?

220 Are all drain covers in good condition and fitting flush ?

28) MATERIAL HANDLING

221 Are there adequate storage facilities available ?

222 Are these areas clearly defined ?

223 Are all racks and steel ages in good condition ?

224 Have you adequate equipment for handling materials ?

225 Do the workers know the hazards associated with manual material handling ?

226 Where manual handling is necessary, are the workers been trained ?

227 Do they practice this ?

228 Do workers follow safe procedures for storage of materials ?

229 Whether contractor workers are trained in safety ?

230 What is the system for handling over plant to the maintenance department and receiving back ?

231 Is the system consistently applied ?

232 What is the system for the preventive and predictive maintenance and how do you ensure its effectiveness ? Give details.

29) TANK STORAGE VESSEL AREA

233 Whether it is pressure vessel or not ?234 Give storage vessels designation ( exceeding

threshold quantities specified in MSIHC. Rules 1989 ).

235 Give the names of storage material in each of them.

236 What are the vessel sizes ( capacity in tones ) ?237 What is the material of construction for each

vessel and what standards followed in designing / fabricating the vessel ?

238 What are the operating pressure and temperature ?

239 What are the vessel location ? (Please indicate on-site plan or plot plan )

240 Indicate whether vessels are above ground / underground.

241 If any of the tanks string flammable material, whether electrical installations are flameproof or not ?

242 Are these storage vessels bunded / dyked ?

243 If yes, what is the capacity of the bunds / dykes ?

245 Are the vessels properly bonded and earthed and whether periodically checked and record maintained ?

246 How are vessels isolated in the event of a mishap ?

247 Are the vessels fitted with remotely controlled isolation valves ?

248 Are vessels provided with emergency vent, relief valve, bursting disc, level indicator, pressure gauge, overflow line?

249 Where do such vents discharge ?

250 Are the vessel provided with alarms for high level, high temperature and high

pressure ? 251 Are stand by empty tanks provided for

employing in case of emergencies ?

252 What are the provisions made for fire fighting / tackling emergency situations around the storage vessels ?

253 Where do such vents discharge ?

254 Are the vessel provided with alarms for high level, high temperature and high pressure ?

255 Are stand by empty tanks provided for employing in case of emergencies ?

256 What are the provisions made for fire fighting / tackling emergency situations around the storage vessels ?

257 Has any consequence analysis been carried out for these vessels ? (If yes, give details )

258 What periodical testing are carried out on the vessels to find out the integrity of the vessels ?

259 Whether these tests are certified by the approved competent persons ?

260 Whether log sheet are filled up on daily basis for recording the parameters of these vessels ?

30) ON-SITE GAS CYLINDER STORAGE AREA

261 What are the various gas cylinder used in the plant ? Give details.

262 What are the storage facilities ?263 What are the measures taken for combating any

emergency in the cylinders storages area ?264 Are valid licenses available for storage all these

cylinders ?265 Whether integrity test certificates are obtained

from the suppliers of the cylinder ?

31) COMMUNICATION SYSTEM ADOPTED IN PLANT

266 Are public address systems available in all plant areas ?

267 Are public address systems provided with uninterrupted power supply ?

268 Whether public address system is checked periodically for its proper functioning ?

269 Is there any hot line provided to fire station ?

270 What is the means of communicating emergency in the plant ?

32) TRANSPORTATION

271 What potentially hazardous materials are transported to or from the site (including ) ?

272 What modes of transport are used ? i) Road ? ii) Rail ? iii) Pipelines ?

i) ROAD

273 Does the company employ licensed vehicle of its own / outside sources ?

274 Are the loading / unloading procedures on-site and safety precautions displayed ?

32) TRANSPORTATION

275 Are loaded tankers or trucks parked in a specific area on-site ?

276 Do all truck and tanker drivers carry TREM card or instruction booked ?

277 Do all truck and tanker driver get training in handling emergencies during transport ?

ii) RAIL278 What hazardous materials are transported by

rail ?279 Does the company have a direct siding on site ?280 Are tankers or other wagons used in

transportation ?

III) PIPELINES

281 What material are transported to and from the site by pipelines ?

282 Are the pipelines underground or over ground ?

283 Are corrosion protection measures employed in pipelines ?

284 Whether intermediate booster pumps are used ?

285 What is the maximum, minimum and average transfer rates ?

286 Are the pipelines extended in the public domain ?

287 Are the pipelines dedicated for each type of chemicals ?

288 Are the pipelines fitted with safety equipment such as leak detectors, automatic shut-off valves, etc ?

289 What is the frequency and method of testing of the pipeline ?

290 Is there written procedure for tackling leakages in pipeline ?

THANKSTHANKSFROMFROM

V. N. PATELV. N. PATEL

DIRECTOR, INDUSTRIAL SAFETY & HEALTHDIRECTOR, INDUSTRIAL SAFETY & HEALTH

GUJARAT STATE GUJARAT STATE