Anda di halaman 1dari 123

<< Back Home Next >>

OISD - GDN - 145


Revision - I
July, 1995
Amended Edition,
September 2001

FOR RESTRICTED
CIRCULATION ONLY

GUIDELINES
ON
INTERNAL SAFETY AUDITS
(PROCEDURE AND CHECKLISTS)

Prepared by:
COMMITTEE ON “ INTERNAL SAFETY AUDITS”

OIL INDUSTRY SAFETY DIRECTORATE


7TH FLOOR, NEW DELHI HOUSE
27, BARAKHAMBA ROAD
NEW DELHI – 110 001.

2
NOTES

OIL INDUSTRY SAFETY DIRECTORATE publications are


prepared for use in the Oil and gas industry under Ministry of
Petroleum and Natural Gas. These are the property of Ministiry of
Petroleum and Natural Gas and shall not be reproduced or copied
and loaned or exhibited to others without written consent from OISD.

Though every effort has been made to assure the accuracy


and reliability of data contained in these documents, OISD hereby
expressly disclaims any liability or responsibility for loss or damage
resulting from their use.

These documents are intended only to supplement and not


replace the prevailing statutory requirements.

Note 3 in superscript indicates the


modification/changes/addition based on the
th
amendments approved in the 19 Safety Council
meeting held in September, 2001July, 1999

3
FOREWORD
Safety Audits have been conducted in the oil/gas
industry in one form or other. Generally, Safety Audits are of two
types viz. Internal Safety Audits and External Safety Audits. While
methodology to be adopted for carrying out the External Safety
Audits is separately dealt with, this document contains guidelines
for conducting Internal Safety Audits in a professional
manner and is expected to assist the industry further in
maintaining and improving the Safety.

Different aspects of the Internal Safety Audits


starting from the need of such Audits, methodology,
preparation of reports, follow up actions on the
recommendation of the Audit Reports have been covered in
Section I of this document- "Internal Safety Audit Procedures".

In addition, comprehensive Check Lists are given in


Section II of the Document covering typical areas in
the oil/ gas industry. These Check Lists would be
useful tool for undertaking in-depth and systematic Internal
Safety Audits and would go a long way in accelerating audits to
ensure that no aspect is overlooked while carrying out such audits.

The present document on Internal Safety Audits (Proce-


dure and checklists) was revised by a Functional Committee con-
stituted from amongst members nominated by the industry for
the committee comprising of refining, marketing, pipelines and gas
processing disciplines.

It is hoped that the provision of this document, if implemented


objectively will go a long way in improving the safety in the oil & gas
industry.

This document will be reviewed periodically for improvements


based on the new experiences and better understanding.
Suggestions from users/industry members may be addressed to:

The Co-ordinator
Committee on Internal Safety Audits
OIL INDUSTRY SAFETY DIRECTORATE
th
7 Floor, ‘New Delhi House’
27, Barakhamba Road
New Delhi – 110 001
.

4
INTRODUCTION

This is the second edition of the OISD


Guidelines on `Internal Safety Audits' (Procedure and
Checklists), first edition of which was published in October,
1989.

The first edition was prepared by OISD and did not


have a regular Functional Committee. A Functional
Committee for the objective of revising the same was
therefore constituted.

The original document has been now revised to


include a new chapter on Internal Audit of cross-country
pipelines in order to make it broad based and
thoroughly updated with the experience gained during
the first round of External Safety Audits of refineries, gas
processing plants, Marketing terminals/LPG Bottling Plants
etc. As during the interim period a number of new OISD
Standards/ Guidelines have been published, reference to the
same has also been provided wherever required.

With the issuance of this edition, the guidelines


contained in earlier edition stands revised.

5
SCOPE

These guidelines are applicable for


refineries/on-shore gas processing units(excluding
all oil-field operations)/ and marketing installations.
Items which may not be applicable in Marketing
have been separately identified by an asterisk (*)
mark. However, it should be clearly understood that
in addition to check points contained in these
guidelines locations may like to further improve the
checklist in order to meet any specific requirements
of the respective safety policy of the concerned
organisation.

In the case of terminals where no pipeline


transfer is taking place, chapters 1,2,3,5,6 and 9
would be applicable.

In the case of terminals where pipeline


transfer is taking place, chapters 1,2,3,5,6,9 and 10
will be applicable.

OISD-STD-144 on “ LPG Bottling Plant


Operations” has recommended a periodicity of once
a year for Internal Safety Audit of individual LPG
Plant (Marketing). The inspection and Maintenance
System as well as Electrical Safety Audits are to be
carried out based on Internal Audit Checklists as
stipulated in OISD-STD-144.

The OISD-145 guidelines are exhaustive and


therefore be adopted for carrying out a
comprehensive Internal Safety Audit of LPG Bottling
Plants (Marketing) for which chapters 1,2,3,7,8 will
be applicable

6
COMMITTEE ON
`INTERNAL SAFETY AUDITS'
REVISION-I

--------------------------------------------------------------------------------------------------------------------------------------
NAME ORGANISATION
--------------------------------------------------------------------------------------------------------------------------------------

LEADER

Shri Barath Balan Hindustan Petroleum Corporation Ltd.


(Marketing)

MEMBERS

Shri M.N. Ahmed Indian Oil Corporation Ltd.


(R&P Division - Pipelines)

Shri S.K. Ray Ex-Official Bharat Petroleum Corporation Ltd.


( Marketing )

Shri T.S.Charvethia Bharat Petroleum Corporation Ltd.


( Refinery )

Shri S.N.Rao Indian Oil Corporation Ltd.


(Refineries & Pipelines Division)

Shri G.C.Sharma Bongaigaon Refinery & Petrochemicals Ltd

Shri M.Bhaskar Rao Hindustan Petroleum Corporation Ltd.


( Refineries )

Shri I.J.Shroff Hindustan Petroleum Corporation Ltd.


( Refineries )

Shri C.T.Ananthakrishnan Indian Oil Corporation Ltd.


(Marketing Division)

Shri K.Madhusudanan Cochin Refineries Ltd.

Shri D.Madhukar Rao Gas Authority of India Ltd.

MEMBER CO-ORDINATOR

Shri S.C. Gupta Oil Industry Safety Directorate

--------------------------------------------------------------------------------------------------------------------------------------

In addition to the above, several other experts from Industry contributed on the preparation, review and
finalisation of this document.

7
OISD - GDN - 145
REVISION-I

GUIDELINES
ON
INTERNAL SAFETY AUDITS

SECTION - 1 INTERNAL SAFETY AUDIT


PROCEDURE

SECTION - 2 INTERNAL SAFETY AUDITS


CHECKLISTS

8
SECTION - 1

INTERNAL SAFETY AUDITS


PROCEDURES

9
--------------------------------------------------------------------------------------------------------------------------------------
SECTION DESCRIPTION PAGE NO.

--------------------------------------------------------------------------------------------------------------------------------------
1.0 INTRODUCTION

2.0 OBJECTIVES OF SAFETY AUDITS

3.0 SCOPE OF SAFETY AUDITS

4.0 TYPES OF SAFETY AUDITS

5.0 METHODOLOGY OF INTERNAL SAFETY AUDITS

5.1 Frequency of Audits

5.2 Formulation of multi-disciplinary Audit Teams

5.3 Duration of Audits

5.4 Use of Safety Audit Check Lists

5.5 Preparation before Site Visits for


Safety Audits

5.6 Briefing

5.7 Site Inspections

5.8 Discussions

5.9 Study of Documents

6.0 PREPARATION OF AUDIT REPORTS

7.0 FOLLOW UP OF AUDIT REPORTS

8.0 IMPLEMENTATION OF RECOMMENDATIONS

--------------------------------------------------------------------------------------------------------------------------------------

10
INTERNAL SAFETY AUDITS

PROCEDURES

1.0 INTRODUCTION

Identification of vulnerable areas and specific potential hazards, is one of the prime function
of loss prevention in oil industry. Safety audit is an important tool in undertaking this function.

2.0 OBJECTIVES OF SAFETY AUDITS

While the basic aim of safety audits is to identify the areas of weaknesses and strengths,
safety audits are undertaken to meet different specific objectives viz.-

1. To identify any design deficiencies and also any weaknesses which might
have cropped up during modifications / additions of facilities.

2. To ensure that fire protection facilities and safety systems are well maintained.

3. To ensure that operating / maintenance procedures, work practices are as per


those stipulated in the manuals and standards, which might have degraded
with time.

4. To check on security, training, preparedness for handling emergencies and


disaster management etc.

5. To check the compliance of statutory regulations, standards, codes, etc.

6. As a social objective to cater to public opinion and concern for safe


environment. This also improves public relation of the organization.

3.0 SCOPE OF SAFETY AUDITS

A Safety Audit subjects various areas of a company's activities to a systematic critical


examination with the objective of minimizing loss. This includes all the components of the
system viz. management policy, attitudes, training, design (Process, Mechanical,
Electrical, etc.) aspect, layout and construction of the plant, operating Inspection &
Maintenance procedures, emergency plans, personal protection standards, accident records.

4.0 TYPES OF SAFETY AUDITS

Two types of Safety Audits are proposed to be carried out as below :

I) Internal Safety Audit


ii) External Safety Audit

11
Audit conducted by Internal Audit teams of the organisation is categorized as Internal Safety
Audit.The methodology for carrying out such Internal Safety Audit is described in greater detail
under paras 5.0 to 8.0. Internal Safety Audits will be coordinated by local management under
the overall direction from the Corporate Office.

External Safety Audits will be carried out by outside teams consisting of technical experts from other
organizations in oil industry, professional bodies and statutory authorities under the overall
coordination of OISD.

5.0 METHODOLOGY OF INTERNAL SAFETY AUDITS

5.1 FREQUENCY OF AUDITS:

All the facilities in a particular Refinery/Installation should be covered minimum once every year.
In case of LPG bottling plants the internal safety audit should be conducted minimum once
a year as per OISD-STD-144. However, facilities' design can be audited every 3 years or after
any major modification or additions. For this purpose, the individual organisation/ installation should
draw up a calendar in advance for carrying such audits for every calendar year which should
be made known to all the Departments and concerned Area Managers. The areas to be audited
should be clearly identified and logically grouped. The suggestive groupings in case of a Refinery
Installation are given below. Similar groupings can be done for other types of Installations.
However, this could be modified depending upon layout and complexity of the individual
installation.

Group -I All LPG Storage, filling & dispatch facilities.

Group – II All dispatch facilities like Tank-Wagon loading Tank - lorry loading, Bitumen
filling and dispatch facilities.

Group - III Oil Movement & Storage (OM&S)


(Rest of all the facilities other than those covered under Group I & II, including TEL
blending)

Group - IV PROCESS UNITS :

Sub Groups -

IV - A Atmospheric / Vacuum Units

IV - B Visbreaking, Coking, Bitumen Blowing Units.

IV - C Secondary Processing Unit like FPU / FCCU/HCU & H2 along with Treating
Units.

IV - D Naphtha HDS, Cat-Reforming, Kero / Diesel HDS etc.

IV - E N2 & Others.

Group - V Power House, Electrical Sub-stations, Water Block, Utilities, Effluent Treatment.

Group - VI Miscellaneous other facilities such as Workshops, Warehouse Laboratories etc.

Group - VII General Audit, Fire Fighting and Safety, Layouts etc.

9
5.2 FORMATION OF MULTI-DISCIPLINARY AUDIT TEAMS:

The Internal Audits should be carried out through multidisciplinary audits teams. The composition of
the Internal Safety Audit may vary depending on the Group and areas to be audited, however,
person(s) concerned should have necessary experience and background to undertake in-depth audit in
a particular discipline. A team of 4 to 5 experienced officers from various disciplines viz. Process /
Production, Maintenance / Inspection, Electrical, Instrumentation, Fire & Safety and with the
activity involvement of concerned Plant / Area Manager is suggested. One of the team members should be
nominated as the leader of the audit team. In multi-unit organizations, the team members could also
be drawn from the Head Office / Corporate Office and other operating Units under its control.

5.3 DURATION OF AUDIT

Depending on the nature of audit and type / complexity of the installations in the selected group, the
duration of internal safety Audit can be fixed. This may vary from 2 to 7 working days for facilities under each
group.

5.4 USE OF SAFETY AUDIT CHECK LISTS

Check lists are the most useful tool for undertaking systematic Safety Audit. Even for a skilled and
well qualified engineer a good check list would be necessary as a guide. Like a code of practice, a
Check List is a means of pooling the knowledge and hard won experience and ensures that no
important aspect is overlooked or forgotten. Such check lists help maintaining uniformity and speeding up
the audits.

In Section-II of this document, detailed model Checklist covering important areas are given. It is
suggested that oil industry members should adopt these model check lists for carrying out
Internal Safety Audits.

5.5 PREPARATION BEFORE SITE VISITS FOR INTERNAL SAFETY AUDITS:

Before the safety Audit team visits any particular facility for carrying out Safety Audit, it would be essential
to study all relevant documents as below to get complete picture :

- Layouts
- P & IDs
- Operating Manuals
- Maint. / Inspection Manuals
- Fire and Safety Manuals, etc.

Depending upon the nature of audit more emphasis can be given to study specific documents. All the
audit team members should study these documents in advance to know the details of the installation.

5.6 BRIEFING:

Before beginning of each audit, all concerned persons of the area/installation be briefed by the team leader
about the purpose of the audit. No impression should be left that audit will throw bad light on them.

5.7 SITE INSPECTIONS:

Most of the information could be gathered through site inspection using ready-made check lists. The
auditors should enter their observations under the remarks column and not simply state "yes" / "no".
Wherever necessary, observations should be recorded in separate sheet. Inspection should be carried out
accompanied by Installation / Plant Manager or the assigned officials.

10
5.8 DISCUSSIONS:

Further information can also be gathered through discussions (formal & informal), with site personnel and
Installation / Plant Manager, who is in-charge of the area or other site officers. The audit team should
interact with persons from various disciplines such as Production, Maintenance, Electrical,
Instrumentation, etc.. Formal discussions could be in the form of brief periodical sessions while informal
discussions could be over a cup of tea with personnel working in the area.

5.9 STUDY OF DOCUMENTS:

In addition to the documents which are already studied before inspection of the facilities, other
documents, such as Operating Instructions, Standing Orders, Log Books, Log sheets, Accident Records,
Minutes of Safety Committee Meetings etc. may also be studied as required.

6.0 PREPARATION OF AUDIT REPORTS

The work of the Internal Safety Audit item should be presented in the form of a Safety Audit Report for
each group which should contain observations & recommendations and also in brief the
modalities adopted in conducting audit and the names of the audit team members.

Before finalizing the report, the Safety Audit Team can give a presentation as feedback to the Operating /
Management personnel of the Area / Installation. Additions or deletions could be made in the draft
report based on the discussions and comments received during the presentation. This approach is always
constructive and does not undermine the technical competence of the audit team.

7.0 FOLLOW UP OF AUDIT REPORTS

Generally, the Internal Safety Audit Reports are submitted to the concerned authority who appoints the audit
team for undertaking needful follow up actions. Only the appointing authority should exercise judgement
in rejecting any of the recommendations. The appointing authority shall be of senior management level (
General Manager and above ).

The crux of the safety audits lie in removing the weakness identified during the audit. Sometimes audit
reports identify only the problem / weakness, but not the solution.

In such cases, it would be necessary to undertake a detailed study of the specific area and to identify the
rectification measures. Wherever the necessary in-house expertise is not available for detailed studies,
help of consultants / professional bodies should be sought for.

8.0 IMPLEMENTATION OF RECOMMENDATIONS

The final and most important phase is the implementation of recommendations. A senior person should
be nominated for coordinating implementation of all accepted recommendation under a time bound
program. Senior management should review the progress of implementation of recommendations
periodically through Management Safety Committee meetings and other review meetings.

11
SECTION : 2

INTERNAL SAFETY AUDITS

CHECKLISTS

12
SECTION : 2

INTERNAL SAFETY AUDIT


CHECKLIST

CONTENTS
-----------------------------------------------------------------------------------------------------------------------
Sr. CHAPTER SAFETY AUDIT PAGE NOS.
CHECK LIST NO.
-------------------------------------------------------------------------------------------------------------------------------------------------
1. GENERAL SAFETY AUDITS OISD-GDN-145-01 6 - 11

2. FIRE PROTECTION OISD-GDN-145-02 12 - 18

3. LAYOUTS OISD-GDN-145-03 19 - 23

4. PROCESS PLANTS OISD-GDN-145-04 24 - 33

5. OIL STORAGE AND MOVEMENT OISD-GDN-145-05 34 - 38

6. POL LOADING AND UNLOADING OISD-GDN-145-06 39 - 51

7. LPG BULK LOADING / OISD-GDN-145-07 52 - 59


UNLOADING

8. LPG BOTTLING AND DISPATCH OISD-GDN-145-08 60 - 68

9. ELECTRICAL SYSTEM OISD-GDN-145-09 69 - 79

10. CROSS - COUNTRY PIPELINES OISD-GDN-145-10 80 - 87

ANNEXURE 88
---------------------------------------------------------------------------------------------------------------------------------------

13
OISD-GDN - 145-01
REVISION I

SAFETY AUDIT CHECKLIST No.OISD-GDN-145-01

GENERAL SAFETY AUDITS


CONTENTS
---------------------------------------------------------------------------------------------------------------------------
SECTION DESCRIPTION PAGE NO.
------------------------------------------------------------------------------------------------------------------------
1.0 ORGANISATION AND ADMINISTRATION

1.1 Management Philosophy


1.2 Procedures
1.3 Safety Audits
1.4 Safety Committee Meetings
1.5 Safety consciousness & Propagation
1.6 Work Permit System
1.7 Contingency/ Disaster Plan
1.8 Plant Security

2.0 INDUSTRIAL HAZARD CONTROL

2.1 House Keeping


2.2 Machine Guarding
2.3 General Safety features
2.4 Maintenance of Tools and Tackles
2.5 Materials handling
2.6 Personnel Protective Equipment
2.7 Toxic Materials and Occupational Health

3.0 EMPLOYEE TRAINING

4.0 FIRES, ACCIDENTS AND NEAR MISSES

4.1 Reporting formats


4.2 Reporting Procedures
4.3 Follow up of Recommendations
4.4 Maintenance of Records & Data
4.5 Review of Accidents Data

14
OISD-GDN-145-01

SAFETY AUDIT CHECKLIST

1.0 GENERAL SAFETY AUDITS

-------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR REMARKS
-------------------------------------------------------------------------------------------------------------------------

1.0 ORGANIZATION AND ADMINISTRATION:

1.1 MANAGEMENT PHILOSOPHY

a) Whether the declared safety policy is made


available to all concerned in written form ?

b) When updated last ?

c) Does the employees contribution towards safety


form a part of the appraisal system ?

1.2 PROCEDURES

a) Whether procedures are well defined and


manuals are available & accessible plant /
facility wise for the following functions ?

- Operation
- Inspection and maintenance
- Electrical
- Mechanical
- Instruments
- Civil
- Fire fighting & Safety
- Emergency and disaster management plans

b) When were these documents updated last ?

1.3 SAFETY AUDITS

a) When was last External/Internal Safety Audit


carried out ?

b) Whether accepted safety audit


recommendations are implemented with time
bound schedules ?

1.4 SAFETY COMMITTEE MEETINGS

Whether Safety Committee Meetings are held


regularly ?

15
--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
-------------------------------------------------------------------------------------------------------------------------------------------------
-
1.5 SAFETY CONSCIOUSNESS & PROPAGATION

a) Whether following items have been taken care of ?


Display of (in languages widely understood)

- sequence of operations where critical / batch


operations are performed.

- Safety posters/slogans.
- Safety precautions at strategic points
through sign boards.

b Whether fire & safety training programs are


conducted periodically and are in line with
OISD-STD-154 ?

c) Whether Safety awareness competitions


are held periodically ?

- Type
- Frequency
- Participants
Any other Motivation scheme exists ?

1.6 WORK PERMIT SYSTEM

Whether work permit system meet the requirements


of OISD Standards 105/137 ?

1.7 CONTINGENCY/DISASTER PLAN

a) Whether disaster management plans are


available for different possible types of scenarios?

b) Whether all the concerned personnel are given


their individual copies?

c) Whether these copies are available at central


place, for emergency uses?

d) Whether these plans are approved by


concerned authorities ?

e) Are mock drills being conducted ?

f) Whether the feed back generated from mock


drills is utilized to improve the plans?

--------------------------------------------------------------------------------------------------------------------------------------------------
16
ITEM AUDITOR’S REMARK
-------------------------------------------------------------------------------------------------------------------------------------------------
1.8 PLANT SECURITY

a) Whether installation has boundary


wall/fence as per prescribed norms?

b) Whether gates are manned?

c) Whether identity badges/cards are issued and


worn by employees, visitors and contractors
personnel for admission to restricted areas?

d)How it is ensured that visitors/contractor personnel


do not trespass into non permitted areas?

e)Whether frisking is done for


contractor personnel / visitors / employees; if
so, how much percentage is covered under
each category?

f) Whether Crisis Management Scheme for BOMB


Threat exists?

g) Whether watch towers exist?

2.0 INDUSTRIAL HAZARD CONTROL

2.1 HOUSE KEEPING


Ratings *
1 2
- Operating areas - -
- Work shops - -
- Stores / godowns / yards - -
- Loading gantries - -
- Effluent treatment facilities - -
- Tank farms - -
- Storm water channels - -
- Utility block - -
- Electrical substation
- Fire water tank
- Any other areas - -

2.2 MACHINE GUARDING

- Rotary equipment in operating


areas - -
- Workshops - -
- Others - -

2.3 GENERAL SAFETY FEATURES


Check For:
- unprotected Floor openings
protected - -
- Slippery defective floors - -
- Stairway surfaces - -
--------------------------------------------------------------------------------------------------------------------------------------------------
17
ITEM AUDITOR’S REMARK
--------------------------------------------------------------------------------------------------------------------------------------------------
- Inadequate illumination - -
- Ventilation - -
- Cross-overs over piping - -
- Platforms/Hand rails - -
- Walk ways in tank farm area - -
- All intrinsic safety devices - -
(For refinery,ref.to 1.7 of OISD-
145-04)

*Ratings:(Notation Followed)

1: Not meeting requirement


2: Meeting requirements satisfactorily

2.4 MAINTENANCE OF TOOLS AND


TACKLES

* Whether all lifting tools and tackles are


tested as per statutory requirements and
record maintained?

2.5 MATERIALS HANDLING( Mechanised/


manual)

Whether safe lifting methods and proper


protective equipment are used?

2.6 PERSONNEL PROTECTIVE EQUIPMENT

a) Whether requirements are identified as per


operating manuals / standards?

b) Are these readily available at the time need?

c) How periodically these are inspected and


records maintained?

d) Whether personnel are trained for effective


use?

2.7 TOXIC MATERIALS AND OCCUPATIONAL


HEALTH

a) Are there any toxic materials in use ?

b) Whether relevant personnel protective


equipment is available (Ref. Section 2.6) as per
requirement?

c) Is storage of toxic materials proper?

d) Is disposal of containers of toxic materials safe ?

--------------------------------------------------------------------------------------------------------------------------------------------------
18
ITEM AUDITOR’S REMARK
--------------------------------------------------------------------------------------------------------------------------------------------------
e) Is there display of Do's and Dont's for handling of
toxic chemicals?

f) How the Health monitoring is done. Whether


records are maintained ?

g) Is First Aid available for toxic chemicals handled?

h) Whether proper communication system exists?

i) Is there any monitoring of work environment for


toxic chemicals /gases etc. and records maintained
thereof? Whether material safety data sheet
Note 3
displayed

3.0 EMPLOYEE TRAINING


-
a) Whether the training given for all employees
(operators / technicians / engineers) is in line with
OISD- STD-154 w.r.t following items :

- syllabi
- course materials
- class room/field on job training
- on job
- fire and safety

b) Whether Refresher courses are conducted for


technical personnel?

c) What is the evaluation and qualifying system?

d) How employees are Motivated for safety


performance?

e) How the contractor personnel are trained/briefed


w.r.t safety procedures?

f) Whether the T/T crew are trained as per the


C.M.V.Rule 9 ?

4.0 FIRES, ACCIDENTS AND NEAR MISSES

4.1 REPORTING FORMATS

Whether reporting formats as per OISD-GDN-107


are available for (preferably separate)?

- fires and explosions


- accidents causing injuries to personnel and
damage to equipments and products
(without the explosion/ fire)
- Near misses

19
--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
-------------------------------------------------------------------------------------------------------------------------------------------------

4.2 REPORTING PROCEDURES

a) Whether responsibilities are clearly defined as


regards to preparation of the reports?

b) Who receives the reports?

c) Whether all minor incidents and near misses as


reported to Safety Dept/Concerned authority?

4.3 FOLLOW UP OF RECOMMENDATIONS

4.3.1 Implementation

a) Whether responsibility is assigned for


implementing the recommendations?

b) Whether the recommendations are implemented


with time bound schedules?

c) How far the recommendations arising out of


previous accidents are implemented?

4.3.2 Dissemination

a) Whether the procedures /systems are


established & streamlined for dissemination of
information?

b) What is the MIS upto Chief Executives level


w.r.t information on fires, accidents and near
misses?

4.4 MAINTENANCE OF RECORDS & DATA

a) Accident statistics of last how many years


are available ?

b) If required, how fast any case history could


be located?

- w.r.t specific case


- based on particular area/type

4.5 REVIEW OF ACCIDENTS DATA

a) Is there any system to periodically review the


trends of accidents for taking necessary
actions ?

20
--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
-------------------------------------------------------------------------------------------------------------------------------------------------
-
b) Whether any review is under taken at top
management/ corporate level periodically, to
review the safety performance and new goals
are set up?

21
OISD-GDN-145-02
REVISION I

SAFETY AUDIT CHECKLIST

FIRE PROTECTION

CONTENTS
---------------------------------------------------------------------------------------------------------------------------
SECTION DESCRIPTION PAGE NO.
------------------------------------------------------------------------------------------------------------------------
1.0 PHILOSOPHY AND STANDARDS 13

2.0 FACILITIES 13

2.1 Fire water 13

2.2 Fire Hydrant System 14


2.3 Foam System 14
2.4 Fire Station 15
2.5 Fire Extinguishers 15
2.6 Fire Hoses and Accessories 15
2.7 Protective/ Safety Equipment 15
2.8 Others 15

3.0 PROCEDURES 16

3.1 Organisations 16
3.2 Disaster Management Plan 17
3.3 Inspection and Testing facilities 17
3.4 Training 17
3.5 Checklist for DMP 18

22
OISD-GDN-145-02

SAFETY AUDIT CHECKLIST

2. FIRE PROTECTION

--------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR'S REMARKS
---------------------------------------------------------------------------------------------------------------------------------------

In order to evaluate the adequacy of fire fighting


facilities and procedures, answers should be
obtained for the following four basic queries:

1. Are the facilities adequate and reliable


for anticipated fires ?

2.Is manpower available and effectively trained to


handle the fire fighting equipment.

3.Are emergency control procedures adequately


established.

Since the scope under each query is too broad and it


is difficult to give simple answers, these are divided
into a number of simpler items/ questions which
could be evaluated/answered with reasonable clarity.

1.0 PHILOSOPHY AND STANDARDS

Does basic philosophy for designing the fire fighting


facilities follow OISD 116 (for Refinery),OISD
117(for Marketing-POL) and OISD 144 (LPG bottling
plants) as necessary ?

2.0 FACILITIES

Whether following facilities are provided adequately


and have the necessary efficacy.

2.1 FIRE WATER

2.1.1 Fire water storage

a.What is the capacity & how was it determined

b.Is it sufficient ? Is the storage AG/UG or other


wise ?

c.What are replenishment source ? Are they


adequate ?

d.What's the internal replenishment rate ?


--------------------------------------------------------------------------------------------------------------------------------------------------
23
ITEM AUDITOR’S REMARK

2.1.2 Fire Water Pump :

a. Is location away (from hazardous area) ?


b. What's the power source ? How many are diesel &
elect driven ?
c. What's the stand by philosophy ?
d. What's the capacity of each pump and at what
head ?
e. What's the priming system?
f. Is there any jockey pump ?
g. What's the capacity ? What's set pressure?
h. What's fire water pump starting system -
manual/auto ?
I. What's the condition of battery of diesel engine ?
j. What's the diesel fuel tank capacity (hrs) ?
k How frequently does jockey pump start ? How
long it runs ?
l. Are the fire water pumps/engines started &
observations logged as per OISD Std. 116/
117/144.

2.2 FIRE HYDRANT SYSTEM

Check and comment on the hydrant system layout


design position of hydrants/monitors, flow rate
pressure at the farthest point, condition of pipeline
etc. Please comment on the system as per the
following.

2.2.1 Network - Grid type/Closed type/Any other

2.2.2 Mains

a. What's the material of construction of pipes ?


b. How corrosion protection is ensured ?
c. How is the sectionalising of hydrants system
?
d. How are the spacings between hydrants
e. Are monitors / hydrants properly distributed
in critical areas and all facilities covered ?
f. Are these hydrants/monitors easily
accessible and operable ?
g. Is the layout vulnerable at any points from
fire hazard

2.3 FOAM SYSTEM

a. What are the types of foam available?


b. What are the dilution potential and the
quantities ?
c. What are the storage arrangements and its
accessibility

--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
24
-------------------------------------------------------------------------------------------------------------------------------------------------

d. Do the coverage and application rate for


floating roof/fixed roof tanks meet OISD
norms ?

e. Are foam branch pipes, nozzles, wheeled


equipments available and adequate as per
OISD Stnadard ?

f. Proportioning equipment - suitability -


proper pick up

2.4 FIRE STATION

a. Is the location away from hazardous


areas ?
b. Are the no. and variety of fire vehicles
sufficient ?
c. Facilities on fire vehicles capacity,
pressure, flow proportioning system etc.
Daily starting of vehicles and other
check logs.?

2.5 FIRE EXTINGUISHERS

a. Are portable extinguishers meeting OISD


requirements ? Are they BIS approved ?

b. Whether periodical inspection, maintenance


and testing of fire extinguisher are
promptly carried out and proper
records maintained in line with OISD Std.?

c. Are replacement of extinguishers on shell


failure or hydrotest ensured and necessary
records available ?

d. Are quantity of cartridge and powder


sufficient at work site and spares available
in store in line with OISD Std. ?

e. What is the monthly consumption of


cartridge and product ?

f. Fire Extinguishers attached to all the vehicles


/ position at various sites shall be numbered
and date of testing shall be written on them
Note 3

g. Fire Extinguishers attached to TTs should


Note 3
also bear the TT number .

2.6 FIRE HOSES AND ACCESSORIES

a. Are no of hoses sufficient w.r.t. no. of


hydrants in the system ?
b. Are the hose boxes strategically placed ?
25
c. Are the hoses easily removable during an
emergency ?

26
--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
-----------------------------------------------------------------------------------------------------------------------------------------------
d. Are the hoses periodically tested/ checked
and replaced?
Note 3
e. Are the hose boxes painted fire red as
per OISD Standard.?
f. Are adequate sand drums / buckets
available ?
g. Are all various types of nozzles/foam branch
pipes etc. provided as per OISD STD.?
Note 3
h. Are the hoses BIS Approved ?

2.7 PROTECTIVE/SAFETY EQUIPMENT

Are safety appliances available in line


with OISD 116/117/144 Standard?

ADDITIONAL ITEMS : FACILITIES AT


PORT

Are the fire fighting facilities (fixed as well


as portable) provided at the port meeting
requirement as per OISD-STD- 156 ?

2.8 OTHERS

Whether the fire siren and fire alarm are


provided at strategic locations and are
audible up to the desired range ?

Whether siren codes are identified for


different types of fire/emergencies ?

2.8.1 Fire siren and fire alarm network (Electrical/


mechanical/ hand operated) Satisfactory
working.

Differentiation between different types of


fires / emergencies.?

Check the locn./range and report

- Within and to outside.


- Normal and emergency.
- Condition of radio communication
equipment.
- Availability of alternate power supply
during normal supply failure
- Inspection and maintenance schedule
- Training of the users.

2.8.2 Ambulance/Other means of transport and


Note 3
First-Aid services with complete kit .

- Contingency Plan for medical


emergency.
27
--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
-------------------------------------------------------------------------------------------------------------------------------------------------

- Evacuation, etc.
- First Aid training to personnel on shift.

2.8.4 Availability of emergency, lights in


critical areas.

2.8.5 Availability of special fire fighting


components aprons / suits / emergency
flood lights, power megaphones, etc.

3.0 PROCEDURES

3.1 ORGANIZATION

a. Whether the organogram of fire fighting


and other supporting services well defined
?
b. Is periodic fire drill conducted,
shortcomings observed and necessary
action initiated ?

c. Does location have well defined fire order ?

Whether organogram has provision to meet


emergency situation during idle shift /
sundays and holidays.

d. Whether relevant fire order is displayed at


various work stations indicating station
employees role during fire / emergency ?

e. Whether following documents are


updated and displayed as reqd.

- Organogram
- Fire hydrants layouts and P & ID
diagrams
- Fire fighting procedures / manual

f. Whether layouts and organogram


displayed ?

3.2 DISASTER MANAGEMENT PLAN


(Ref.to new checklist for DMP)

a. Whether mutual aid schemes are made


with neighboring industries, local fire
brigades, etc.

b. Whether resource requirements are worked


out

28
--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
-------------------------------------------------------------------------------------------------------------------------------------------------

3.3 INSPECTION AND TESTING FACILITIES

Whether periodic inspection and maintenance /


testing is done and proper records maintained for
following :

a. Pumps

- Is flow vs. pressure meeting the


requirement ?
- Is lubrication periodically carried out ?

b. Hydrants

- Are pressure and flow at different


points adequate enough ?
- Are all valves easy to operate ?

c. How effective is the fire water spray


system ?

d. Is foam proportioning equipment in


working order ?

e. Whether hydrotesting and regular


inspection of fire gate mains undertaken and
records maintained ?

f. Whether various checks & records of


periodical running of Diesel engines
carried out?

g. FIRE HOSE AND ACCESSORIES

- Are hoses , nozzles, adapters, hose


holders, wrenches etc. inspected
regularly ?

h. Foam concentrate

- What is the inventory ? Are the


procurement / expiry date
record maintained?

- Whether protein foams churned


regularly and record maintained ?

3.4 TRAINING

Whether training provided fire crew / other


employees / CISF etc. is in line with OISD
std. 154?

29
--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
-------------------------------------------------------------------------------------------------------------------------------------------------
3.5 CHECKLIST FOR DMP

1. What is the frequency of DMP drill ? When was


it last conducted ? Whether the short comings
observed during drills were analyzed and action
taken to prevent repetition ?

2.Whether mutual aid schemes are planned with


neighboring units local fire brigade etc. ? Is the
scheme periodically discussed with members ?
Are they trained to fight fire in oil / gas installation
/

3. Whether the resources of the operating location


and the mutual aid members properly tabulated ?
Whether assessment of necessary man power
and equipment studied and action taken for the
shortfall ?

4. Whether organogram of various co-ordinators,


succession charts showing alternate persons
and sub-organisation chart well displayed ?

5. Are responsibilities of various neighboring


industrial units, discussed and recorded ?
Whether the duties of various coordinators
and team members well defined ?

6. Are the following information included in the DMP


?

Name, address, telephone numbers (Off.and Res.


) of anchorages / key persons are to be clearly
shown.

a. Mutual aid members


b. Police, fire and district authorities.
c. Hospitals and doctors
d. Medical shops, ambulance, blood bank,
blood donors,
e. Water supply dept. water transporter, elect.
boards, railways, port trust, telephone
exchange.
f. Generator hire service, transport hire service
, welfare bodies, social organization and
catering services.

7. Is emergency control centre planned and


properly furnished / fitted to meet the
requirement ?

8. Whether DMP is based on MCA and risk


analysis ?

30
OISD-GDN-145-03
REVISION I

SAFETY AUDIT CHECK LIST No. OISD GDN-145-03

LAYOUTS

CONTENTS
--------------------------------------------------------------------------------------------------------------------------------------
SECTION DESCRIPTION PAGE NO.
------------------------------------------------------------------------------------------------------------------------------------------

1.0 TOPOGRAPHY OF INSTALLATION 20

2.0 SURROUNDING OF THE INSTALLATION 20

3.0 INTER - DISTANCES 20

4.0 TANKFARMS 20

4.1 Grouping of tanks 20


4.2 Dykes 20
4.3 LPG storage 20

5.0 PROCESS UNITS 21

5.1 Location 21
5.2 Control room 21
5.3 Field 21

6.0 OTHER FACILITIES AND EQUIPMENT 21

6.1 Electrical power lines 21


6.2 Electrical switchgear 21
6.3 Roads 22
6.4 Administrative buildings/ workshops/canteen 22
6.5 Boiler plants 22
6.6 Gantries 22
6.7 Waste water facilities 22
6.8 Water cooling towers 22
6.9 Elevated platforms 22
6.10 Piping 22
6.11 Rail spurs 23
6.12 Fire hydrants/ monitors/ safety showers/ hose etc. 23
6.13 Compressors 23
6.14 Miscellaneous 23
-------------------------------------------------------------------------------------------------------------------------------------------------

OISD-GDN-145-03
31
SAFETY AUDIT CHECKLIST
LAYOUTS

-------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR'S REMARKS
-------------------------------------------------------------------------------------------------------------------------------------------------

1.0 TOPOGRAPHY OF INSTALLATION

- Susceptibility for flooding


- Location of process units and tank
farms in undulating areas.

2.0 SURROUNDING OF THE INSTALLATION

- Flammables / Toxics/ Ignition sources


up/ down wind

3.0 INTER-DISTANCES

Code / standard/ regulations followed /deviated


(Ref.OISD-STD-118/144).

- Equipment/block/facility to boundary walls

- Block/facility to block/facility

- Equipment to Equipment switch in a block /


facility.

4.0 TANKFARMS

4.1 GROUPING OF TANKS

- Mixing of different class products in POL


tank farm

- Accessibility of tanks for fire fighting.

4.2 DYKES

- Aggregate capacity of tanks in each


Dyke / enclosure

- Capacity of Dykes with respect to


relevant group

- Construction and dimensions of dyke wall

- Routing / Cris- crossing of process /


fire hydrant lines inside dyked tank
farm

- Provision of fire walls.

32
--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
-------------------------------------------------------------------------------------------------------------------------------------------------

4.3 LPG STORAGE

- Orientation w.r.t. wind direction


- General state of terrain without depression /
large ditches

- No of vessels in each group and the aggregate


capacities

-Provisions of slope and spill collection shallow


pumps.
- Vapour trap

5.0 PROCESS UNITS

5.1 LOCATION

- Consolidated / Scattered

- Separation from tank farm/concentration of people

- Down wind from ignition sources

5.2 CONTROL ROOM

- Design for minimum occupancy


- Electrical area /equipment classification
- Upwind from sources of flammables / toxic
materials
- Easy approach to entrance and to fire fighting
facilities
- Safety of control room from any blast situation
- Emergency Light during power failure at Process
Note 3
Control room.

5.3 FIELD

- Positioning of process equipment without stacking

- Segregation of equipment handling hazardous /


materials

- Adequacy of accessways for the movement of


equipment and people.

- Strategic location of fire fighting equipment

- Over head clearances for passage of heavy


equipment like cranes

- Adequate provision of oily water and storm water


sewers and catch pits.

- Packing and grinding of susceptible leaky areas


33
34
--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
-------------------------------------------------------------------------------------------------------------------------------------------------

6.0 OTHER FACILITIES AND EQUIPMENT

6.1 ELECTRICAL POWER LINES

- Rooting below / above ground

- Passing over critical facilities

- Separation from elevated structures which may


fall across power lines

- Location of power receiving station & layout hazard

6.2 ELECTRICAL SWITCHGEAR

- Upwind from flammable sources

- High ground in flooding areas

- Routes of overhead power cable and


instrument cable trays and their fire protection/
fire proofing

6.3 ROADS

- Road widths and turning radii for movement of


large fire fighting vehicles .

- Separate entry points for employees and


product movement

- Layout of the roads for minimum truck traffic in


grass

- Accessibilities to each process unit/tank

- Crossing of pipe alleys

- Concreted / asphalted (condition)


- Process Plants and facilities shall have access
Note 3
roads for fire tenders from at least two sides.

6.4 ADMINISTRATIVE BUILDINGS /WORKSHOPS/


CANTEENS

- Peripheral locations
- Separation from hazardous areas
- Upwind from sources of flammable / toxics

6.5 BOILER PLANTS

- Upwind and separation from sources of


flammable materials

35
--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
-------------------------------------------------------------------------------------------------------------------------------------------------

6.6 GANTRIES

- Peripheral location

- Downwind from ignition sources

- Separation from main line of rail / road

6.7 WASTE WATER FACILITIES

- Peripheral locations

- Down wind from ignition sources /


concentrations of people

- Any treatment facility to dischargeable water for


pollution control

6.8 WATER COOLING TOWERS

- Down wind from ignition sources/ concentration


of people

6.9 ELEVATED PLATFORMS

- Permanent platforms for all operating points

- Alternate routes for descent

- Landing at grade in safe locations

6.10 PIPING

- Head bumpers, shin splitters and tripping


hazards

- Personnel protection from hot lines

- Fire proofing of pipe racks.

6.11 RAIL SPURS

- Clearance for derailments

- No facility opposite the end of the spur.

6.12 FIRE HYDRANTS / MONITORS / SAFETY


SHOWERS / HOSE ETC.

- No obstruction for approach. Good path for


retreat

36
--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
------------------------------------------------------------------------------------------------------------------------------------------------
6.13 COMPRESSORS

- Not in closed buildings

- Down wind from rest of unit

6.14 MISCELLANEOUS

- Location of fire station and fire pump

- Location of smoke booths

- Display of Layout drawing and display of


P & I DRAWING

-Check piping layout for minimum piping

- Greenscaping area

- Flood light towers & security towers

- Grading of various block facilities

- Storm water drains & easy drainage

- Height of flares is adequate

- TTL gantry and easy exit through the


product movement gate

- Provision of Truck parking area

37
OISD-GDN-145-04
REVISION I

SAFETY AUDIT CHECKLIST No.OISD GDN-145-04

PROCESS PLANTS

CONTENTS
---------------------------------------------------------------------------------------------------------------
SECTION DESCRIPTION PAGE NO.
----------------------------------------------------------------------------------------------------------------

1.0 GENERAL 25

1.1 Layout and Drainage 25

1.2 Fire Protection facilities 25

1.3 Housekeeping 26

1.4 Training 26

1.5 Inspection & Maintenance 26

1.6 Electrical 27

1.7 Instrumentation 27

2.0 PROCESS SUB-SYSTEMS 27

2.1 Control room 27

2.2 Pump House 28

2.3 Compressor house 29

2.4 Heat exchangers/ condensers/ coolers 29

2.5 Process vessels and columns 30

2.6 Process furnaces 30

2.7 Process piping 31

2.8 Relief and Disposal System 32

2.9 First aid 33

38
SAFETY AUDIT CHECKLIST

4.0 PROCESS PLANTS

-----------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITORS REMARKS
------------------------------------------------------------------------------------------------------------------------------------------
1.0 GENERAL

1.1 LAYOUT AND DRAINAGE

a) OIDF-STD-118 ? (deviations, if any to be


specified)

b) Whether the location of the control room


& furnace meets the OISD-STD-118

c) Whether proper approach roads to the


plant have been provided ?

d) Whether ladders, platforms provided are


as per standard engineering practices and
can be considered adequate ?

e) Whether oil water sewers are adequately


sized and the manholes on these sewers
covered properly ?

f) Whether the plant surface drainage systems


are adequately sized and
properly maintained ?

g) Whether a closed blow down system has


been provided for draining of hydrocarbon
from the vessels / equipments with proper
pump out arrangement from underground
tank ?

1.2 FIRE PROTECTION FACILITIES

a) Whether the fire water network provided


is well designed (Ring type) and covers
all sides of the plant ? refer OISD116.

b) Whether the hydrants, water monitors are


provided from all sides of the plant ?And are
they located more than 15 meters away from
nearest hazard ?

c) Whether steam lancers have been provided


and are adequate ?

d) Whether all hydrants, monitors, hose


boxes are easily accessible ?

e) Whether adequate number of portable fire


extinguishers have been provided all over
39
the plant as per the OISD-116 ?

40
--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
--------------------------------------------------------------------------------------------------------------------------------------------------

f) Whether communication systems, fire alarms


and p.a. system have been provided ? Are
they working ?

g) Whether a copy of fire fighting manual is available


in the plant control room ?

h) Whether safety committee meetings are


conducted at plant level ? Is the
frequency adequate?

1.3. HOUSEKEEPING :

a) Whether the plant floors particularly in


pump house, heat exchanger areas are
regularly washed to avoid Oil Accumulation ?
Any visible Oil Accumulation on the floor, drains found ?

b) Are redundant pipes/valves/ pump foundations


/insulation debris removed from process area ?

c) Whether the general housekeeping in the


area can be considered as ;
- adequate
- not adequate

1.4 TRAINING

a) Are copies of updated operating manual,


fire & safety manual, disaster control
manual, standing instructions available
in the control room ?

b) Are the working personnel in the area


given thorough training on operations,
safety and fire fighting at the induction
stage ?

c) Whether subsequent refresher training


programs are organized-periodically?

d) Whether contractor employees are given


basic training on hazards of petroleum
products & safe practices ?

e) Whether the workers are using proper


personnel protective clothing such as
hand gloves, safety shoes, helmet, face
shield etc. ?

41
--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
-------------------------------------------------------------------------------------------------------------------------------------------------
-

1.5 INSPECTION & MAINTENANCE

a) Whether inspection of equipments/ tanks


/piping /safety valves etc. are carried
out as per schedules? Are history cards
maintained ? Refer OISD129 / OISD-127.

b) Whether all the modification works are


undertaken only with approved engineering
drawings ?

c) Whether a well designed work permit


system exists for the following and is
rigidly followed ;
Refer OISD-105.
- Hot/Cold work
- Energizing and de-energizing of electrical
Equipment.
- Excavation
- Vessel Entry
- Entry of Vehicle into battery area.

1.6. ELECTRICAL

a) Whether all motors, electrical fittings


in the plant are as per area
classification ? Is area classification
drawing available ?

b) Whether equipments properly earthed ?


readings taken periodically ? Are
records maintained ?

c) Whether illumination can be considered


adequate ?

d) Whether emergency lighting system has


been provided ?

e) Whether any interlocks bypassed and


recorded ?

1.7 INSTRUMENTATION:

a) Whether electronic instrumentation


provided are as per area classification?

b) Whether minimum safety instrumentation


provided for furnace, vessels,
compressors etc. and is well maintained ?

42
--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
-------------------------------------------------------------------------------------------------------------------------------------------------
c) Whether any schedule exists for checking
up of various interlocks, shutdown
systems ? Are such schedules followed
and recorded ?

d) Whether any process interlock bypassed


and recorded ?

e) Whether smoke / heat / gas / hydrocarbon


detectors are provided and are working ?

2.0 PROCESS SUB-SYSTEMS

2.1 CONTROL ROOM

a) Whether fire protection provided and


considered adequate ?

b) Whether updated P & I diagram available ?

c) Whether emergency shutdown controls are


available ?

d) Whether requisite PPE & first aid kit


available ?

e) Whether control room is blast proof, if


it is hazardous area ?

f) Whether the cable entry in the control


room is properly sealed ?

g) Whether control room pressurization has


been provided and working satisfactorily ?

2.2 PUMP HOUSE :

a) Whether the location of the pump house


with respect to furnace is as per OISD
118 ?

b) Whether hot pump have been segregated


from pump handling lighter hydrocarbons ?

c) Whether hot pumps are properly located


so as to prevent fire due to spillage of
hydrocarbon from over head ?

d) Whether piping arrangement w.r.t.


personnel's movement satisfactory ?

e) Whether hot pumps are properly insulated ?


(including the associated piping) ?

43
--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
-------------------------------------------------------------------------------------------------------------------------------------------------
f) Whether the hot pumps are provided with
warm up lines ?

g) Are vents / drains of hot pumps cooled


before discharge ?

h) Whether reciprocating pumps have proper


safety release system, if discharge is
blocked ?

i) Are the threaded joints on the pump


vents / drain lines found corroded?

j) Whether all pump drains are connected to


CBD and OWS ? Any of the drains found
congealed ?

k) Does the pump house floor drain have a


proper water seal to prevent
propagation of fire from OWS to pump
house ?

l) Are the auto start / stop of the pumps


(where applicable) checked as per
schedule and recorded ? Check at random ?

2.3 COMPRESSOR HOUSE

a) Whether the location is well ventilated ?

b) Whether the following are in working


condition ?

- Vibration monitoring system


- Anti surge device
- Speed control system
- Shut down system
- Lubrication system

c) Whether various alarms and signaling


systems are in working condition ?

d) Are the safety valves on the discharge


side of the compressor checked as per
schedule ?

e) Whether suction strainer is periodically


cleaned ?

f) Whether the compressor has a proper


depressurising system ? Is venting system proper ?

g) Whether there is a condensate collection


system at suction / discharge of the
compressor ? if so, is it functional ?
44
--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
-------------------------------------------------------------------------------------------------------------------------------------------------
h) Whether the compressor has nitrogen
inerting system ? if so,is it functional ?

i) Do compressor safety valve atmospheric


vents have nitrogen / steam purging
especially for hydrogen rich gases ?

2.4. HEAT EXCHANGERS/CONDENSERS/COOLERS

a) Are adequate nos. of high vents / low


points drains with proper isolation
provided ?

b) Whether provision for thermal relief/


thermal expansion has been provided ?
Are TSVs on line ?

c) Whether the insulation / cladding is


fully covering the exchanger ? Is
earthing proper ? Are supports fire
proofed ?

d) Does sacrificial anode exist for


coolers / condensers where different
metals are in contact ?

e) Whether the operating parameters and


test pressures have been tagged on the
equipment and is being operated within that?

f) Whether the over head condenser platform


is within reach for fire fighting and
does the overhead condenser platform
have two sets of staircases at either end ?

2.5 PROCESS VESSELS AND COLUMNS: (REFER OISD


STD-152)

a) Whether relief valves are periodically


tested and records maintained ?

b) Whether all the utility connections are


in working condition ?

c) Whether the vessel has been provided


with adequate safety instrumentation ?

d) Are the nozzles, nipples on idle drains


and vents capped / blinded ?

e) Whether vessel supports are fire proofed


and it is in proper condition ?

f) Whether insulation / painting is proper ?

45
--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
-------------------------------------------------------------------------------------------------------------------------------------------------
g) Do all columns have two sets of level
indicators ?

2.6 PROCESS FURNACES; (REFER OISD-STD-111)

a) Whether the pass flows are provided with


recorder and controller and are properly
working ?

b) Whether skin temperature and bridge


temperatures are recorded ?

c) Whether each main burner has a pilot


burner ?

d) Whether electric igniters are


provided for each burner and are they well
maintained?

e) Whether fuel oil supply header is properly


steam traced and insulated ?

f) Whether both oil and gas lines have proper


blinding facilities at the battery limit ?

g) Whether the furnace has a trip system /


flame out protection system ? Whether
on line testing of the same is done ?

h) Whether furnace has step ladder & monkey


ladders to reach each platform ? Is
alternative escape ladder available from
burner-valves platform ?

i) Whether safety wears such as safety goggles,


face shield etc. are used by operators regularly
while adjusting / viewing burners ?

j) Whether the location of the explosion door


can be considered safe ?

k) Is the snuffing and purging steam valve


manifold easily accessible ? Is it away
from fire radiation risk zone ?
Is the coil purging steam facility in line
with OISD-111 Annexure -1 ?

l) Whether the damper control system is


satisfactory ? Is position of damper
readable from ground level ?

m) Whether the control system for drop out


doors opening can be tested on line ?

46
--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
-------------------------------------------------------------------------------------------------------------------------------------------------
n) Whether the location and height of FD fan
air intake can be considered safe ?

o) Whether the furnace has a decoking system


which is operative ?

p) Whether noise level near the furnace is


within permissible limit ? Is it
monitored atleast once a year ?

q) Can the condensate draining, OWS line


connection & manhole location for the
furnace be considered safe ?

r) Whether the support structures are


properly fire proofed ?

2.7 PROCESS PIPING

a) Whether expansion loops / expansion joints


in working order ?

b) Whether TSVs provided are periodically


tested, records maintained ?

c) Whether pipe supports (sliding / spring


supports ) guides and anchors are in order ?

d) Does the piping slope towards drain points


/ knockout pots ?

e) Whether all piping above 60 deg. C surface


temperature have safety insulation ?

f) Whether continuity jumpers provided


between flange joints for LPG, naphtha,
ATF etc, (Refer OISD-STD-106 ).

2.8 RELIEF AND DISPOSAL SYSTEM

a) Whether the relief valves have been set


at 10% over normal operating pressure ?

b) Whether difference between set pressure


and the normal operating pressure is
maintained minimum 2.0 kg / sq.cmg ?

c) Whether safety valve has been installed


directly on the protecting equipment /
on the connected piping without any isolation
valve ?

d) Whether multiple safety valves have been


used ? if so, whether the set pressure
is within design pressure ?
47
--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
-------------------------------------------------------------------------------------------------------------------------------------------------
e) Whether any spare safety valves have
been used with isolation valves ? if so
what is the safe guard against inadvertent
closing of isolation valves of operating
safety valves ?

f) Whether any relief valve on hydrocarbon /


toxic gas services relieves to atmosphere ?
if so whether the following points are
considered :

- discharge vertically upward through


individual stack

- minimum exit velocity of 15.0 m/second.

- snuffing steam provided ?

g) Whether use of common atmosphere vent


stack for several relief valves is
observed ?

h) Whether any vent stack is observed


discharging at an elevation of less than
3m above the tallest structure, within 15m
radius

i) Whether acoustic insulation has been


provided on vents producing excessive
noise ?

j) Whether toxic vapors like SO2, phenol,


chlorine etc. are disposed through closed
system ?

k) Whether isolation valves with spectacle


blinds have been provided at the battery
limits of the plant ? if so whether their stems
are pointing downward to avoid
accidental closure ?

l) Whether unit knock out drums have been


provided ? if so , can it hold liquid discharge
for 5 - 10 minutes from a single contingency ?

m) Whether pumps with auto start / stop at


high / low level have been provided to
pump out the contents ?

n) Whether high / low level alarms for the knock out


pots have been provided in the control room ?

48
--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
-------------------------------------------------------------------------------------------------------------------------------------------------
o) Whether vapor depressurising system has
been provided for emergency situations
such as runaway reaction, exposure to
fire etc.?

2.9 FIRST AID

a) What is the percentage of shift employees


trained in first aid ? how many can provide
artificial resuscitation ?

b) Does every control room including pump


houses possess a first aid box, water gel
blanket and explosive meter ?

c) What is the accident record of the last


two years ?
Note 3
d) All incidents requiring first aid should be recorded.

49
SAFETY AUDIT CHECKLIST No.OISD-GDN-145-05

OIL STORAGE AND MOVEMENT

CONTENTS

--------------------------------------------------------------------------------------------------------------------------------------
-
SECTION DESCRIPTION PAGE NO.
--------------------------------------------------------------------------------------------------------------------------------------
-
1.0 TANK FARM 35

2.0 TANKS 35

3.0 PIPING 36

4.0 OPERATING PROCEDURES 37

5.0 INSPECTION & MAINTENANCE 38

6.0 ADDITIONAL CHECK LIST ITEMS 38

50
SAFETY AUDIT CHECKLIST

5.0 OIL STORAGE AND MOVEMENT

-----------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR'S REMARKS
-----------------------------------------------------------------------------------------------------------------------------------------

1.0 TANK FARM :

1.1 GENERAL :

a) Whether the location, layouts


interspacing in the tank farm meet
OISD-STD-118/statutory requirements?

b) Whether Dyke / fire walls meet


OISD-118 / statutory requirements ?

c) Whether the roads are


available around the tank farm for
movement for fire tenders ?

d) Whether piping in the dyke farm is


kept minimum ?

e) Whether any piping not connected


with the tanks to any individual
dyke is passing through it ?

f) Whether any hydrocarbon detection


system has been provided ? If so,
is it working satisfactorily ?

g) Whether house keeping in the area


is satisfactory and it is free of
any dry vegetation.

h) Whether communication system is


available in the tank farm areas.

i) Whether illumination in the area is


adequate / inadequate

j) What is the procedure adopted for


recovery and disposal of the tank
bottom sludges ?

51
--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
--------------------------------------------------------------------------------------------------------------------------------------------------

k) Whether leaded gasoline sludge if


any, buried into the tank farm with
clear demarcation ?

1.2 SEWERS :

a) Whether the tank farm closed


drains, drains are clear ?

b) Whether provision exists to divert


tank farm drainage either to storm
water or to oily water sewer ?

2.0 TANKS :

a) Whether tanks properly painted and


important specifications, are
marked on the tank ?

b) Whether all nozzles of 2" and above


sizes have been provided with
reinforcing pads with tell - tale
holes ?

c) Whether all tanks are provided with


circumferential railings ?

d) Whether the roof drain of floating


roof tanks is provided with a check
valve ?

e) Whether any alternative arrangement


to read / record level in the tanks
have been provided ?

f) Whether the tanks with steam heating


/ blanketing are provided with high
temp., high pressure indicator and
alarms ?

g) Whether any product is stored above


its flash point ? If yes what are
the additional safety consideration?

h) Whether the breather valves


provided matches the pumping in /
pumping out requirements of the
tank ?

i) Whether any depression due to tank


settlement observed on the tank pad
along the circumference ?
46
--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
--------------------------------------------------------------------------------------------------------------------------------------------------

j) Whether steam coils provided have


any flange connections inside the
tank ? Whether provision exists to
check oil leak through condensate
outlet line ?

k) Whether the tanks on ATF, Naphtha,


chemicals services are internally
coated ?

l) Whether fixed/semi-fixed foam system


are provided on all tanks storing A
class and B class products (18 M
and above for floating roofs ) and
also tanks storing C class products
of more than 40 m dia
(floating/fixed roof tanks) ?

m) Whether sprinkler systems are


provided on all fixed roof tanks as
per OISD norms ?

n) Whether Halon system is provided on


any tank. If so, whether
periodically the Halon system is
checked and records maintained ?

o) Whether the tanks are properly


painted and numbered ?

p) Whether flame arrestors are provided


on fixed roof storage tanks which
are likely to have explosive
mixture in the vapor space ?

q) Whether goose neck type vent


connections are provided with
suitable wire mesh to avoid birds
entry /formation of nests ?

r) Whether oil of proper viscosity is


used in oil breather valves ?

3.0 PIPING :

a) Whether pipe alleys properly graded


to ensure that no oil/water gets
accumulated below ?

47
-------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
------------------------------------------------------------------------------------------------------------------------------------------------
b) Whether pipe supports, anchors,
guides are in order ?

c) Whether pipes carrying heavy


products have been properly heat
traced and insulated ?

d) Whether proper color codings,


products identification marks have
been provided ?

e) Whether low point drains and high


point vents have been provided with
proper caps ?

f) Whether the tanks are having proper


manifolds and are located outside
the dyke ?

g) Whether Hammer blinds are provided


on the tank manifolds and are operable ?

h) Whether the floor under the


manifold are paved, have curb walls
and drains connected to OWS ?

i) Whether steam traps of tracer lines


are functioning properly ?

j) Whether any bolt is found missing


on flanges of hydrocarbon lines,
particularly of LPG, MS, Naphtha
etc.

k) Whether the redundant lines are


kept positively isolated with all the ends
plugged/blinded and actions are taken
to get them removed ?

4.0 OPERATING PROCEDURES :

a) Whether a copy of updated operating


manual with operating instructions,
blending etc. are available to all
concerned and a copy available in
the C/R.

b) Whether there is any possibility of


product contamination during tank
line up/changeover.

48
-------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
--------------------------------------------------------------------------------------------------------------------------------------

c) Whether the blending pumps, lines


are segregated from other lines
with positive isolation during
blending operation ?

d) Whether periodical checks are made


for locating any leakage on tank,
floating roof valves, piping etc.
and recorded for rectification.

e) Whether the roof drain valves of


floating roof tanks are normally kept
open .

f) Whether pre- monsoon checks are


carried out.

g) Whether any blending of DP product


and NDP product is resorted to ? If
so, what are the procedures & safety
precautions taken.

h) Whether cross checking of auto level


gauge is done through manual gauge,
while the tanks are under operation.

i) Whether it is ensured during initial


filling a flow velocity of maximum
1 m/sec is maintained for products
like SKO, ATF ?

j) Whether use of nylon rope for


sampling was observed ?

49
--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
--------------------------------------------------------------------------------------------------------------------------------------------------

k) How it is ensured that side entry


mixers are operated only when liquid
level is above the blades ?
(Wherever applicable )

5.0 INSPECTION & MAINTENANCE :

a) What are the schedules of inspection


of tanks (floating / fixed) and
whether records maintained in-line
with OISD STD-129.

b) What is the frequency of inspection


of PV vents, relief valves, breather
valves, flame arrestors ? Whether
records are maintained in line with
OISD STD-129.

c) Whether any provision exists for


static electricity discharge ? What
is the frequency of inspection of
earthing connections and whether
records maintained.

d) Whether the pontoon covers are in


place and are in good condition ?

e) Whether foam/neoprene seals are


checked regularly for perfect
sealing and record maintained.

f) Whether any documented procedure


exists for tank cleaning ? What is
the methodology to ensure strict
adherence ?

g) Whether the ladders, stairways are


in good condition ?

h) Whether the pipeline relief valves


are kept relieving to tanks or to
outside ?

i) Whether any inspections are carried


out on repaired tanks before taking
them into operation ? Whether
inspection schedule of radar gauges
provided on storage tanks have been
Note 3
followed.

j) What are the schedules for painting


of tanks ?
50
51
--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
--------------------------------------------------------------------------------------------------------------------------------------------------
k) Whether Nitrogen blanketing system
provided on any tank. If so, what
is the frequency of inspection &
whether records maintained ?

6.0 ADDITIONAL CHECKLIST ITEMS :

For detailed checklist on individual areas refer other OISD checklists as follows :

General Admn. & Organization OISD-GDN-145-01

Fire Fighting OISD-GDN-145-02

Layouts OISD-GDN-145-03

Electrical systems OISD-GDN-145-09

52
SAFETY AUDIT CHECKLIST No.OISD-GDN-145-06

POL LOADING & UNLOADING

A. TANK WAGONS

CONTENTS

--------------------------------------------------------------------------------------------------------------------------------------------------
SECTION DESCRIPTION PAGE NO.
--------------------------------------------------------------------------------------------------------------------------------------------------

1.0 FACILITIES AND SYSTEMS 40

1.1 Tank Wagon Gantry 40

1.1.1 General 40

1.1.2 Drainage 40

1.1.3 Miscellaneous 40

1.1.4 Electrical 40

2.0 OPERATING PROCEDURES AND PRACTICES 40

2.1 Placement of rakes and loading 40

2.2 Sick wagons 41

2.3 House keeping 41

53
OISD-GDN-145-06

SAFETY AUDIT CHECKLIST

6.0 POL LOADING & UNLOADING-TANK WAGONS

A. TANK WAGONS

--------------------------------------------------------------------------------------------------------------------------------------------------
AUDITOR'S REMARKS
--------------------------------------------------------------------------------------------------------------------------------------------------
1.0 FACILITIES AND SYSTEMS

1.1 TANK WAGON GANTRY

1.1.1 General

a. Whether proper facilities have been


provided for handling sick wagons ?

b. Whether the rail sleepers are of concrete


/ metallic construction ?

1.1.2 Drainage

Whether concrete flooring has been


provided below rail track and with proper
slope ?

1.1.3 Miscellaneous

Whether No-shunting device / caution


boards are provided to avoid movement of
wagons while filling / decantation is in
progress ?

1.1.4 Electrical

a. Whether the rail tracks are provided with


bonding strips and connected to well
maintained earthing system ?

b. Whether the diesel shunter used is


equipped with spark arrestors and proper
cooling of engine exhaust ?

2.0 OPERATING PROCEDURES AND PRACTICES

2.1 PLACEMENT OF RAKES AND LOADING

a. Whether the type of loco


used are :

-diesel
-steam
-electric

54
--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
--------------------------------------------------------------------------------------------------------------------------------------------------

b. If steam /diesel loco is used for placement


/removal of wagons whether safe distance from
first loading point is maintained by use of dummy
wagons ?

c. Whether replacement check is carried out to


ensure that platform , loading arms/hoses do
not hit the incoming rake ?

d. Whether the wagons are placed with master valve


closed and bottom sluice valve and cover plate
normally in opened position ?

e. Whether checks are made for any left over


materials, previous product & fitness of wagons
by operating staff on placement ?

f. Whether the TXR staff check / inspect each wagon


and issue a formal certificate prior to
loading ?

g. Whether wagons declared defective are shown on tally


sheets and also marked on the wagons ?

h. Whether Railways are informed in writing about


wagons found defective during loading ?

i. Whether the tightness of Master valve is checked by


TXR staff during this initial filling and in case of leak
declared as SICK WAGON ?

j. Whether, in case of open type wagons,pre-fabricated


fill pipes are available for use ?

k. Whether the following are ensured after completion of


loading :
- fill pipes (if exists) are properly capped

- Top covers are properly closed and sealed

- Bottom sluice valves fully closed


- Bottom cover plates are boxed up with
proper gaskets

l Whether any loose shunting is done ?

m Whether the shunting speed of 10 kmph


(Max.) is maintained ?

n Whether necessary caution boards


are displayed while loading / unloading
in progress ?

55
--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
--------------------------------------------------------------------------------------------------------------------------------------------------

2.2 Sick wagons

Whether the following are ensured before


removing the defective / sick wagons :

- Top lid covers closed


- bottom cover plate is kept
loose and hanging
- Checks made for any left out product

2.3 House keeping

a Whether the gantry floor, drain channels


are well maintained and tracks are regularly
washed to avoid oil accumulation ?
Any visible oil accumulation in the area ?

b Whether sand spreading is being done on


slippery working areas, railway tracks
etc. ?

c Whether Rly. tracks / sliding is free from unused


T.W. fittings ?

56
SAFETY AUDIT CHECKLIST No. OISD GDN-145-06

POL LOADING & UNLOADING -

B. TANK TRUCKS

CONTENTS
--------------------------------------------------------------------------------------------------------------------------------------------------
SECTION DESCRIPTION PAGE NO.
--------------------------------------------------------------------------------------------------------------------------------------------------
1.0 FACILITIES & SYSTEMS 43

1.1 Headers & loading hoses 43

2.0 OPERATING PROCEDURES AND PRACTICES 43

2.1 Placement of trucks 43

2.2 Loading operations 43

3.0 VEHICLE CREW AND CHECK 43

4.0 ADDITIONAL CHECKLIST ITEMS 51

57
SAFETY AUDIT CHECKLIST

6.0 POL LOADING & UNLOADING - TANK TRUCKS

B. TANK TRUCKS

--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR'S REMARKS
--------------------------------------------------------------------------------------------------------------------------------------------------
1.0 FACILITIES AND SYSTEM

1.1 HEADERS & LOADING HOSES

Whether proper arrangement has been


provided for securing the hose nozzle
with truck manhole ?

a Whether facility is provided to


drain overfilled truck to a closed
system with proper pump out
arrangement ?

2.0 OPERATING PROCEDURES AND PRACTICES

2.1 PLACEMENT OF TRUCK

a Whether any system exists to regulate


number of trucks coming at a time to loading
area ?

b Whether any parking / place has been


provided for the trucks near the loading area ?

c Whether the placement of trucks in the gantry


is allowed only on production of filling advice ?

d Whether any safety checks are carried out on the


trucks before issuing loading advice ?

2.2 LOADING OPERATIONS

a Whether it is ensured that the trucks,


loading hoses are properly connected to
earthing system before commencing
loading ?

b Whether decantation of any over filled


truck done to closed system (for DP)
and with close supervision ?

c Whether the following are ensured after


completion of loading :

- Fill pipes properly capped


- Top covers are properly closed and
sealed

58
--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
--------------------------------------------------------------------------------------------------------------------------------------------------

3.0 VEHICLE AND CREW CHECK

a Whether the vehicles design has been


approved by CCE ?

b Whether license and explosives


certificates are available in the vehicle ?

c Whether the vehicle is in good condition and the


RTO has issued a fitness certificate?

d Whether the vehicle has non-sparking


electrical fitting and external wiring through
conduits ?

e Whether the vehicle has a cut off master


switch for electrical system ?

f Whether there is facility to shut off the


drain valves in case of emergency ?

g Whether the vehicle has two fire


extinguishers ?

h Whether the gross and tare weight painted


on the vehicle tally with the permit

i Whether the vehicle has First Aid Box,


Tool Box and Emergency Lighting ?

j Whether there are any sources of ignition


like candles, etc in the vehicles ?

k Whether the vehicle has atleast a driver


and a cleaner as its crew member ?

l Whether the driver has a valid driving


license ?

m Whether the crew is trained for hazardous


nature of petroleum products, emergency
procedures, emergency communication etc ?

n Whether the driver has a copy of standing


instruction and TREM Card ?

o Whether the exhaust is wholly in front


of tank truck and has ample clearance
from Fuel oil system and combustible
material ?

59
--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
--------------------------------------------------------------------------------------------------------------------------------------------------
p Whether approved quality spark
arrestors provided on the engine
exhaust and Muffler / Silencer is
not cut off from the exhaust ?

q Whether each compartment of Tank is


fitted with independent PV vents with
minimum opening of 3 sq. cms. ?

r Whether vent openings are covered with


two layers of wire-mesh of size not less
than 11 mesh per centimeter ?

s Whether Tank Truck is conspicuously


marked on each side and rear, in bold
letters at least 7 cm high and on a
back ground of sharp contrasting
color. (The word "flammable " and name
of product are required to be marked )
as per UN code.

t Whether effective spark arrestors fitted


on air intake system of the engine ?

u Whether electric wiring is of heavily


insulated quality and adequate carry
maximum loads ?

v Whether suitable over current protection


in the form of fuses / automatic circuit
breakers etc. have been provided ?

w Whether all junction boxes are sealed


properly ?

x Whether electrical equipments like


generator switches, fuses and circuit
breakers are located inside the cabin
or engine compartment ?

y Whether battery is in easily accessible


position with a heavy duty switch
close by, to cut off the battery in
emergency ?

z Whether battery terminals have protective


rubber covers ?

aa) Whether vehicle's cabin is checked for


presence of any flammable/explosive
substance being carried by the crew ?

60
OISD-GDN-145-06 REVISION I

SAFETY AUDIT CHECKLIST OISD GDN-145-06

POL LOADING AND UNLOADING

C. COMMON CHECKLIST FOR LOADING AND


UNLOADING OF TWs & TTs

CONTENTS
--------------------------------------------------------------------------------------------------------------------------------------------------
SECTION DESCRIPTION PAGE NO.
--------------------------------------------------------------------------------------------------------------------------------------------------
1.0 FACILITIES & SYSTEMS

1.1 Pump house

1.2 Structure & platforms

1.3 Headers and loading arms

1.4 Drainage

1.5 Miscellaneous

1.6 Electrical

2.0 OPERATING PROCEDURES AND PRACTICES

2.1 Inspection & maintenance

2.2 Work Permit Systems

2.3 House keeping

2.4 Training

2.5 Miscellaneous

3.0 FIRE PROTECTION FACILITIES

4.0 ADDITIONAL CHECKLIST

61
SAFETY AUDIT CHECKLIST

6.0 POL LOADING AND UNLOADING

C. COMMON CHECKLIST FOR LOADING AND


UNLOADING OF TWs & TTs

--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR'S REMARKS
-------------------------------------------------------------------------------------------------------------------------------------------------
1.0 FACILITIES AND SYSTEMS

1.1 PUMP HOUSE

a) Whether the pumps are numbered/name of


product handled written ?

b) Whether white oil and black oil pumps are


segregated ?

c) In case of common service pumps whether


these are properly grouped keeping
product quality (flash point) in view ?

d) Whether the hot pumps and the associated


piping are heat traced and properly
lagged ?

e) Whether delivery to suction bypass line /


recirculation line to storage tank has been
provided ?

f) Whether adequate ventilation exists (in case of


covered pump house) ?

g) What is the system of communication


between pump house, gantry and control
room during normal operation/emergency ?

h) Whether all the drains are routed to OWS


and the system has water seal to act as
fire barrier ?

i) Whether the idle loading headers, not in use


for long time, have been blinded off?

j) Whether P.D. meters (if provided) have


proper electrical fittings as per area classification ?

1.2 STRUCTURE & PLATFORMS

a) Whether easy access available to the


platform from both sides of the gantry ?

b) Whether escape ladders provided along


the platforms are adequate ?
62
--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
--------------------------------------------------------------------------------------------------------------------------------------------------
c) Whether the swing ladders are provided
with counter weight, security chain,
rubber pads and other safety features to
avoid frictional spark ? Are these in
good working condition ?

d) Whether the supporting columns are fire


proofed ?

e) Whether the gantry shed is covered with


asbestos sheet and has side protection ?

f) Whether the ladders from platform to the


top of the vehicles are provided with
railings/security chain, rubber pads and
other safety features to avoid
frictional spark ?

g) Whether handrails are provided on the


platform ?

1.3 HEADERS & LOADING ARMS

a) Comment as to how the loading


velocities are maintained within safe
limits ?

b) Whether shock eliminators are provided on


each header ?

c) Whether quick isolation valves/MOV provided


for emergency shut off of loading headers ?
Are they operable during emergencies ?

d) Whether color coding has been provided


for loading headers and individual
loading points?

e) Whether heavy oil headers are heat traced


and properly insulated up to loading valve ?

f) Whether product compatibility has been


considered in case of common loading arm ?

g) Whether any of the loading arms swivel


joints/valves are leaking, if so how
many ?

h) Whether proper arrangement has been


provide for securing the hose nozzle with
manhole and properly secured after loading
(T/T & T/W)?

i) Whether vacuum breaker is provided on the


loading arm ?
63
--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
--------------------------------------------------------------------------------------------------------------------------------------------------

j) Whether the rubber hose are of proper


diameter, length, quality and condition & meets
BIS norms?

k) Whether the idle loading headers/


loading arms not in use for long time
are blinded off ?

1.4 DRAINAGE

a) Whether oily water drains from the area


are connected to effluent treatment/disposal
facility (OWS)?

b) Whether a well designed system exists for


draining and transfer of heavy oils like
LSHS to avoid congealing of OWS system ?

c) Whether the heavy oily drain


collection system is steam traced ?

d) Whether concrete flooring has been


provided with slope towards drains to
avoid spillage accumulation ?

1.5 MISCELLANEOUS

a) Whether road barriers have been provided


in the gantry area to restrict entry of
unauthorized persons/vehicles ?

b) Whether smoking booths with CODE approval


have been provided for the area at safe
locations ?

c) Whether the electric lighters, installed in


the smoking booths, are well
maintained ?

1.6 ELECTRICAL

a) Whether all electrical fittings, welding


apparatus receptacles, lighting provisions,
etc. are as per hazard area
classification ?

b) Whether illumination in the gantry & pump


house is adequate ?

c) Whether ground level illumination is


provided and found adequate ?

64
--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
--------------------------------------------------------------------------------------------------------------------------------------------------
d) Whether the loading arms/hoses are having
proper electrical continuity provision and
earthing connection ?

e) Whether the loading headers/other pipes


laid on the rack are properly earthed ?

f) How frequently are the tests of bonding /


earthing carried out ? Any records
maintained ?

g) Whether the No. of earthing pits are


adequate and they are inter connected ?

h) Whether condition of FLP fittings are


periodically checked and records
maintained ?

i) Whether the motors are provided with


proper earthing.

j) Whether structure is earthed as per std.


and earth test done every year and
records maintained. Is the catwalk
antiskid ?

k) Whether earthing bosses with flexible


cable and robust clamping device have
been provided adjacent to loading points ?

2.0 OPERATING PROCEDURES AND PRACTICES

a) Check and comment on earthing and bonding


practices during loading / unloading.

b) Whether initial filling is done at a slow rate


for safeguard against hazard off static
charges ?

c) Whether established communication system


exists between gantry & pump house to
control loading rates / pumping rate ?

d) Whether the loading operation is done under


the close supervision ?

f) Whether operator's constant attention is


there while the loading points have been
opened ?

g) Whether it is ensured that "no vehicle


entry" in the gantry area is permitted
during loading and unloading operations ?

65
--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
--------------------------------------------------------------------------------------------------------------------------------------------------

h) Whether initial loading is done at a rate


not exceeding 1 M/Sec, till the filling
pipe is completely submerged and
thereafter at the rate not exceeding 6
M/Sec ?

2.1 INSPECTION & MAINTENANCE

a) Whether any schedules exist for


lubrication for loading valves/swivel
joints and records are maintained ?

b) Whether schedules exist for inspection


the loading headers, arms/hoses, etc. ?
Whether records are maintained ?

c) Whether adequate inventories are


maintained for prompt replacement of
passing valves and damaged hoses ?

c) Whether all modification jobs are undertaken


only with approved engineering standards ?

2.2 WORK PERMIT SYSTEM

a) Whether as per OISD 105 (for Hot/Cold works


and OISD 137 for Electrical Equipment being
followed.

b) Whether display boards have been provided


at strategic locations covering key
safety instructions ?

c) Whether Emergency and Disaster Control


Plans for the area is available with
written procedures ?

2.3 HOUSE KEEPING

a) Whether the house keeping in the area can


be considered :

good ?
satisfactory ?
needs improvement ?

b) Whether hot water points/system points


provided for flushing/washing operations
& house keeping, or light hydrocarbons
are used ?

c) Whether the gantry floor are regularly


washed to avoid oil accumulation ? Any
visible oil accumulation in the area ?
66
--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
--------------------------------------------------------------------------------------------------------------------------------------------------
d) Whether the drain channels are cleaned &
well maintained ?

2.4 TRAINING (REFER OISD 154 STD.)

a) Whether subsequent refreshed


training programs are also organized
periodically ?

b) Whether contract employees (if any) are


given basic training on hazards of
petroleum products and safe
practices ?

c) Whether the workers are using required


personal protective wears ?

2.5 MISCELLANEOUS

a) Whether Operating Manuals/Standing


Instructions are available at site ?

3.0 FIRE PROTECTION FACILITIES

a) Whether the fire water network


Provided is well designed (Ring type)

b) Whether isolation valves exist for


isolation of each section maintenance

c) Whether hydrants, long range water/foam


monitors are provided on both sides of
gantry and are they safely located ?

d) Whether all hydrants, monitors are easily


accessible ?

e) Whether proper approach roads exist for


Fire Tenders and Fire Fighting Equipment ?

f) Whether communication system like Fire


Alarms, PA system provided and are
working ?

g) Whether the communication system,


sprinklers are periodically checked
and records maintained ?

h) Whether any mock drills are conducted


for fire fighting ?

i) Whether adequate number of portable


extinguishers have been provided all
along the gantry ?
67
--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
--------------------------------------------------------------------------------------------------------------------------------------------------
j) Whether a copy of Fire Fighting manual is
available in the gantry control room ?

4.0 ADDITIONAL CHECK LIST ITEMS

a) For comprehensive check lists on


individual areas also refer OISD check
lists as indicated below:

b) General admn. organization OISD-GDN-145-01


Fire fighting OISD-GDN-144-02
Layouts OISD-GDN-145-03
Electrical Systems OISD-GDN-145-09

68
SAFETY AUDIT CHECKLIST No.OISD-145-07

LPG BULK LOADING & UNLOADING

CONTENTS
--------------------------------------------------------------------------------------------------------------------------------------------------
SECTION DESCRIPTION PAGE NO.
--------------------------------------------------------------------------------------------------------------------------------------------------
1.0 BULK STORAGE AREA 53

2.0 PUMPS/ COMPRESSORS AREA 55

3.0 TANK WAGON GANTRY AREA 56

4.0 TANK TRUCK GANTRY AREA 58

5.0 TRAINING 59

6.0 ADDITIONAL CHECKLIST ITEMS 59

69
SAFETY AUDIT CHECKLIST

7.0 LPG BULK LOADING & UNLOADING

--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR'S REMARKS
--------------------------------------------------------------------------------------------------------------------------------------------------

1.0 BULK STORAGE AREA:

1.1 GENERAL:

a) Whether the layout, area classification drawings


have been duly approved by CCE ?

b) Whether any new facilities (permanent or temporary


natural) have been installed Area they considered to
be safe.

c) Whether general house keeping in the area is satis-


factory ?

d) Whether storage vessels are insulated. If so, what


is the condition of insulation.

e) Whether five year hydraulic test records are avail-


able ?

f) Whether any signs of corrosion observed on


pipelines? Whether paintings are done as per
schedule ?

g) Whether all bolts of proper sizes are put on the


flanges or some are found missing or of smaller
sizes

i) Whether any portion of pipe length found buried


with soil or undergrowth?

1.2 RELIEF SYSTEM:

a) Whether relief system is adequately designed ?

b) Whether minimum two relief valves are provided in


each vessel?

c) Whether the relief valves are opened to flare /


atmosphere? Any steam connection given? Is
system opened to atmosphere?

d) Whether the relief valves are provided with isola-


tion valves?If so what is the system/ method to
avoid inadvertent closing of isolation valves ?

e) Whether the safety valves are periodically tested


and records maintained ?
70
--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
--------------------------------------------------------------------------------------------------------------------------------------------------
1.3 DRAINING

a) Whether water drain chamber has been provided


away from shadow of sphere ?

b) Whether the area under the sphere is having


concrete pavement with proper slope ?

c) Whether antifreeze valve provided on the drain line

d) Whether double block valves have been provided


on water draining line (quick shut off type near
the chamber and the other a globe valve) ?

e) Whether safety instructions for draining operations


have been prominently displayed?

f) Whether draining is done under constant


supervision ?

g) Whether sampling points are provided with duplicate


valves?

1.4 INSTRUMENTATION:

a) Whether level gauge of two types have been provided


for direct level measurement and counter checking?

b) Whether monitoring of levels of all the vessels are


done ?

c) Whether High Level alarms have been provided in


storage vessels and are in working conditions ?

d) Whether remote operated valves (ROVs) have been


provided on liquid outlets/inlets and are checked
for proper operations ?

1.5 FIRE AND SAFETY:

a) Whether gas detection system is provided in the


area and is working satisfactorily?

b) Whether capacity of fire water pumps and header


are adequately designed?

c) Whether sprinkler/Deluge system are provided on all


the vessels and are periodically tested for
satisfactory operation ?

d) Whether the sprinkler/Deluge Valve are remote


operated and are located 15M away from storage
vessels?

e) Whether the supports of the vessels are fire


71
--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
--------------------------------------------------------------------------------------------------------------------------------------------------

proofed?

f) Whether periodical checks are done with


explosive meters to detect any gas leaks?

1.6 ELECTRICAL:

a) Whether bonding strips have been used across the


flanges for electrical continuity ?

b) Whether all the electrical fittings in the area


meet area classification requirement?

c) Whether earthing connections are provided and are


properly maintained?

d) Whether illumination in the area is adequate?

2.0 PUMPS/COMPRESSORS AREA:

2.1 FACILITIES:

a) Whether the layout of the area meets statutory


requirements in terms of safety distance from
storage vessels, roads and other facilities?

b) Whether the pumps have double mechanical seals to


minimize leakage? Are the seals in good condition?

c) Whether recirculation line to storage vessels have


been provided?

d) Whether the venting is done through high


rise vents? Whether steam connections are
provided for atmospheric vents ?

e) Whether the drains/vents/sample points have double


isolation valves and are provided with caps?

f) Whether Gas Detection system has been provided in


the area and working satisfactorily?

2.2 ELECTRICAL:

a) Whether all the motors and other electrical


equipments such as terminal/junction boxes,
lighting fittings etc. are weather proof/
flameproof and are as per hazard area
classification requirements?

b) Whether the motors are provided with proper


earthing?

c) Whether illumination is adequate in the area ?


72
--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
--------------------------------------------------------------------------------------------------------------------------------------------------
2.3 GENERAL:

a) Whether all the equipments in the area are properly


painted?

b) Whether an established communication system exists


between the loading area and the pump area during
normal operation/emergency?

c) Whether safety instructions have been displayed?


(e.g. `NO SMOKING', `MEN AT WORK' etc.)

d) Whether all maintenance tools used in the area


are non sparking type?

2.4 FIRE PROTECTION:

a) Whether long range monitors/sprinkler system have


been installed to cover the area and are in good
working condition?

b) Whether adequate nos. of fire extinguishers have


been provided?

3.0 TANK WAGON GANTRY AREAS:

3.1 FACILITIES:

a) Whether the layout of the gantry meets statutory


requirements?

b) Whether the design, material selection and


installation of the gantry platform, loading
header, loading hoses etc. have been done as
per standard engineering norms adopting
proper safety guidelines of established norms.

c) Whether loading arm swivel joint gas seals are


periodically greased and maintained properly?

d) Whether high vent flame arrestors are cleaned


periodically?

e) Whether facilities have been provided to handle


leaky wagons in situ (Evacuation of T/Wagons)?

f) Whether emergency stop push button for loading


pumps exists in the gantry?

3.2 LOADING HEADERS AND ARMS:

a) Whether quick isolation valve/MOV has been provided


on the loading header and is operative?
b) Whether independent isolation valve provided on each
loading point?
73
--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
--------------------------------------------------------------------------------------------------------------------------------------------------

c) Whether loading velocities are maintained within


safe limits by providing restriction orifice on
each loading point ?

d) Whether loading headers are provided with proper


earthing/bonding connections?

e) Whether loading hoses not in use are stored


properly and open end is kept blinded?

f) Whether loading hoses are having any sign of


kinks/wears etc.?

g) Whether the following facilities are available on


each loading point ?

Excess flow check valve on the filling line

- vapor return line with check valve back to


storage vessel
- flexible hoses on filling vapor return line

h) Whether depressurising system has been provided


on the gantry header discharging to high vents/flare?

i) Whether temperature and pressure gauges have been


provided at convenient points ?

j) Whether the loading header is provided with ISV


relieving to high point vent ?

k) Whether proper capacity weigh bridge has been


provided on each spur of the gantry Any risk of
gas accumulation observed in the pit ?

l) Whether bonding strips as provided for


continuity of rail tracks ?

m) Whether bonding connectors (copper strips/wires


are provided for piping ?)

3.3 FIRE PROTECTION AND SAFETY :

a) Whether water sprinkler system has been provided


and working satisfactorily ?

b) Whether adequate nos. fire hydrants, long range


water monitors have been provided ?

c) Whether gas detector system have been provided


with alarm in the control room ?

74
--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
--------------------------------------------------------------------------------------------------------------------------------------------------
3.4 OPERATING PROCEDURE AND PRACTICES :

a) Whether updated operating manual


with loading/unloading procedures is available
In the control room and is well understood
by the operating crew ?

b) Whether the TXR staff check and issue fitness


certificates in writing for fitness of tank wagons ?

c) Whether checks are done for gaskets. "O" rings,


physical damage, any corrosion on tanker,
safety valve, thermometer etc. before commencement
of loading operation?

d) Whether the following are ensured before loading ?

- All engines nearby are switched off


- All hot jobs in the area are stopped
- Proper earthing connection are made
- All wagons are secured by hand brake

e) Whether it is ensured that non sparking tools


are used for connecting/disconnecting the hoses?

f) Whether used of any synthetic fiber material


was observed?

g) Whether loading hoses are periodically hydraulic


tested, discarded/replaced and records maintained?

h) Whether all hoses carry test code & date?

i) Whether constant supervision is ensured during


loading/unloading operation?

j) For detailed checklist for loading T/W pl.


refer to OISD-STD-144?

4.0 TANK TRUCK GANTRY AREAS

4.1 FACILITIES

a) Whether the truck loading facilities have


been installed as per CCE approved drawings?

b) Whether separate entry/exit gates exist for


the tank trucks?

c) Whether weigh bridge is available within the


Installation and is calibrated periodically
and maintained?

d) Whether the no. of trucks parked at the


gantry area is restricted?
75
--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
--------------------------------------------------------------------------------------------------------------------------------------------------
e) Whether facility available for evacuation/
decantation of defective/leaky trucks with
necessary high point vents with steam
connections?

f) Whether the following random checks are done


the tank trucks?

- Valid licenses
- fittings as per CCE such as flame arrestor,
fire screen etc.
- safety instruction booklet

g) Elimination of ignition sources like


loose wires, uncovered battery terminals etc.
Whether gas detection system has been
provided in the area & working satisfactory

4.2 OPERATION

a) Whether the vehicle engine is always shut


off during loading operations?

b) Whether it is ensured that earthing connection is


properly checked before connecting hoses to tank
truck?

c) Whether blank flanges are fitted on the truck


inlet flange and to the end of hoses when not in
use?

g) Whether loading arm open and is blinded when


not in use?

4.3 FIRE PROTECTION AND SAFETY

a) Whether water sprinkler system has been


provided and working satisfactorily?

b) Whether adequate nos. fire hydrants, long range


water monitors have been provided?

c) Whether gas detector system has been provided


with alarm in the control room?

d) Whether provision to start water sprinklers


from loading gantry/Control Room / Weigh
Bridge exists?

e) Whether water sprinkler system adequately covers


T/T bullet ?

f) Provision to stop pump from loading gantry / WB


Cabin ?

76
--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
--------------------------------------------------------------------------------------------------------------------------------------------------

5.0 TRAINING

a) Whether pocket size instruction booklets/manuals in


widely understood languages, have been issued to
all concerned employees ?

b) How it is ensured that loading operations such as


hose connection etc. are always done by plant
operators rather than tank truck crew ?

c) Whether operating procedures have been displayed


in vicinity of the tank loading bays ?

d) Whether protective gloves are being used by the


operating crew ?

e) Whether the vehicle crew has been trained on


hazardous nature of LPG and to handle emergency
situation ?

6.0 ADDITIONAL CHECKLIST ITEMS

For detailed checklist on specific areas refer


other OISD check lists as follows :

General (Organization Admn.


Training etc ) OISD-GDN-145-01

Fire fighting OISD-GDN-145-02

Layouts OISD-GDN-145-03

Gantry Operations OISD-GDN-145-06

Electrical OISD-GDN-145-09

BULK TT CHECKING :

How it is made sure that only TT fit for loading


are taken up for filling?(w.r.t. oxygen content
etc.)

For detailed checklist for loading TT pl .ref.to


OISD-STD-144.

77
SAFETY AUDIT CHECKLIST No.OISD GDN-145-08

LPG BOTTLING AND DISPATCH

CONTENTS
--------------------------------------------------------------------------------------------------------------------------------------------------
SECTION DESCRIPTION PAGE NO.
--------------------------------------------------------------------------------------------------------------------------------------------------
1.0 GENERAL ORGANISATION AND ADMINISTRATION 61

2.0 MANPOWER AND TRAINING 61

3.0 CYLINDER STORAGE AREA 62

4.0 BOTTLING SHED 63

5.0 NEW AND DEFECTIVE CYCLINDERS 64

6.0 CYLINDER LOADING 65

7.0 SAFETY AND FIRE PROTECTION 66

8.0 ADDITIONAL CHECKLIST ITEMS 67

9.0 SUGGESTED INSPECTIONS MAINTENANCE CHECKS 67

78
SAFETY AUDIT CHECKLIST
LPG BOTTLING AND DISPATCH

--------------------------------------------------------------------------------------------------------------------------------------------------
AUDITOR'S REMARKS
--------------------------------------------------------------------------------------------------------------------------------------------------
1.0 GENERAL ORGANISATION AND ADMINISTRATION

a) Check for valid licenses of CCE pertaining


to the locations.
- Storage of LPG
- Storage of LPG cylinders
- Filling of LPG cylinders

b) Whether inter distances from/to admn. offices,


maintenance offices, check & change rooms,
smoking booths etc. are meeting safety
requirement.

c) Whether plant approach/access roads are well


maintained & at least one emergency exit
is provided.

d) Whether adequate no. of escape routes/staircases


available around each of the facilities viz.,
filling shed, cylinder storage area?

e) Whether fencing/boundary wall around the Plant


is in proper condition?

f) Whether truck parking area has been provided as


per OISD-STD-144.

g) Whether frisking of employees, contractor,


personnel and visitors ensured?

h) Whether work permit/clearance (for hot & cold


jobs) procedures followed as per approval?

i) Whether following manual/documents are


available and updated.

- LPG Operations Manual


- S&EP Manual
- Emergency/Disaster Control Plan
- Operation/Inspection/Repair Manual of
epuipment supplied by vendor.
- OISD Standards.

j) Whether updated P&ID drawings & layouts &


other facilities available?

k) Whether records of Daily Safety Check reports


are reviewed and corrective action taken?

l) Is the general housekeeping okay?


Any specific comments.
79
--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
--------------------------------------------------------------------------------------------------------------------------------------------------

2.0 MANPOWER & PLANNING

a) Whether supervisory/managerial cadre


staff fully trained in all aspects of LPG
Plant operations, Disaster Control/
Emergency handling?

b) Whether Safety Officer is available and


duly designated as safety officer.
Does he possess fire/safety engineering
qualifications and his duty list drawn
clearly?

c) Whether Training Programs are organized


periodically in LPG Operations fire
fighting/emergency handling etc. for:
- Regular Staff
- Tank Truck Operators/drivers
- Contractor Workmen
- Security Staff.

d) Whether operating manuals and standing


instructions are provided to working
personnel?

e) Whether safety booklets distributed to


all including contractor employees.
(English/Hindi/local language)?

f) Whether important Do's and Dont's


displayed prominently in operating areas?

3.0 CYLINDER STORAGE AREA

a) Whether Transfer of cylinders from/to


truck is done through
- Telescopic Conveyer/ Trolleys /Conveyers?
Any dropping, rolling, mishandling
noticed?

b) Whether Inspection/visual checks are done


to detect leaky/defective cylinders to
segregate spurious leaky/defective
cylinder?

c) Whether storage is segregated and marked


for?
- Spurious cylinders
- 5 year testing due cylinders
- Other defective cylinders

d) Whether cylinders stacked in vertical


position in tiers as per the norms?

80
--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
--------------------------------------------------------------------------------------------------------------------------------------------------

e) Whether stacking discipline with small


lots of 4 rows and 25 cylinder lengths
followed with a minimum access path of
1 M maintained on both sides of 4 rows.

f) Whether cylinders stacking areas are


periodically inspected for leakage with
explosimeter or probable leak detector?

g) Whether cylinder offload bay platform


provided with proper buffers?

i) Whether stacks of cylinder are identified


by markers to show empties, filed and
gas free cylinders?

j) Whether the daily stocks of cylinders


(empty/filled/defective) are displayed?

4.0 BOTTLING SHED

a) Whether cylinder washing facility


provided?

b) Whether filling/loading/unloading/storage
areas are adequately covered with mastic
coating on floors and pillars to avoid
accidental sparks?

c) Check for condition of mastic flooring.

d) Whether tare weight of the body is marked


distinctly on the body of the cylinder?

e) Whether empty cylinders are checked for


'o' ring presence?

f) Whether filling is done based on gross


weight?

g) Whether AUTO CUT OFF facility exists on


filling machines?

h) Whether filling head gun hoses are of


approved quality and periodically tested?

i) Whether proper earthing provided to?


a. Conveyers
b. Carousel units (bonding of filling
guns).
c. Unit filling Machines.
d. Evacuation units.

j) Check for accumulation of vapors in


81
--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
--------------------------------------------------------------------------------------------------------------------------------------------------
recess/pits in the area with the
explosimeter

k) Whether vapor extraction system with


suction points at carousel, evacuation
unit, valve change shed is provided and
in working condition?

- Whether standby blower is available?


- Whether carousel unit is interlocked
with vapor extraction system?

l) Whether accuracy of check scales being


checked daily and records maintained?

m) Whether filling machine check scales are


calibrated periodically and records
maintained?

n) Whether facilities are provided for


100% cross checking of weight of filled
cylinders? Are they in use?

o) Whether check weigh scales are -


calibrated periodically?

p) Whether CVT checks done after filling


for`O' ring and valve defects?

q) Check for facilities:


- To check for conveyors
- To check defective cylinders
- To check 'O' Ring
- To check weight correction.

r) Whether bung leak/body leak checks are


done through in-line water bath for both
14.2. Kg. and 19 Kg. cylinders?

s) Whether capping/sealing facilities are


provided - Al foil/PVC seal?

t) Check for neck labels plastic/paper.

u) Whether tagging of overfilled/underfilled


cylinders done?

v) Check for leakage from carousel filling guns.

w) Whether persons working on carousel wear


hand gloves & safety shoes?

x) Whether Statistical Quality Control


checks (SQC) carried out & records
maintained? (See foot notes)
82
--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
--------------------------------------------------------------------------------------------------------------------------------------------------

y) Whether Movement of cylinders is done


through floor conveyers/trolleys?
statistical checks include

- Total No, of cylinders filled.


- Total No. of cylinders checked at
random.
- No. of cyls. found defective.
- % of cyls. found defective. in last
month
- Weight variation (Over filling)
- Weight variation (under filling)
- Valve leak
- Bung leak
- "O" Ring missing
- Defective "O" Ring (by CVT Test)
- 'Pressure Control valve' Filling
procedure
- Cyls. due for retesting
- Other minor defects
- Remarks if any.

5.0 NEW/DEFECTIVE/LEAKY CYLINDERS

a) Whether Purging facilities are available


for new/retested cylinders?

b) Whether Facilities provided for evacuation


of leaky/partially filled cylinder are
working satisfactorily?

c) Whether venting/cold flaring of LPG is


done at safe height - 2 meter above the
roof edge?

d) Whether Cold Repair facilities are


available? If so, are they at
appropriate location?

e) Whether wire mesh provided on cold flare


line?

f) Whether degassing facility provided in


cold repair shed? Is it 15 M away?

g) Whether cylinder repairs/valve change


etc are supervised?

h) Whether stock of leaky cylinders is below


the stipulated limits?

i) Whether Torque wrenches with proper


settings are used for valve removal
replacement (20 +/- 2 kg. Mt.)?
83
--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
--------------------------------------------------------------------------------------------------------------------------------------------------

j) Whether PTFE tape/paste used while fixing


valves?

k) Whether cylinders are checked for denting


are declared defective?

l) Whether records of defective cylinders


maintained supplierwise?

m) Whether records of leaky /defective


cylinders (company wise) detected during
filling/are maintained on daily basis with
following particulars:

- Cylinders filled
- Valve leak
- Bung leak
- Body leak
- "O" ring defect
- Spurious cylinders

n) Whether record of defective cylinders


returned by distributors is maintained on
daily basis?

o) Whether spurious cylinders and cylinders


declared as scrapes are destroyed by
crushing properly and records maintained?

6.0 CYLINDERS LOADING INTO TRUCK

a) Whether covered facilities/sheds provided


for positioning of trucks 15 M away from
storage shed for receipts / loading of
cylinders with sprinkler protection and
lighting?

b) Whether cylinders are loaded into trucks


through conveyers?

c) Whether cylinders stacked vertically


without protrusions?

d) Whether explosimeter checks are done


before releasing the truck?

e) Whether Loading/unloading of cylinders is


done in safe manner?

7.0 SAFETY & FIRE PROTECTION

a) Whether Contingency Plans are available


and updated for tackling major emergencies?

84
--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
--------------------------------------------------------------------------------------------------------------------------------------------------
b) Whether fire organisation chart is
prepared upto date and displayed?

c) Whether important telephone nos. of state


Fire Services/Police/Dist. Admn. /
Hospitals / other offices etc. are displayed?

d) Whether Fire/Emergency mock drills


conducted periodically?

e) Whether Fire Water Network provided


around the facilities is as per prescribed
norms and adequate?

f) Whether Pressure and flow are adequate at


farthest end?

g) Is system painted as per standard norms


(Hydrant pipelines - Red; risers/monitors
-yellow; & sprinkler system- Blue)

h) Whether hydrants/monitors are provided at


a minimum distance of 15 meters from the
sheds and provided for every 30 meters
distance?

i) Whether adequate No. of hydrants, long


range monitors etc. are provided and
periodically inspected and records
maintained?

j) Whether MV Spray Sprinkler System having


remote / local operated deluge valves
provided in the storage shed and in
working condition. Also whether in
critical areas like carousel evacuation
unit, valve change shed, automatic
detection of heat / flame for automatic
operation of sprinkler system provided?

k) Whether deluge valves are located 15


meters away from the limits of sheds and
protected by fire walls (One deluge valve
to cover an area of about 520 Sq. meters)?

l) Whether portable DCP Fire Extinguishers


are provided at appropriate location?
-2 Nos. 10 Kg. DCP FE per 200 Sq. Meters
area.
- 1 No. 100/70 Kg. DCP Mobile unit per
shed.

m) Whether gas monitoring system having


sensors to monitor gas leak near
carousel, evacuation unit, valve
85
--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
--------------------------------------------------------------------------------------------------------------------------------------------------
change shed provided? if so:

- Whether working satisfactorily?


- Whether periodically inspected and
records maintained?

n) Whether fire alarm/manually operated fire


siren and communication system consisting
paging system / flameproof telephones is
available & adequate?

o) Whether 'No smoking' and other cautions


sign in Hindi/English/local language
displayed at prominent places?

p) Whether Emergency lighting system


provided in strategic locations and is
working satisfactorily?

q) Whether Flame proof torches available?

8.0 ADDITIONAL CHECK LIST ITEMS

For detailed checklist on specific areas


refer other OISD check lists as follows:

General (Organisation
Admn. Training etc) OISD-GDN-145-01

Fire Fighting OISD-GDN-145-02

Layouts OISD-GDN-145-03

Gantry Operations OISD-GDN-145-06

Electrical OISD-GDN-145-09

86
-----------------------------------------------------------------------------------------------------------------------
ITEMS AUDITORS REMARKS
-------------------------------------------------------------------------------------------------------------------------------------------

SUGGESTED INSPECTION & MAINTENANCE CHECKS

9.1 DAILY MAINTENANCE

a) Cleaning the cover plate of introduction device,


ejction device, air service units, filling guns, CVT
etc.

b) Water draining from filters of check


scales & filling gun.

c) Air leak control from check scale.

d) Checking/control of oil level in check


scale & filling gun.

e) Zero checking of Introduction


Device/Ejection Device, Air Service
Units, CVT etc.

f) Calibrations/Adjustments of devices
indicated in above.

g) Checking the sensitivity of check scales

h) Conducting test run/test filling to see


the performance of filling-gun, check
scales, introduction/ejection devices,
CVT etc.

9.2. WEEKLY MAINTENANCE

a) Oil topping in Air service unit/cleaning


of Air Filters.

b) Oil topping in dampers of in-line check


scales and calibration with standard
weights.

c) Cleaning of the bearings and suspensions


of Filling machines

d) Greasing & leakage control of


Introduction system & Ejection System.

e) Greasing/lubrication of :
- Central column
- Carousel Driving unit.

87
--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
--------------------------------------------------------------------------------------------------------------------------------------------------
9.3 QUARTERLY MAINTENANCE

a) Earthing strip tightness of equipment


like in-line control Check Scale & Filling
Machine.

b) Checking the filling hoses for stiffness


and replacement, if necessary.

c) Inspection of Gun hanger, ropes & pulley


inspections.

d) Inspection of wear & tear for knife edges


& bearing.

e) Calibration of filling machines with


standard weights.

f) Checking the level of Introduction system


& Ejection system.

9.4 ANNUAL MAINTENANCE

a) Overhauling of machines & replacement of


defective parts of filling machines,
check scales, introduction/ejection
system, central column & driving units.

b) Inspection of power cylinder of


introduction system & cleaning.

c) Inspection of ejection system for wear &


tear.

d) Inspection of rails of conveyer system


for setting &tightening of fish plate.

e) Inspection & adjustment for proper


functioning of Differential Pressure
valve.

88
SAFETY AUDIT CHECKLIST NO. OISD GDN-145-09
ELECTRICAL SYSTEM

CONTENTS
--------------------------------------------------------------------------------------------------------------------------------------------------
SECTION DESCRIPTION PAGE NO.
------------------------------------------------------------------------------------------------------------------------------------------------
1.0 SPECIAL REQUIREMENTS 70

2.0 SUBSTATION (EQUIPMENT & BUILDING) 71

3.0 SWITCHYARD AND OUTDOOR EQUIPMENT 73

4.0 CABLE NETWORK TERMINATIONS & JOINTS 73

5.0 MOTORS CONTROL STATIONS 74

6.0 LIGHTING INSTALLATIONS 75

7.0 EARTHING & BONDING 75

8.0 CAPTIVE GENERATION 77

9.0 BATTERY CHARGER/ UPS 78

10.0 ELECTRICAL HEAT TRACING 78

11.0 PORTABLE APPARATUS/ MOBILE 78


EQUIPMENT (ELECTRICAL /BATTERY OPERATED)

89
SAFETY AUDIT CHECKLIST
ELECTRICAL SYSTEM
--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR'S REMARKS
--------------------------------------------------------------------------------------------------------------------------------------------------
1.0 SPECIAL REQUIREMENTS

a) Whether main single line diagrams of


Electrical Power Distribution
"updated" and "As-built"?

b) Whether the Installations are duly


approved by the Chief Electrical
Inspectorate to Govt. for
energisation? (DGMS for Oil Field
Installations)

c) Is there any unauthorized


installation in operation including
temporary construction power
installations?

d) Whether action taken on IE inspector


visit report?

e) Whether electrical installations/repairs to


existing installations are being carried out
through licensed electrical contractors under
the supervision of Licensed Electrical
Supervisor (approved by State Govt.) As per
I.E. Rule No. 45)?

f) Are the electrical equipment installed conforming


to the Area Classification (IS:5572) approved by
CCE?

g) Whether there has been revision in


the hazardous area classification
from the original (due to
modifications/expansions etc.) and
the electrical equipment was
accordingly replaced to conform to
revised classification?

h) Whether the suggested remedial


measures given in the Accident Investigation
Reports, if any, have been implemented?
(Review the Accident Report of the last 5
years)?

i) Whether the list of electrical "authorized persons"


is being maintained (I.E. Rule No. 3) and
displayed?

j) Whether inspection of electrical equipment is


carried out, as per approved schedule (Review
the inspection records)?
90
--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
--------------------------------------------------------------------------------------------------------------------------------------------------
k) Whether approved work Permit System
is being followed?

l) Are the installations generally


rust/corrosion protected effectively?
(such as by using cadmium plated
Bolts/nuts, painting at regular
intervals etc)

m) Whether the substations / power


plant rooms/control room /MCC rooms
etc. are used as storage area for
scraps,oil drums, clothes, spares and such
other foreign materials

n) Are the flameproof features maintained intact


for flameproof equipment? (Any damages or missing
bolts /nut in the junction boxes/panel covers /terminal
boxes etc. convert the equipment to non-flameproof)

o) Whether flameproof telephones are used in the


classified hazardous areas?

p) Whether the Transformer & Switchyards are free


of vegetation/dry grass?

q) Whether all the electrical equipment( switchboards,


Relays, Motors, Transformers & Busducts etc.)
and junction / terminal boxes etc. are vermin proof?

r) Whether preventive Maintenance Schedules as


per OISD-STD-137 etc. carried out?

s) Whether CO2 fire extinguishers provided for


electric fires?

t) Whether sand-buckets provided?

2.0 SUBSTATION (EQUIPMENT & BUILDINGS)

a) Is the substation equipment freely


accessible for Operation, Inspection
and Maintenance?

b) Are the minimum clearances around


the equipment maintained as per I.E.
Rule 51?

c) Are all the substation equipment


provided with double earthing
connections?

91
--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
--------------------------------------------------------------------------------------------------------------------------------------------------

d) Are the live parts of equipment made


inaccessible from inadvertent
contacts? (by barriers/shrouds)?

e) Whether the rubber glove and mats


with voltage test seals are provided
in front of the switchboards and are
in good condition?

f) Whether the switchboards are


dust / verminproof? Is pest control
treatment given for substations?

g) Are any unused cable entries left open?

h) Have the protective relays been set


at the recommended values (as per the
design)?

i) Whether the fuses used are of HRC


Type and of ratings specified in the
single line diagrams ?

j) Whether each outgoing distinct


circuit from the switchboard is
separately controlled by a suitable
linked switch fuse or circuit breaker
of required capacity?

k) Whether circuit identification marks/


tags are provided or not?

l) Are the relays and meters tested for


proper functioning/calibration as per
approved schedule?

m) Whether the bus bars are provided with


distinct color identification ( Red,
Yellow, Blue and Black)?

n) Whether the conduits used for cable


entry are sealed and earthed?

o) Are the energized electrical equipment


provided with caution notices?

p) Is the substation building made


water tight and all the openings in
walls ( such as cable trench entry/
bus duct entry) sealed?

q) Whether any water stagnation is there


inside the cable trenches?

92
--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
--------------------------------------------------------------------------------------------------------------------------------------------------
r) Are all the power (H.T. & L.T) and
control cables in trenches properly
segregated?

s) Are the cables near the terminations


clamped?

t) Is there any combustible material


used for construction of substation
building?

u) Whether the cable trenches are


provided with concrete slabs /
chequered plates?

v) Are the earth electrodes periodically


tested and maintained properly?

w) Are the earth resistance of the grid


measured, checked and recorded
periodically?

x) Is the substation provided with


Emergency Lighting?

y) Is the substation provided with


telephone?

z) Is the trench sump pump ( for


dewatering ) in working condition
( wherever provided ) ?

aa) Are floors kept clean,free of tripping


hazards?

bb) Whether the switchgear rooms located


in the hazardous area are pressurized?
(if not, are these provided with
flameproof equipment)?

cc) Whether all panel doors are kept closed?

dd) Whether all the indicating lamps in


the Panel are in operating condition
(i.e. not fused)?

ee) Are the oil immersed starters filled


with oil to the required level and of
required dielectric strength?

ff) Whether shock restoration chart & First Aid Box provided?

93
--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
--------------------------------------------------------------------------------------------------------------------------------------------------

3.0 SWITCHYARD AND OUTDOOR EQUIPMENT.

a) Are the following components individually


earthed with two separate earthleads
( No. 8 SWG copper or equivalent)?

- Metal Frameworks
- A.B. Switches and circuit breakers
- D/O and H/G Fuses
- Poles/switches/insulator pins/stay
clamps
- Operating handle of the A.B. switch

b) Whether the vertical and horizontal


clearances from O.H. conductors are
maintained as per I.E. Rule (79)?

c) Are the earth electrodes provided in


sufficient number? Whether the
earth pits are properly maintained and
tests carried out as per schedule?

d) Whether the lightning arrestors are


connected after the A.B.switch, for
the protection of transformer/circuit
breaker?

e) Whether a separate earth electrode of


proper size is provided properly for
the lightning arrestors?

f) Is there O.H. shielding for lightning


protection and whether it is properly
maintained?

g) Whether there is locking arrangement


for the Transformer bay to prevent
entry to the yard by unauthorized
persons? If so, is it being followed?

h) Whether the doors of the gate are rusted


and need to be painted?

4.0 CABLE NETWORK/TERMINATIONS & JOINTS

a) Have the route markers and joint


location indicators been provided in
a permanent way throughout the Plant
and Off site areas?

94
--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
--------------------------------------------------------------------------------------------------------------------------------------------------
b) Whether the underground cables in
excavated trenches are laid at designed
depth with sand filling, brick
protection? (check at on Random trial
pit basis) Is u/g cable exposed at any
location?

c) Are the cables provided with


identification tags at intervals of
every 30 mts? (On Random Trial Pit
basis)

d) Whether all the cables throughout


their route protected mechanically
from any external damages?

e) Are the flameproof type terminations


for cables carried out in the
classified (Zone 1) areas?

f) Are the cable joints staggered and


having identification marks (when 2
or more cables laid in the same
trench)?

g) Is the oil seepage from process units


getting drained through or collected
in the cable trench/manholes?

h) Whether the armour of cables exposed at


the termination?

i) Are the cables directly taken to the


terminals without suitable cable
glands/clamps/armour earthing?

j) Are the cables above ground supported


with proper clamps?

k) Whether the cables :


(telephone/ power / lighting cables) are
taken through overhead system? (inside
Refinery / Process / Areas)? If so, what
is the arrangement?

l) Whether one run of earthing strip


fixed through the entire length of
cable Tray (wherever cable tray is
used) ?

95
--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
--------------------------------------------------------------------------------------------------------------------------------------------------

m) Whether proper mechanical protection


and water sealing arrangement
provided to cables especially at the
following locations:

- Road crossings
- Railway installations
- Cathodically protected u/g piping
- Water logged areas
- Drainage & other u/g facilities
- RCC structures/brick walls
- Where cables rise above ground

n) What are the fire protection arrangements


adopted for cables laid above ground?

o) Are the G.I. pipes (conduits) used for cable


entries (sleeves) sealed at both ends, and
conduits earthed?

p) Are all conduit ends for cables sealed at both


ends?

5.0 MOTORS CONTROL STATIONS

a) Whether there is annunciation facility in


case of failure of air supply ( wherever air
purging is used for flame proofness )? Is it
in working condition and monitored
regularly?

b) Is the approved inspection schedule


followed ? Records maintained?

c) Whether Terminal / junction Box properly


sealed / covered?

d) Is there any unauthorized modification


carried out ( by way of local fabrication etc.)
on the flameproof motors/control stations /
terminal boxes? ( to accommodate XLPE cable
termination etc.)

e) Whether the insulation resistance


values between phases and between
phases and earth of the motors are
within acceptable limits ? ( Select
a few critical motors at random)

f) Whether Emergency Isolating device


for the motor is installed near the
motor?

96
--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
--------------------------------------------------------------------------------------------------------------------------------------------------

g) Whether the double earthing provided


are from two separate distinct earth
connections of the grid?

h) Are the motors (75KW) provided with


spaceheater and local ammeters.

i) Whether painting of motor body


control station and supporting
structure are in good condition?

j) Whether there are motor guards


provided to prevent inadvertent
contact over the moving shaft?

k) Are the nameplates of Motors worn


out? Whether the inscriptions are
visible?

l) Whether the drive belts are


antistatic fire resistant type?

6.0 LIGHTING INSTALLATIONS

a) Whether separate distribution for


lighting system adopted from main
switchboard, through subdistribution/
fuse distribution & lighting panel final circuit boards?

b) Whether lighting provided is sufficient?


( compare with IES chart for required
levels of illumination at selected locations)?

c) Is there auto changeover system


provided for normal to emergency
system and if so, is it functioning
satisfactorily? (test this)

d) Whether the body of lighting fixtures


are separately earthed in addition to
cable armor earthing?

7. EARTHING & BONDING

a) Is the earthing carried out as per


IS:3043?

b) Is the earth leakage protection


wherever provided functioning
satisfactorily?

97
--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
--------------------------------------------------------------------------------------------------------------------------------------------------

c) Are the earth electrodes being tested


periodically? (Check the test records)

d) What is the grid resistance (in ohms)?


Is this periodically measured and recorded?

e) Whether all 3 phase equipments double


earthed and single phase equipment
single earthed?

f) Are all the loading arms earthed?

g) Is there earth continuity between the


flexible hoses and loading arms ?

h) Are the tanks, vessels, process


piping, steel columns, metallic
structures / sheds and buildings and
fencing etc. earthed?

I) Are the hardware used free from rust


or corrosion?

j) Are the Rail Tracks within the gantry


premises earthed and bonded?

k) Are the earthing connections to


lighting protection and electrical
system protection ( Neutral earthing
and body earthing) provided separately?

l) Whether there is any discontinuity of


earthing connections?

m) Whether the flexible wire used for


tanker body earthing ( TTL Gantry ) is
soldered to crocodile clips?

n) Whether crocodile clips have lost the


spring action causing improper grip
with the surface?

o) Whether earth jumpers across the pipe


flanges (of gantry piping) are provided?

p) Is the buried underground earth


conductors getting exposed at any
location?

98
--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
--------------------------------------------------------------------------------------------------------------------------------------------------

q) Whether the earth pits with chambers


are exposed and visible or is
embedded inside the loose earth?

r) Whether the earth strip connections


on the earth electrode are loose /
sheared off / tight?

s) Are the weigh bridge (truck) platforms


earthed?

t) Whether the earth strip joints are


having an overlapping equivalent to
the width of the strip (minimum) and
all the four sides are welded?

u) Whether all product and utility


pipelines earthed at every 25 meters
apart and also at the point where it
enters and leaves a shed, where
volatile liquids and vapors are handled?

v) Whether the earth strip runs


continuously through conveyers and
are the supporting structures also
earthed?

w) Whether all electronic equipments


which stores electrical energy are
properly earthed?

8.0 CAPTIVE GENERATION

a) Is the neutral of the generator


provided with an isolator?

b) Whether the neutral of the generator


is earthed by not less than two
separate and distinct earth
connections and whether the earthing
is after the isolator?

c) In case of High Voltage Generators


(Voltage above 650 V) whether the
neutral point is earthed by two
separate and distinct connections
with earth each having its own
electrode?

d) Whether the exposed wires near the


Generator/Generator to switch board
is in metallic conduit and the
conduit earthed?

99
--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
--------------------------------------------------------------------------------------------------------------------------------------------------

e) Whether the control panel for the


generator is earthed with two
separate and distinct connections with
earth?

f) Whether the generator panels are made


vermin proof?

g) Whether more than one generator is


provided, whether provision of
individual breakers are kept for
paralleling arrangement?

h) Whether danger notice is provided for


the generator enclosure?

i) Whether location (where generator is


installed ) is dry and dust free and
nearer to the loads?

j) Whether provided with fire and weather


proof enclosure with ventilation?

k) Whether the exhaust provision


provided is away from the enclosure?

l) Whether control panel is available


near to the generator, equipped with all
protections ( short circuit, overcurrent,
and earthfault)?

m) If synchronized with grid, whether


effective measures are available to
prevent backfeeding?

n) For Prime Mover where fuels like


Naphtha, LSHS are used additional
safety precautions should be taken.

9.0 BATTERY / CHARGER/UPS

a) What is the type of battery used?

b) Whether the Battery room is clean and


well ventilated? Are the floors acid
proof?

c) Whether exhaust fans provided ?

100
--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
--------------------------------------------------------------------------------------------------------------------------------------------------

d) Are the cell voltage, specific


gravity of cell, and level of the
electrolyte being checked and
recorded as per approved schedules?

e) Is there any corrosion on terminals /


connectors?

f) Whether all the safety equipment


(Rubber apron, goggles, acid proof
hand gloves etc.) are available?

g) Is the operation of UPS satisfactory?


(Test for critical services)

h) Whether trickle charger working and


checked properly.

10.0 ELECTRIC HEAT TRACING

a) Whether all indication lamps are


functioning properly in the panel to
ensure healthiness of tracer circuits.

b) What is the automatic control or


protection provided for temperature
raising above allowable limit?
(Especially at hazardous areas) Is
this being tested periodically for
proper functioning.

c) Are there damages to insulation /


traces?

d) Is the system water tight?

101
--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
--------------------------------------------------------------------------------------------------------------------------------------------------

11.0 PORTABLE APPARATUS/MOBILE EQUIPMENT


(ELECTRICAL BATTERY OPERATED)

a) Is the electrical system of the


portable apparatus/mobile equipment
provided with Intrinsically safe /
flameproof features when required
to be taken to the classified hazardous
areas? ( check test certificates)

b) Are safe voltage (24 volts) being


maintained for use of portable
appliances such as hand lamps, torches,
etc. (used for inspection / testing) especially
in classified areas?

c) Whether the flexible cables used for


portable tools are free from damages
and consisting of too many joints?
Are the cables protected from
mechanical damages ( by providing
metallic sleeves etc.)?

d) Whether the cables used for portable


tools/equipment are 3 core for single
phase and four core for three phase
equipment respectively? Whether the 3rd /
4th core is used to earth the metallic
body/screen covering of the cable?

e) Are the power cables used for


portable equipment such as welding
machines, generators, switchboards
etc., provided with 'armoring' and
`gland' type terminations? Is the
armoring bonded to earth?

f) Are the portable tools/equipment


being checked every time before use
that there is no earth leakage? Is it
ensured safe to use, by a "competent"
person before issuing.

g) Whether ELCB provided for portable


equipment?

h) Are the portable equipment, including


the electrical system in the mobile
equipment / vehicles (Battery Operated),
and test instruments and tools
inspected regularly?

102
--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
---------------------------------------------------------------------------------------------------------------------------------------------

i) Whether all wiring and current carrying parts


of an industrial electric truck, so constructed
and enclosed as to protect from mechanical
damages?

j) Whether any uninsulated current carrying part is


exposed especially on the outer surface of the truck?

k) Whether all the components are accessible for


maintenance/repairs?

l) Whether the battery has the protection by


means of a non combustible enclosure?

m) Are the Battery terminals provided with protective


rubber gloves?

n) Whether the battery enclosure is provided with


sufficient ventilation to minimize the possibility of
accumulation of explosive hydrogen air mixtures
above the battery?

o) Are there reported accidents due to improper


maintenance / the wrong use/wrong selection etc.
of Portable tools/Mobile equipment (Electrically
operated) in the last 2 years? (if so, verify the
accident investigation reports and
compliance of recommendations)

p) Whether connecting a welding machine


the return path of the welding
machine is directly connected to the work
piece with proper insulation?

103
SAFETY AUDIT CHECKLIST

10.0 CROSS-COUNTRY PIPELINE

CONTENTS
--------------------------------------------------------------------------------------------------------------------------------------------------
SECTION DESCRIPTION PAGE NO.
--------------------------------------------------------------------------------------------------------------------------------------------------

1) COATING CONDITION 81

2) CATHODIC PROTECTION 81

3) POWER SUPPLY TO CP STATION 82

4) ULTRASONIC THICKNESS SURVEY 82

5) INTERNAL CORROSION 82

6) PIGGING 82

7) INHIBITOR INJECTION 83

8) CPL/EWP SURVEY 83

9) SOIL TESTING 84

10) MAINLINE VALVE 84

11) HYDROSTATIC TESTING 84

12) PIPELINE PATROLLING 84

13) TELECOMMUNICATION & TELEMETRY 84

14) SINGLE BUOY MOORING SYSTEM 86

15) CONTINGENCY PLANS 87

16) DOCUMENTATION 87

104
SAFETY AUDIT CHECKLIST
ELECTRICAL SYSTEM

--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR'S REMARKS
--------------------------------------------------------------------------------------------------------------------------------------------------
1.0 COATING CONDITIONS:

1.1 Is rolling plan for pearson, coating conductance


and current drainage surveys made? Yes/No

1.2 If 'yes' is the schedule maintained Yes/No

1.3 Coating Condition (Survey report Satisfactory /


to be checked not Satisfactory

1.4 Type of coating and its application method .....

2.0 CATHODIC PROTECTION:

(No. of C.P. Stations .....Nos.)

2.1 After revisioning of coating whether PSP


readings are recorded and monitored to
observe improvements Yes/No

2.2 Periodic calibration of AC & DC volt


meter/Ammeter and PSP Meter of CP Units Yes/No

2.3 Number of insulating joints .....Nos.

2.4 Dielectric strength of Insulation Joints Satisfactory/


Not satisfactory
2.5 Is schedule made for inspection of
insulation joints/couplings (yearly) Yes/No

2.6 No. of test lead points for PSP Survey ..... Nos.

2.7 Condition of test led points

2.8 Is schedule made for PSP survey Good/Bad


(PSP readings at feeding points) (PSP readings at
Test lead points quarterly) Yes/No

2.9 If 'yes' the findings Satisfactory/


Not Satisfactory
2.10 If 'not satisfactory, any action plan
drawn for correcting the deficiencies
on short term and long term basis? Yes/No

2.11 (a) Effectiveness of C.P. (To check


PSP profile graphs in conjunction Satisfactory / Not Satisfactory
with CP station reports) Not Satisfactory

(b) Is any stretch of pipeline left


cathodically unprotected for a period more
than one year Yes/No
105
-------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
--------------------------------------------------------------------------------------------------------------------------------------------------

2.13 If 'YES' any action taken/plan drawn


for correcting the deficiencies Yes/No

2.14 Is the C.P. unit connected with


the earthing electrode ? Yes/No

2.15 Is the earthing resistance of


C.P. earthing electrode taken & record
maintained Yes/No

2.16 Are all the C.P. units provided


with the lightening arrestors Yes/No

2.17 Whether Lightening arrestor grid and


Equipment Earthing grids are segregated Yes/No

2.18 Safety aspects for fault condition


due to AC/DC power system -------

2.19 Is the ground bed circuit resistance


record maintained ? Yes/No

2.20 Is the di-electric strength of C.P. transformer


oil checked ? Yes/No

3.0 POWER SUPPLY TO CP STATION

3.1 Inspection of source .....

3.2 Power availability of CP


stations, average ........hrs./day

3.3 Condition of back up power Satisfactory/


supply, if any. Not Satisfactory

4.0 ULTRASONIC THICKNESS SURVEY

4.1 Is schedule made and followed for


thickness survey of mainline at :

4.1.1 Exposed section of Pipelines Yes/No

4.1.2 Sharp pipe bends/Riser bends Yes/No

4.2 If 'Yes", the findings Satisfactory/ Not satisfactory

4.3 If 'NOT SATISFACTORY', any


action plan for correcting
the deficiencies drawn Yes/No

4.4. Is two yearly schedule made for


thickness survey of unprotected
pipeline section from I/F to
scrapper launcher/receiver Yes/No
106
--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
--------------------------------------------------------------------------------------------------------------------------------------------------

5.0 INTERNAL CORROSION

5.1 Whether coupons are installed Yes/No

5.2 If yes, corrosion rate < 1 MPY 1 to 4.9 MPY/


> 4.9 MPY

5.3 Whether Electrical Resistance


probes are installed Yes/No

5.4 If yes, corrosion rate ? .....

6.0 PIGGING

6.1.0 Descaling

6.1.1 Is schedule made for pigging ? Yes/No

6.1.2 And,is followed Yes/No

6.1.3 Is pig residue/dirty product


analysis carried out? Yes/No

6.1.4 If yes, what is the value of


a) Fe 0 % by mass .....
b) Water, % by mass .....
c) pH value .....
d) Acidity, mg KOH/gm, .....

6.1.5 Based on pig residue analysis Satisfactory/Not satisfactory


internal condition of pipeline

6.2.0 Intelligent Pigging

6.2.1 Is any IPS survey carried


out ? Yes/No

6.2.2 If no, any schedule made for


carrying out the survey (once in
five years). Yes/No

6.2.3 If the survey has been carried


out, findings of the survey,
(To check the reports). Satisfactory /Not satisfactory

6.2.4 If not satisfactory, any


action plan has been drawn
to implement the recommendations Yes/No

7.0 INHIBITOR INJECTION

7.1 Is inhibitor injection being


done and records maintained Yes/No

107
--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
--------------------------------------------------------------------------------------------------------------------------------------------------

7.2. Average dosing of corrosion


inhibitor injection ...PPM/day

8.0 CPL/EWP SURVEY

8.1 Is any CPL/EWP SURVEYS CARRIED OUT Yes/No

8.2 If No, any schedule made for Yes/No


Carrying out the survey
(once in five years)

8.3 If the survey has been carried out,


what are the findings (To check the report) Satisfactory/Not Satisfactory

8.4 If not satisfactory, any action plan has been


drawn to implement the recommendations. Yes/No

9.0 SOIL TESTING

9.1 Soil samples within ROW being


tested once in five years. Yes/No

9.2 Is there any industrial affluent


flowing over the ROW Yes/No

9.3 If `yes', said sample tested to


determine the efficacy of the
existing coating of the pipe lines. Yes/No

9.4 Variations observed in soil resistivity .....

10.0 MAINLINE VALVE


(NO. OF MAINLINE VALVES .... NOS.)
10.1 Is schedule made for maintenance
of mainline valve Yes/No

10.2 If `yes', schedule followed and


valves operating freely. Yes/No

10.3 Supply to Motor Operated Valves


(MOV) available Yes/No

10.4 MOV working Locally/Remotely

11.0 HYDROSTATIC TESTING

11.1 Whether all repaired piping system are being


tested in accordance with OISD - 141&API -
1110 Yes/No

11.2 Whether sufficient number of pipe lengths, pretested


and kept at vulnerable locations for replacement
if required Yes/No
108
--------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
--------------------------------------------------------------------------------------------------------------------------------------------------

12.0 PIPELINE PATROLLING

(Total length of Pipeline .....km)

12.1 Is the schedule made for

12.1.1 Ground Patrolling by Patrolman


each segment twice in a week
by physical walking. Yes/No

12.1.2 Helicopter surveillance


once in a month Yes/No

12.1.3 Right of way inspection and


maintenance of above ground
structures along ROW once
in a year Yes/No

12.1.4 Inspection of Pipeline crossings at

12.1.4.a Rail/Road Bridge and suspended


crossing (exposed pipeline)
quarterly Yes/No

12.1.4.b Road/Highway crossing


quarterly Yes/No

12.1.4.c Submerged river crossing


before and after monsoon Yes/No

12.2 If reply to the above is yes,


whether various reports filled/
monitored regularly and proper
checks on line patrolman
exercised ...

13.0 TELECOMMUNICATION & TELEMETRY


(NO.OF REPEATER STN...NOS)

13.1 Availability of Power supply Yes/No

13.2 If no, (other than load shedding)


corrective action taken Yes/No

13.3 Whether all the lights and


fans are working ? Yes/No

13.4 State Electricity Board Energy


Meter working ? Yes/No

13.5 Energy Meter Readings being noted Yes/No

13.6 All the Radio Parameters as per


109
-------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
--------------------------------------------------------------------------------------------------------------------------------------------------
format are being checked Yes/No

13.7 Whether all the Radio Units are


in working condition ? Yes/No

13.8 If no, number of faulty units ... Nos.

13.9 Whether Engineering order wire


(E.O.W) working. Yes/No

13.10 Whether Rooms are in dust


free condition Yes/No

13.11 Whether all the parameters of


charger are properly working. Yes/No

13.12 Whether all the Battery voltages are


(should be above 2 volts)being checked Yes/No

13.13 Sick cells, if any, are being


identified and corrective action taken Yes/No

13.14 Whether specific Gravity of all the


cells recorded in a register Yes/No

13.15 Sufficient reserve of distilled


water available Yes/No

13.16 Check for the proper running


of D.G. Set carried out. Yes/No

13.17 Auto change over working ? Yes/No

13.18 Is it free from leakages ? Yes/No

13.19 Whether Diesel Tank of DG


set is full Yes/No

13.20 Whether all the alarms are


in working order ? Yes/No

13.21 Whether no. of fire buckets/


extinguishers adequate and
in working order ? Yes/No

13.22 Whether aviation tower lights


are in working condition ? Yes/No

13.23 Whether twilight switches


are in working condition ? Yes/No

13.24 Whether the tower painting is


done as per rolling plan ? Yes/No

13.25 Check the resistance of lightning


110
-------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
--------------------------------------------------------------------------------------------------------------------------------------------------
arrestor (better than 2 ohms)

13.26 Whether Telecommunication link


VHF/UHF/Microwave/Fiber optics
is available ? Yes/No

13.27 Whether all the desired telesupervisory


signals are passed on to master control
station through remote terminal Unit
(RTU) and data monitored? Yes/No

13.28 Functional test of telecommunication/


telemetry system are being carried
out daily Yes/No

13.29 Telecommunication / Telemetry


equipments are being inspected
as per manufacturer's recommendations Yes/No

13.30 Pressure/Temperature/Flow recorder


charts are in working order and
are being checked for its safe limits Yes/No

13.31 Maintenance and inspection of


safety instrumentation are being followed
as per OISD-153. Yes/No

13.32 Whether Unauthorized Entry Alarm /


Signal system is in working condition? Yes/No

14.0 SINGLE BUOY MOORING SYSTEM

14.1 Whether the following items are being


inspected daily and records kept ?
- Free floatation of buoys Yes/No
- Draft Yes/No
- Free movement of rotating assembly Yes/No

14.2 Whether following items are being inspected


weekly and records kept ?

- Mooring ropes and ancillary equipments Yes/No


- Batteries Yes/No
- Navigational aids Yes/No

14.3 Whether visual inspection of buoys


and equipments for external corrosion
is carried out on monthly basis ? Yes/No

14.4 Whether following item are being inspected


on quarterly basis ?

- Anchor chains of buoys for wear


tear and tension Yes/No
- Fenders for damage Yes/No
111
-------------------------------------------------------------------------------------------------------------------------------------------------
ITEM AUDITOR’S REMARK
-------------------------------------------------------------------------------------------------------------------------------------------------
- Draft of buoys Yes/No
- Hose configuration Yes/No
- Hose with respect to PLEM Yes/No
- Sacrificial anodes Yes/No
- Swivel joints and turn tables Yes/No

14.5 Whether following items are being


inspected annually ?

- Expansion joints Yes/No


- Oil swivel seals Yes/No

14.6 Whether inspection of Hoses are


being done as per the requirements
of OISD-STD-135 Yes/No

15.0 CONTINGENCY PLANS:

15.1 Is there updated contingency


plans for emergencies at ?

- Installations Yes/No
- Mainlines Yes/No
- Off-shore facilities Yes/No

15.2 Is the contingency plans(s)


displayed in conspicuous place ? Yes/No

15.3 Are all the employees familiar


with it ? Yes/No

15.4 Is the list of Mainline emergency


equipments/tools available ? Yes/No

15.5 Are the mainline emergency equipments/


tools stacked separately and marked for
easy identification ? Yes/No

16.0 DOCUMENTATION

16.1 Whether the basic datas and parameters


of the Pipelines/SBM system layout,
length, diameter etc. are available in
Pipeline installation ? Yes/No

16.2 Whether complete route strip map


showing all the details of the
passage of the pipeline and all
isolation M/L valve locations
are available on record in
Pipeline installation? Yes/No

16.3 Whether list of various codes to


which Pipeline and SBM systems ?

112
<< Back Home Next >>