OISD-GDN-145

Sr.Number:OISD/DOC/2013/172 Page No. I OISD - GDN - 145 REVISION - 1 FOR RESTRICTED CIRCULATION ONLY GUIDELINES ON INTERNAL SAFETY AUDITS (PROCEDURE AND CHECKLISTS) OISD-GDN-145 Revision - 1 First Edition, July 1995 Amended Edition, September 2001 Oil Industry Safety Directorate Government of India Ministry of Petroleum & Natural Gas 8th Floor, OIDB Bhavan, Plot No. 2, Sector – 73, Noida – 201301 (U.P.) Website: www.oisd.gov.in Tele: 0120-2593800, Fax: 0120-2593802 Sr.Number:OISD/DOC/2013/172 Page No. II 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 8th Floor, OIDB Bhavan, Plot No. 2, Sector - 73 Noida – 201301 (U.P.) Sr.Number:OISD/DOC/2013/172 Page No. III Preamble Indian petroleum industry is the energy lifeline of the nation and its continuous performance is essential for sovereignty and prosperity of the country. As the industry essentially deals with inherently inflammable substances throughout its value chain – upstream, midstream and downstream – Safety is of paramount importance to this industry as only safe performance at all times can ensure optimum ROI of these national assets and resources including sustainability. While statutory organizations were in place all along to oversee safety aspects of Indian petroleum industry, Oil Industry Safety Directorate (OISD) was set up in 1986 Ministry of Petroleum and Natural Gas, Government of India as a knowledge centre for formulation of constantly updated world-scale standards for design, layout and operation of various equipment, facility and activities involved in this industry. Moreover, OISD was also given responsibility of monitoring implementation status of these standards through safety audits. In more than 25 years of its existence, OISD has developed a rigorous, multi-layer, iterative and participative process of development of standards – starting with research by in-house experts and iterating through seeking & validating inputs from all stake-holders – operators, designers, national level knowledge authorities and public at large – with a feedback loop of constant updation based on ground level experience obtained through audits, incident analysis and environment scanning. The participative process followed in standard formulation has resulted in excellent level of compliance by the industry culminating in a safer environment in the industry. OISD – except in the Upstream Petroleum Sector – is still a regulatory (and not a statutory) body but that has not affected implementation of the OISD standards. It also goes to prove the old adage that self-regulation is the best regulation. The quality and relevance of OISD standards had been further endorsed by their adoption in various statutory rules of the land. Petroleum industry in India is significantly globalized at present in terms of technology content requiring its operation to keep pace with the relevant world scale standards & practices. This matches the OISD philosophy of continuous improvement keeping pace with the global developments in its target environment. To this end, OISD keeps track of changes through participation as member in large number of International and national level Knowledge Organizations – both in the field of standard development and implementation & monitoring in addition to updation of internal knowledge base through continuous research and application surveillance, thereby ensuring that this OISD Standard, along with all other extant ones, remains relevant, updated and effective on a real time basis in the applicable areas. Together we strive to achieve NIL incidents in the entire Hydrocarbon Value Chain. This, besides other issues, calls for total engagement from all levels of the stake holder organizations, which we, at OISD, fervently look forward to. Jai Hind!!! Executive Director Oil Industry Safety Directorate Sr.Number:OISD/DOC/2013/172 Page No. IV 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 (Procedure and checklists) was revised by a Functional Committee constituted 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 8th Floor, OIDB Bhavan, Plot No. 2, Sector - 73 Noida – 201301 (U.P.) . Sr.Number:OISD/DOC/2013/172 Page No. V NOTE 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 Ministry 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 amendments approved in the 19th Safety Council meeting held in September, 2001July, 1999 Sr.Number:OISD/DOC/2013/172 Page No. VI 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. 3.2. 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-144.2. In the case of terminals where pipeline transfer is taking place.5.Sr. VII SCOPE These guidelines are applicable for refineries/on-shore gas processing units(excluding all oil-field operations)/ and marketing installations.6 and 9 would be applicable. 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.8 will be applicable . 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 1.9 and 10 will be applicable. However. In the case of terminals where no pipeline transfer is taking place.5.6.7. chapters 1.3.2. 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).Number:OISD/DOC/2013/172 Page No.3. Items which may not be applicable in Marketing have been separately identified by an asterisk (*) mark. chapters 1. (R&P Division . ( Marketing ) Shri T.Ananthakrishnan Indian Oil Corporation Ltd. Ahmed Indian Oil Corporation Ltd. Shri D.Sr.Bhaskar Rao Hindustan Petroleum Corporation Ltd. MEMBER CO-ORDINATOR Shri S.Number:OISD/DOC/2013/172 Page No.N.T.K. review and finalisation of this document. Ray Ex-Official Bharat Petroleum Corporation Ltd.Madhusudanan Cochin Refineries Ltd.Madhukar Rao Gas Authority of India Ltd.Charvethia Bharat Petroleum Corporation Ltd.Pipelines) Shri S. ( Refineries ) Shri C. .C.Shroff Hindustan Petroleum Corporation Ltd.J. (Refineries & Pipelines Division) Shri G.Sharma Bongaigaon Refinery & Petrochemicals Ltd Shri M. several other experts from Industry contributed on the preparation. VIII COMMITTEE ON `INTERNAL SAFETY AUDITS' REVISION-I -------------------------------------------------------------------------------------------------------------------------------------NAME ORGANISATION -------------------------------------------------------------------------------------------------------------------------------------LEADER Shri Barath Balan Hindustan Petroleum Corporation Ltd.Rao Indian Oil Corporation Ltd. (Marketing Division) Shri K. (Marketing) MEMBERS Shri M.C. Gupta Oil Industry Safety Directorate -------------------------------------------------------------------------------------------------------------------------------------In addition to the above. ( Refineries ) Shri I.S. ( Refinery ) Shri S.N. 145 REVISION-I GUIDELINES ON INTERNAL SAFETY AUDITS SECTION .1 SECTION .Number:OISD/DOC/2013/172 Page No.Sr.GDN .2 INTERNAL SAFETY AUDIT PROCEDURE INTERNAL SAFETY AUDITS CHECKLISTS . IX OISD . 4 Use of Safety Audit Check Lists 3 5.1 Frequency of Audits 5. -------------------------------------------------------------------------------------------------------------------------------------1. DESCRIPTION PAGE NO.6 Briefing 3 5.0 OBJECTIVES OF SAFETY AUDITS 1 3.2 Formulation of multi-disciplinary 2 Audit Teams 3 5.0 IMPLEMENTATION OF RECOMMENDATIONS 4 ----------------------------------------------------------------------------------------------------------------------- .0 TYPES OF SAFETY AUDITS 1 5.7 Site Inspections 3 5.0 INTRODUCTION 1 2.Number:OISD/DOC/2013/172 Page No.3 Duration of Audits 3 5.8 Discussions 3 5. NO.9 Study of Documents 4 6.0 SCOPE OF SAFETY AUDITS 1 4.5 Preparation before Site Visits for Safety Audits 3 5.0 METHODOLOGY OF INTERNAL SAFETY AUDITS 2 5.0 FOLLOW UP OF AUDIT REPORTS 4 8.0 PREPARATION OF AUDIT REPORTS 4 7.1 INTERNAL SAFETY AUDITS PROCEDURES -------------------------------------------------------------------------------------------------------------------------------------SL. X SECTION .Sr. training.” . External Safety Audits will be carried out by outside teams consisting of technical experts from other organizations in oil industry. standards. work practices are as per those stipulated in the manuals and standards. Safety audit is an important tool in undertaking this function.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 Audit conducted by Internal Audit teams of the organisation is categorized as Internal Safety Audit. training. Electrical. To identify any design deficiencies and also any weaknesses which might have cropped up during modifications / additions of facilities. Mechanical. 4. design (Process. which might have degraded with time. accident records. To check the compliance of statutory regulations.0.0 INTRODUCTION Identification of vulnerable areas and specific potential hazards. attitudes. To ensure that fire protection facilities and safety systems are well maintained.0 OBJECTIVES OF SAFETY AUDITS While the basic aim of safety audits is to identify the areas of weaknesses and strengths. etc. layout and construction of the plant. This includes all the components of the system viz. is one of the prime function of loss prevention in oil industry. preparedness disaster management etc. codes.Sr. emergency plans. To ensure that operating / maintenance procedures. management policy.1. personal protection standards. 6. professional bodies and statutory authorities under the overall coordination of OISD. safety audits are undertaken to meet different specific objectives viz. “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines. 4. 2. 3. for handling emergencies and for safe 3.The methodology for carrying out such Internal Safety Audit is described in greater detail under paras 5. As a social objective to cater to public opinion and concern environment.Number:OISD/DOC/2013/172 Page No.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. 2.0 to 8.) aspect. To check on security. Internal Safety Audits will be coordinated by local management under the overall direction from the Corporate Office. This also improves public relation of the organization. etc. operating Inspection & Maintenance procedures. 5. 1 OISD – GDN – 145 INTERNAL SAFETY AUDITS PROCEDURES INTERNAL SAFETY AUDITS PROCEDURES 1. Instrumentation. however. Group . IV . Group . Bitumen filling and dispatch facilities.1 FREQUENCY OF AUDITS: All the facilities in a particular Refinery/Installation should be covered minimum once every year. 2 OISD – GDN – 145 INTERNAL SAFETY AUDITS PROCEDURES 5. The composition of the Internal Safety Audit may vary depending on the Group and areas to be audited. Warehouse Laboratories etc. Kero / Diesel HDS etc. Process / Production.B Visbreaking. “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines. Water Block.VI Miscellaneous other facilities such as Workshops. Group .2 FORMATION OF MULTI-DISCIPLINARY AUDIT TEAMS: The Internal Audits should be carried out through multidisciplinary audits teams. One of the team members should be nominated as the leader of the audit team.0 METHODOLOGY OF INTERNAL SAFETY AUDITS 5. IV . The suggestive groupings in case of a Refinery Installation are given below. Coking.VII General Audit. 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.V Power House. In multi-unit organizations. Group – II All dispatch facilities like Tank-Wagon loading Tank . Group -I All LPG Storage. the team members could also be drawn from the Head Office / Corporate Office and other operating Units under its control.Number:OISD/DOC/2013/172 Page No. Cat-Reforming.A Atmospheric / Vacuum Units IV . However. Fire Fighting and Safety. Layouts etc. Effluent Treatment.Sr. However. filling & dispatch facilities.E N2 & Others. including TEL blending) Group . For this purpose. 5. facilities' design can be audited every 3 years or after any major modification or additions. The areas to be audited should be clearly identified and logically grouped. Electrical Sub-stations.IV PROCESS UNITS : Sub Groups IV . Maintenance / Inspection. Bitumen Blowing Units.lorry loading. Group . Utilities. In case of LPG bottling plants the internal safety audit should be conducted minimum once a year as per OISD-STD-144.D Naphtha HDS. Similar groupings can be done for other types of Installations. Electrical. person(s) concerned should have necessary experience and background to undertake in-depth audit in a particular discipline. Fire & Safety and with the activity involvement of concerned Plant / Area Manager is suggested. A team of 4 to 5 experienced officers from various disciplines viz.III Oil Movement & Storage (OM&S) (Rest of all the facilities other than those covered under Group I & II.C Secondary Processing Unit like FPU / Units. FCCU/HCU & H2 along with Treating IV . this could be modified depending upon layout and complexity of the individual installation.” . Layouts . Maintenance. a Check List is a means of pooling the knowledge and hard won experience and ensures that no important aspect is overlooked or forgotten. In Section-II of this document. Inspection should be carried out accompanied by Installation / Plant Manager or the assigned officials. 5. 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.” . Instrumentation. 5. Electrical. All the audit team members should study these documents in advance to know the details of the installation.OISD – GDN – 145 Sr.Number:OISD/DOC/2013/172 Page No. it would be essential to study all relevant documents as below to get complete picture : . with site personnel and Installation / Plant Manager. The audit team should interact with persons from various disciplines such as Production. Depending upon the nature of audit more emphasis can be given to study specific documents. / Inspection Manuals . detailed model Checklist covering important areas are given. “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines.4 USE OF SAFETY AUDIT CHECK LISTS Check lists are the most useful tool for undertaking systematic Safety Audit.5 PREPARATION BEFORE SITE VISITS FOR INTERNAL SAFETY AUDITS: Before the safety Audit team visits any particular facility for carrying out Safety Audit.Fire and Safety Manuals. Like a code of practice. It is suggested that oil industry members should adopt these model check lists for carrying out Internal Safety Audits. 5. the duration of internal safety Audit can be fixed. This may vary from 2 to 7 working days for facilities under each group. observations should be recorded in separate sheet. etc.8 DISCUSSIONS: Further information can also be gathered through discussions (formal & informal). etc. Even for a skilled and well qualified engineer a good check list would be necessary as a guide. 3 INTERNAL SAFETY AUDITS PROCEDURES 5.Maint..P & IDs . who is in-charge of the area or other site officers. 5.Operating Manuals .7 SITE INSPECTIONS: Most of the information could be gathered through site inspection using ready-made check lists.6 BRIEFING: Before beginning of each audit. No impression should be left that audit will throw bad light on them. The auditors should enter their observations under the remarks column and not simply state "yes" / "no". Wherever necessary. Such check lists help maintaining uniformity and speeding up the audits.3 DURATION OF AUDIT Depending on the nature of audit and type / complexity of the installations in the selected group. all concerned persons of the area/installation be briefed by the team leader about the purpose of the audit. 5. Only the appointing authority should exercise judgement in rejecting any of the recommendations. Additions or deletions could be made in the draft report based on the discussions and comments received during the presentation. 6. but not the solution. The crux of the safety audits lie in removing the weakness identified during the audit. This approach is always constructive and does not undermine the technical competence of the audit team. other documents. “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines. such as Operating Instructions. A senior person should be nominated for coordinating implementation of all accepted recommendation under a time bound program. Accident Records. Senior management should review the progress of implementation of recommendations periodically through Management Safety Committee meetings and other review meetings. Minutes of Safety Committee Meetings etc. Wherever the necessary in-house expertise is not available for detailed studies. 8. Log sheets. Standing Orders. 7. Sometimes audit reports identify only the problem / weakness. the Safety Audit Team can give a presentation as feedback to the Operating / Management personnel of the Area / Installation. it would be necessary to undertake a detailed study of the specific area and to identify the rectification measures.Number:OISD/DOC/2013/172 Page No.9 STUDY OF DOCUMENTS: In addition to the documents which are already studied before inspection of the facilities. Before finalizing the report. help of consultants / professional bodies should be sought for. may also be studied as required. Log Books. the Internal Safety Audit Reports are submitted to the concerned authority who appoints the audit team for undertaking needful follow up actions. 4 INTERNAL SAFETY AUDITS PROCEDURES 5. In such cases.0 FOLLOW UP OF AUDIT REPORTS Generally.0 IMPLEMENTATION OF RECOMMENDATIONS The final and most important phase is the implementation of recommendations.” .OISD – GDN – 145 Sr. The appointing authority shall be of senior management level ( General Manager and above ).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. 5 INTERNAL SAFETY AUDITS PROCEDURES SECTION : 2 INTERNAL SAFETY AUDITS CHECKLISTS “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines.” .OISD – GDN – 145 Sr.Number:OISD/DOC/2013/172 Page No. CHECK LIST NO. LPG BOTTLING AND DISPATCH OISD-GDN-145-08 73 9. PROCESS PLANTS OISD-GDN-145-04 30 5.Number:OISD/DOC/2013/172 Page No. CHAPTER SAFETY AUDIT PAGE NOS. ------------------------------------------------------------------------------------------------------------------------------------------------1.” .Sr. LPG BULK LOADING / UNLOADING OISD-GDN-145-07 65 8.COUNTRY PIPELINES OISD-GDN-145-10 99 ANNEXURE 108 --------------------------------------------------------------------------------------------------------------------------------------- “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines. 6 OISD – GDN – 145 INTERNAL SAFETY AUDITS PROCEDURES SECTION : 2 INTERNAL SAFETY AUDIT CHECKLIST CONTENTS ----------------------------------------------------------------------------------------------------------------------Sr. POL LOADING AND UNLOADING OISD-GDN-145-06 57 7. FIRE PROTECTION OISD-GDN-145-02 16 3. GENERAL SAFETY AUDITS OISD-GDN-145-01 8 2. CROSS . LAYOUTS OISD-GDN-145-03 23 4. ELECTRICAL SYSTEM OISD-GDN-145-09 84 10. OIL STORAGE AND MOVEMENT OISD-GDN-145-05 41 6. 7 House Keeping Machine Guarding General Safety features Maintenance of Tools and Tackles Materials handling Personnel Protective Equipment Toxic Materials and Occupational Health 8 8 8 8 8 9 9 9 10 10 10 10 10 11 11 11 11 3.4 4.145-01 REVISION I SAFETY AUDIT CHECKLIST No.Number:OISD/DOC/2013/172 Page No.OISD-GDN-145-01 GENERAL SAFETY AUDITS CONTENTS --------------------------------------------------------------------------------------------------------------------------SECTION DESCRIPTION PAGE NO.1 1.1 2.2 1. ACCIDENTS AND NEAR MISSES 12 4.7 1.0 EMPLOYEE TRAINING 12 4.6 2.5 Reporting formats Reporting Procedures Follow up of Recommendations Maintenance of Records & Data Review of Accidents Data “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines.3 1.8 Management Philosophy Procedures Safety Audits Safety Committee Meetings Safety consciousness & Propagation Work Permit System Contingency/ Disaster Plan Plant Security 2.4 2.0 INDUSTRIAL HAZARD CONTROL 2.3 4.4 1.3 2.6 1.Sr.2 2.5 1. 7 OISD – GDN – 145 INTERNAL SAFETY AUDITS PROCEDURES OISD-GDN .2 4.0 ORGANISATION AND ADMINISTRATION 1.1 4.” 12 12 12 12 13 .0 FIRES.5 2. -----------------------------------------------------------------------------------------------------------------------1. 2 PROCEDURES a) Whether procedures are well defined and manuals are available & accessible plant / facility wise for the following functions ? .Electrical .0 ORGANIZATION AND ADMINISTRATION: 1.Fire fighting & Safety .Instruments .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.Civil .Operation .OISD – GDN – 145 Sr.” . 8 INTERNAL SAFETY AUDITS PROCEDURES OISD-GDN-145-01 SAFETY AUDIT CHECKLIST 1.Mechanical .4 SAFETY COMMITTEE MEETINGS Whether Safety Committee Meetings are held regularly ? “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines.Number:OISD/DOC/2013/172 Page No.0 GENERAL SAFETY AUDITS -----------------------------------------------------------------------------------------------------------------------ITEM AUDITOR REMARKS ------------------------------------------------------------------------------------------------------------------------1.Inspection and maintenance .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. for emergency uses? d) Whether these plans concerned authorities ? are central approved by e) Are mock drills being conducted ? f) Whether the feed back generated from mock drills is utilized to improve the plans? “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines. 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 ? .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 place.Type .Safety precautions at strategic points through sign boards.sequence of operations where critical / batch operations are performed.Safety posters/slogans.Participants Any other Motivation scheme exists ? 1.5 SAFETY CONSCIOUSNESS & PROPAGATION a) Whether following items have been taken care of ? Display of (in languages widely understood) .Number:OISD/DOC/2013/172 Page No.Frequency . . 9 INTERNAL SAFETY AUDITS PROCEDURES -------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK ------------------------------------------------------------------------------------------------------------------------------------------------1.OISD – GDN – 145 Sr.” . .6 WORK PERMIT SYSTEM Whether work permit system meet the requirements of OISD Standards 105/137 ? 1. 10 INTERNAL SAFETY AUDITS PROCEDURES -----------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK ------------------------------------------------------------------------------------------------------------------------------------------------1.0 INDUSTRIAL HAZARD CONTROL 2. if so.” .Stairway surfaces -------------------------------------------------------------------------------------------------------------------------------------------------“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines.8 PLANT SECURITY a) Whether installation has wall/fence as per prescribed norms? boundary b) Whether gates are manned? c) Whether identity badges/cards are issued and worn by employees. how much percentage is covered under each category? f) Whether Crisis Management Scheme for BOMB Threat exists? g) Whether watch towers exist? 2.Rotary equipment in operating areas .Number:OISD/DOC/2013/172 Page No.2 MACHINE GUARDING 2.Workshops .1 HOUSE KEEPING - 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 Ratings * 1 2 - - - .unprotected Floor openings protected . 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.OISD – GDN – 145 Sr.Slippery defective floors .3 GENERAL SAFETY FEATURES Check For: .Others - - 2. ” .OISD – GDN – 145 Sr.Walk ways in tank farm area .5 MATERIALS HANDLING( Mechanised/ manual) Whether safe lifting methods and proper protective equipment are used? 2.to 1.All intrinsic safety devices (For refinery. Section 2.Number:OISD/DOC/2013/172 Page No.6) as per requirement? c) Is storage of toxic materials proper? d) Is disposal of containers of toxic materials safe ? -------------------------------------------------------------------------------------------------------------------------------------------------“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines.7 TOXIC MATERIALS AND OCCUPATIONAL HEALTH a) Are there any toxic materials in use ? b) Whether relevant personnel protective equipment is available (Ref.ref.7 of OISD145-04) *Ratings:(Notation Followed) 1: Not meeting requirement 2: Meeting requirements satisfactorily 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.Inadequate illumination .Cross-overs over piping .4 MAINTENANCE OF TOOLS AND TACKLES * Whether all lifting tools and tackles are tested as per statutory requirements and record maintained? 2.Ventilation .Platforms/Hand rails . 11 INTERNAL SAFETY AUDITS PROCEDURES ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------. accidents causing injuries to personnel and damage to equipments and products (without the explosion/ fire) .” . 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. ACCIDENTS AND NEAR MISSES 4.fires and explosions .t safety procedures? f) Whether the T/T crew are trained as per the C.STD-154 w.OISD – GDN – 145 Sr.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 performance? are Motivated for safety e) How the contractor personnel are trained/briefed w.Rule 9 ? 4.r.Number:OISD/DOC/2013/172 Page No.Near misses -------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines.1 REPORTING FORMATS Whether reporting formats as per OISD-GDN-107 are available for (preferably separate)? .V.0 EMPLOYEE TRAINING a) Whether the training given for all employees (operators / technicians / engineers) is in line with OISD.M. 12 INTERNAL SAFETY AUDITS PROCEDURES 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. and records maintained thereof? Whether material safety data sheet displayed Note 3 3.0 FIRES. 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? .3. 13 INTERNAL SAFETY AUDITS PROCEDURES ------------------------------------------------------------------------------------------------------------------------------------------------4.2 Dissemination a) Whether the procedures /systems are established & streamlined for dissemination of information? b) What is the MIS upto Chief Executives level w.3.5 REVIEW OF ACCIDENTS DATA a) Is there any system to periodically review the trends of accidents for taking necessary actions ? -------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines.Number:OISD/DOC/2013/172 Page No.r.3 FOLLOW UP OF RECOMMENDATIONS 4.” .t specific case . accidents and near misses? 4.OISD – GDN – 145 Sr.1 a) Implementation Whether responsibility is assigned implementing the recommendations? for b) Whether the recommendations are implemented with time bound schedules? c) How far the recommendations arising out of previous accidents are implemented? 4.based on particular area/type 4.r.t information on fires.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.w. Number:OISD/DOC/2013/172 Page No.OISD – GDN – 145 Sr. to review the safety performance and new goals are set up? “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines. 14 INTERNAL SAFETY AUDITS PROCEDURES ------------------------------------------------------------------------------------------------------------------------------------------------b) Whether any review is under taken at top management/ corporate level periodically.” . 8 Fire water Fire Hydrant System Foam System Fire Station Fire Extinguishers Fire Hoses and Accessories Protective/ Safety Equipment Others 16 17 17 18 18 18 19 19 3.4 3.” .0 PROCEDURES 20 3.6 2.1 3.5 Organisations Disaster Management Plan Inspection and Testing facilities Training Checklist for DMP 20 20 21 21 22 “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines.2 2.0 FACILITIES 16 2.Sr. -----------------------------------------------------------------------------------------------------------------------1. 15 OISD – GDN – 145 INTERNAL SAFETY AUDITS PROCEDURES OISD-GDN-145-02 REVISION I SAFETY AUDIT CHECKLIST FIRE PROTECTION CONTENTS --------------------------------------------------------------------------------------------------------------------------SECTION DESCRIPTION PAGE NO.0 PHILOSOPHY AND STANDARDS 16 2.3 2.Number:OISD/DOC/2013/172 Page No.7 2.2 3.4 2.3 3.5 2.1 2. 3. Since the scope under each query is too broad and it is difficult to give simple answers. 1.Are emergency control procedures adequately established. Are the facilities adequate for anticipated fires ? and reliable 2.Number:OISD/DOC/2013/172 Page No.1 Fire water storage a.” . FIRE PROTECTION -------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR'S REMARKS --------------------------------------------------------------------------------------------------------------------------------------In order to evaluate the adequacy of fire fighting facilities and procedures. 16 INTERNAL SAFETY AUDITS PROCEDURES OISD-GDN-145-02 SAFETY AUDIT CHECKLIST 2.0 FACILITIES Whether following facilities are provided adequately and have the necessary efficacy. What's the internal replenishment rate ? “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines.1. answers should be obtained for the following four basic queries: 1. What is the capacity & how was it determined b. Is it sufficient ? Is the storage AG/UG or other wise ? c. these are divided into a number of simpler items/ questions which could be evaluated/answered with reasonable clarity. 2.OISD – GDN – 145 Sr. What are replenishment source ? Are they adequate ? d.0 PHILOSOPHY AND STANDARDS Does basic philosophy for designing the fire fighting facilities follow OISD 116 (for Refinery).1 FIRE WATER 2.Is manpower available and effectively trained to handle the fire fighting equipment.OISD 117(for Marketing-POL) and OISD 144 (LPG bottling plants) as necessary ? 2. 116/ 117/144.Number:OISD/DOC/2013/172 Page No. 2.3 a.1. What's the power source ? How many are diesel & elect driven ? c. e.2. What's the condition of battery of diesel engine ? j. 2. d. 2.2. Please comment on the system as per the following. Are the fire water pumps/engines started & observations logged as per OISD Std. 17 INTERNAL SAFETY AUDITS PROCEDURES -------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK 2.2 FIRE HYDRANT SYSTEM Check and comment on the hydrant system layout design position of hydrants/monitors.2 Fire Water Pump : a. What's fire water pump starting system manual/auto ? I. condition of pipeline etc. flow rate pressure at the farthest point.Grid type/Closed type/Any other Mains What's the material of construction of pipes ? How corrosion protection is ensured ? How is the sectionalising of hydrants system ? How are the spacings between hydrants Are monitors / hydrants properly distributed in critical areas and all facilities covered ? Are these hydrants/monitors easily accessible and operable ? Is the layout vulnerable at any points from fire hazard FOAM SYSTEM What are the types of foam available? What are the dilution potential and the quantities ? What are the storage arrangements and its accessibility Do the coverage and application rate for floating roof/fixed roof tanks meet OISD norms ? “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines. What's the diesel fuel tank capacity (hrs) ? k How frequently does jockey pump start ? How long it runs ? l. What's the stand by philosophy ? d.OISD – GDN – 145 Sr. d. What's the capacity of each pump and at what head ? e. Is there any jockey pump ? g. What's the priming system? f. b. Network . c.” . f.1 2. g.2 a. What's the capacity ? What's set pressure? h. c. Is location away (from hazardous area) ? b. b. t.5 a.? c. What is the monthly cartridge and product ? f. Are quantity of cartridge and powder sufficient at work site and spares available in store in line with OISD Std. ? e.Number:OISD/DOC/2013/172 Page No.? b. Are foam branch pipes. c. FIRE EXTINGUISHERS Are portable extinguishers meeting OISD requirements ? Are they BIS approved ? b. flow proportioning system etc. c. Proportioning equipment . pressure. Whether periodical inspection.6 a. Daily starting of vehicles and other check logs. FIRE HOSES AND ACCESSORIES Are no of hoses sufficient w. consumption of “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines. FIRE STATION Is the location away from hazardous areas ? Are the no.suitability proper pick up 2. also bear the TT number 2. nozzles. 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.4 a. of hydrants in the system ? Are the hose boxes strategically placed ? Are the hoses easily removable during an emergency ? b. Fire Extinguishers attached to TTs should Note 3 . wheeled equipments available and adequate as per OISD Stnadard ? f.r.” . 18 INTERNAL SAFETY AUDITS PROCEDURES -------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK ------------------------------------------------------------------------------------------------------------------------------------------------e. 2. Are replacement of extinguishers on shell failure or hydrotest ensured and necessary records available ? d.OISD – GDN – 145 Sr. maintenance and testing of fire extinguisher are promptly carried out and proper records maintained in line with OISD Std. and variety of fire vehicles sufficient ? Facilities on fire vehicles capacity. no. Within and to outside. “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines. Are adequate sand drums / buckets available ? g.Number:OISD/DOC/2013/172 Page No. .? h.Training of the users.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. Are the hoses BIS Approved Note 3 ? 2. Are the hose boxes painted fire red Note 3 as per OISD Standard. Are the hoses periodically tested/ checked and replaced? e. .? f. - Contingency Plan for medical emergency./range and report .Inspection and maintenance schedule .? of Check the locn.156 ? 2. 2.8. Are all various types of nozzles/foam branch pipes etc.Normal and emergency.” .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. . provided as per OISD STD. Differentiation between different types fires / emergencies.Availability of alternate power supply during normal supply failure .OISD – GDN – 145 Sr.Condition of radio communication equipment. 19 INTERNAL SAFETY AUDITS PROCEDURES -------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK ----------------------------------------------------------------------------------------------------------------------------------------------d.1 Fire siren and fire alarm network (Electrical/ mechanical/ hand operated) Satisfactory working.2 Ambulance/Other means of transport and First-Aid services with complete kit Note 3. c.Number:OISD/DOC/2013/172 Page No. d. Whether following documents are updated and displayed as reqd. etc. Whether mutual aid schemes are made with neighboring industries. . etc. shortcomings observed and necessary action initiated ? b. etc.2 DISASTER MANAGEMENT PLAN (Ref. 3.First Aid training to personnel on shift.4 Availability of critical areas.Fire fighting procedures / manual f.8.Organogram . Whether the organogram of fire fighting and other supporting services well defined ? Is periodic fire drill conducted.Fire hydrants layouts and P & ID diagrams .1 ORGANIZATION a. Whether layouts and organogram displayed ? 3.0 PROCEDURES 3.to new checklist for DMP) a. local fire brigades. b. power megaphones. 2.5 Availability of special fire fighting components aprons / suits / emergency flood lights. lights in Does location have well defined fire order ? Whether organogram has provision to meet emergency situation during idle shift / sundays and holidays.OISD – GDN – 145 Sr. Whether resource requirements are worked out “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines. . Whether relevant fire order is displayed at various work stations indicating station employees role during fire / emergency ? e.” . 20 INTERNAL SAFETY AUDITS PROCEDURES -------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK ------------------------------------------------------------------------------------------------------------------------------------------------.Evacuation.8. 2. emergency. What is the inventory ? Are the procurement / expiry date record maintained? . Pumps . hose holders.4 TRAINING Whether training provided fire crew / other employees / CISF etc. inspected regularly ? h.3 INSPECTION AND TESTING FACILITIES Whether periodic inspection and maintenance / testing is done and proper records maintained for following : a. Hydrants .Whether protein foams churned regularly and record maintained ? 3.Are all valves easy to operate ? c.OISD – GDN – 145 Sr. nozzles.Are hoses .Is lubrication periodically carried out ? b. Whether hydrotesting and regular inspection of fire gate mains undertaken and records maintained ? f. Foam concentrate . is in line with OISD std.Are pressure and flow at different points adequate enough ? . pressure meeting the requirement ? . 21 INTERNAL SAFETY AUDITS PROCEDURES -------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK ------------------------------------------------------------------------------------------------------------------------------------------------3. Whether various checks & records of periodical running of Diesel engines carried out? g.Is flow vs.Number:OISD/DOC/2013/172 Page No. wrenches etc. How effective is the fire water spray system ? d. FIRE HOSE AND ACCESSORIES . adapters. Is foam proportioning equipment in working order ? e.” . 154? “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines. ” . Generator hire service.Number:OISD/DOC/2013/172 Page No. discussed and recorded ? Whether the duties of various coordinators and team members well defined ? 6. water transporter.and Res. f. 22 INTERNAL SAFETY AUDITS PROCEDURES -------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK ------------------------------------------------------------------------------------------------------------------------------------------------3. telephone exchange. fire and district authorities. Are responsibilities of various neighboring industrial units. b. boards. port trust. ambulance. blood bank. Whether DMP is based on MCA and risk analysis ? “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines.Whether mutual aid schemes are planned with neighboring units local fire brigade etc. address.5 CHECKLIST FOR DMP 1.OISD – GDN – 145 Sr. elect. Whether organogram of various co-ordinators. railways. transport hire service . Hospitals and doctors Medical shops. Is emergency control centre planned and properly furnished / fitted to meet the requirement ? 8. blood donors. ) of anchorages / key persons are to be clearly shown. 7. Water supply dept. Mutual aid members Police. d. Are the following information included in the DMP ? Name. succession charts showing alternate persons and sub-organisation chart well displayed ? 5. ? 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. social organization and catering services. e. a. c. 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. telephone numbers (Off. welfare bodies. 0 INTER .0 SURROUNDING OF THE INSTALLATION 24 3.1 Electrical power lines 26 6.3 Grouping of tanks Dykes LPG storage 24 24 25 5.0 PROCESS UNITS 25 5.5 Boiler plants 26 6.0 TANKFARMS 24 4.1 4.Number:OISD/DOC/2013/172 Page No.0 TOPOGRAPHY OF INSTALLATION 24 2.9 Elevated platforms 27 6.” .2 Electrical switchgear 26 6. OISD GDN-145-03 LAYOUTS CONTENTS -------------------------------------------------------------------------------------------------------------------------------------SECTION DESCRIPTION PAGE NO.6 Gantries 27 6.12 Fire hydrants/ monitors/ safety showers/ hose etc.14 Miscellaneous 28 ------------------------------------------------------------------------------------------------------------------------------------------------- OISD-GDN-145-03 “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines. 23 OISD – GDN – 145 INTERNAL SAFETY AUDITS PROCEDURES OISD-GDN-145-03 REVISION I SAFETY AUDIT CHECK LIST No.13 Compressors 28 6.3 Location Control room Field 25 25 25 6.7 Waste water facilities 27 6.8 Water cooling towers 27 6.Sr.0 OTHER FACILITIES AND EQUIPMENT 26 6.4 Administrative buildings/ workshops/canteen 26 6. ------------------------------------------------------------------------------------------------------------------------------------------ 1.2 5.3 Roads 26 6.1 5.DISTANCES 24 4.10 Piping 27 6. 27 6.2 4.11 Rail spurs 27 6. OISD-STD-118/144).2 DYKES .Number:OISD/DOC/2013/172 Page No.Equipment to Equipment switch in a block / facility.0 INTER-DISTANCES Code / standard/ regulations followed /deviated (Ref.Equipment/block/facility to boundary walls . “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines.Location of process units and tank farms in undulating areas. .0 TOPOGRAPHY OF INSTALLATION .1 GROUPING OF TANKS .OISD – GDN – 145 Sr.0 SURROUNDING OF THE INSTALLATION . 4.Construction and dimensions of dyke wall .Mixing of different class products in POL tank farm - Accessibility of tanks for fire fighting.Block/facility to block/facility . 24 INTERNAL SAFETY AUDITS PROCEDURES SAFETY AUDIT CHECKLIST LAYOUTS ------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR'S REMARKS ------------------------------------------------------------------------------------------------------------------------------------------------1.0 TANKFARMS 4. 2.Routing / Cris.Provision of fire walls. 4.Susceptibility for flooding .Flammables / Toxics/ Ignition sources up/ down wind 3.Capacity of Dykes with respect relevant group to .” .crossing of process / fire hydrant lines inside dyked tank farm .Aggregate capacity of tanks in each Dyke / enclosure . Segregation of equipment handling hazardous / materials .Emergency Light during power failure at Process Control room. . .General state of terrain without depression / large ditches .Adequate provision of oily water sewers and catch pits.Design for minimum occupancy . wind direction .Positioning of process equipment without stacking . water and storm .Easy approach to entrance and to fire fighting facilities . 25 INTERNAL SAFETY AUDITS PROCEDURES -------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK ------------------------------------------------------------------------------------------------------------------------------------------------4.3 LPG STORAGE .t.3 FIELD .” .Packing and grinding of susceptible leaky areas “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines.0 PROCESS UNITS 5.Safety of control room from any blast situation .Number:OISD/DOC/2013/172 Page No.2 CONTROL ROOM .No of vessels in each group and the capacities aggregate -Provisions of slope and spill collection shallow pumps.Over head clearances for passage of heavy equipment like cranes .1 LOCATION .Down wind from ignition sources 5.Orientation w.Adequacy of accessways for the movement of equipment and people.Consolidated / Scattered .OISD – GDN – 145 Sr.Electrical area /equipment classification .r. Note 3 5.Upwind from sources of flammables / toxic materials .Separation from tank farm/concentration of people .Vapour trap 5.Strategic location of fire fighting equipment . 5 BOILER PLANTS Upwind and separation from flammable materials sources of -------------------------------------------------------------------------------------------------------------------------------------------------“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines.Rooting below / above ground .Routes of overhead power cable and instrument cable trays and their fire protection/ fire proofing 6.Accessibilities to each process unit/tank .Road widths and turning radii for movement of large fire fighting vehicles .Number:OISD/DOC/2013/172 Page No.Process Plants and facilities shall have access roads for fire tenders from at least two sides.OISD – GDN – 145 Sr.3 ROADS .Separation from elevated structures which may fall across power lines . 26 INTERNAL SAFETY AUDITS PROCEDURES -------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK ------------------------------------------------------------------------------------------------------------------------------------------------6.High ground in flooding areas .” .Crossing of pipe alleys . Note 3 6.Concreted / asphalted (condition) .Upwind from flammable sources .Layout of the roads for minimum truck traffic in grass . - Separate entry points product movement for employees and .0 OTHER FACILITIES AND EQUIPMENT 6.Location of power receiving station & layout hazard 6.Passing over critical facilities .2 ELECTRICAL SWITCHGEAR .4 ADMINISTRATIVE BUILDINGS /WORKSHOPS/ CANTEENS - Peripheral locations Separation from hazardous areas Upwind from sources of flammable / toxics 6.1 ELECTRICAL POWER LINES . 9 ELEVATED PLATFORMS .Fire proofing of pipe racks.No facility opposite the end of the spur.Any treatment facility to dischargeable water for pollution control 6. .6 GANTRIES .10 PIPING .Peripheral locations .Landing at grade in safe locations 6.Downwind from ignition sources .No obstruction for approach.Number:OISD/DOC/2013/172 Page No.Peripheral location .” .Head bumpers. 6.Clearance for derailments .Permanent platforms for all operating points . shin splitters and tripping hazards .Separation from main line of rail / road 6. 27 INTERNAL SAFETY AUDITS PROCEDURES ITEM AUDITOR’S REMARK ------------------------------------------------------------------------------------------------------------------------------------------------6. Good path for retreat “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines.12 FIRE HYDRANTS / MONITORS / SAFETY SHOWERS / HOSE ETC.OISD – GDN – 145 Sr.7 WASTE WATER FACILITIES .Alternate routes for descent .8 WATER COOLING TOWERS .Personnel protection from hot lines . 6.Down wind from ignition sources/ concentration of people 6.11 RAIL SPURS .Down wind from concentrations of people ignition sources / . Storm water drains & easy drainage .Grading of various block facilities .Height of flares is adequate .OISD – GDN – 145 Sr.Flood light towers & security towers .TTL gantry and easy exit through the product movement gate .13 COMPRESSORS .Provision of Truck parking area “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines.14 MISCELLANEOUS .Location of fire station and fire pump .Greenscaping area .” .Down wind from rest of unit 6.Display of Layout drawing and display of P & I DRAWING -Check piping layout for minimum piping . 28 INTERNAL SAFETY AUDITS PROCEDURES -------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -----------------------------------------------------------------------------------------------------------------------------------------------6.Number:OISD/DOC/2013/172 Page No.Not in closed buildings .Location of smoke booths . OISD GDN-145-04 PROCESS PLANTS CONTENTS --------------------------------------------------------------------------------------------------------------SECTION DESCRIPTION PAGE NO.Number:OISD/DOC/2013/172 Page No.1 Layout and Drainage 30 1.5 Process vessels and columns 35 2.4 Training 31 1.2 Fire Protection facilities 30 1.7 Instrumentation 32 2. ---------------------------------------------------------------------------------------------------------------1.0 GENERAL 30 1.0 PROCESS SUB-SYSTEMS 33 2.1 Control room 33 2.7 Process piping 37 2. 29 OISD – GDN – 145 INTERNAL SAFETY AUDITS PROCEDURES OISD-GDN-145-04 REVISION I SAFETY AUDIT CHECKLIST No.4 Heat exchangers/ condensers/ coolers 35 2.6 Electrical 32 1.3 Compressor house 34 2.9 First aid 39 “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines.5 Inspection & Maintenance 32 1.2 Pump House 33 2.Sr.3 Housekeeping 31 1.6 Process furnaces 36 2.8 Relief and Disposal System 37 2.” . 0 PROCESS PLANTS ----------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITORS REMARKS -----------------------------------------------------------------------------------------------------------------------------------------1. 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.Number:OISD/DOC/2013/172 Page No.1 LAYOUT AND DRAINAGE a) OIDF-STD-118 ? (deviations. 30 INTERNAL SAFETY AUDITS PROCEDURES SAFETY AUDIT CHECKLIST 4. hose boxes are easily accessible ? e) Whether adequate number of portable fire extinguishers have been provided all over the plant as per the OISD-116 ? system has hydrocarbon with proper underground “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines.0 GENERAL 1.” .OISD – GDN – 145 Sr. 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.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. monitors. b) Whether the hydrants. 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 been provided for draining of from the vessels / equipments pump out arrangement from tank ? 1. 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.Number:OISD/DOC/2013/172 Page No.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.not adequate 1. 31 INTERNAL SAFETY AUDITS PROCEDURES -------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------f) Whether communication systems.4 TRAINING a) Are copies of updated operating manual. ? “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines.3. heat exchanger areas are regularly washed to avoid Oil Accumulation ? Any visible Oil Accumulation on the floor. HOUSEKEEPING : a) Whether the plant floors particularly in pump house.adequate . 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 . fire alarms and p. fire & safety manual. disaster control manual. face shield etc.” . safety shoes. helmet.OISD – GDN – 145 Sr. compressors etc. and is well maintained ? “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines. 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 .Number:OISD/DOC/2013/172 Page No. vessels. . 1. are carried out as per schedules? Are history cards maintained ? Refer OISD129 / OISD-127.6.OISD – GDN – 145 Sr. Refer OISD-105.Vessel Entry .5 INSPECTION & MAINTENANCE a) Whether inspection of equipments/ tanks /piping /safety valves etc. 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.Entry of Vehicle into battery area.7 INSTRUMENTATION: a) Whether electronic instrumentation provided are as per area classification? b) Whether minimum safety instrumentation provided for furnace. ELECTRICAL a) Whether all motors.Energizing and de-energizing of electrical Equipment. 32 INTERNAL SAFETY AUDITS PROCEDURES -------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK ------------------------------------------------------------------------------------------------------------------------------------------------1.Excavation . .” .Hot/Cold work . ” .OISD – GDN – 145 Sr.t.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.Number:OISD/DOC/2013/172 Page No. 33 INTERNAL SAFETY AUDITS PROCEDURES -------------------------------------------------------------------------------------------------------------------------------------------------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. personnel's movement satisfactory ? e) Whether hot pumps are properly insulated ? (including the associated piping) ? “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines.r.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. 34 INTERNAL SAFETY AUDITS PROCEDURES -------------------------------------------------------------------------------------------------------------------------------------------------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.OISD – GDN – 145 Sr. 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.” .Number:OISD/DOC/2013/172 Page No.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 ? “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines. 4.OISD – GDN – 145 Sr. 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 ? “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines. 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. HEAT EXCHANGERS/CONDENSERS/COOLERS a) Are adequate nos.” .Number:OISD/DOC/2013/172 Page No. 35 INTERNAL SAFETY AUDITS PROCEDURES -------------------------------------------------------------------------------------------------------------------------------------------------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 ? 2.5 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. (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.Number:OISD/DOC/2013/172 Page No. 36 INTERNAL SAFETY AUDITS PROCEDURES -------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK ------------------------------------------------------------------------------------------------------------------------------------------------g) Do all columns have two sets of level indicators ? 2.6 PROCESS FURNACES.OISD – GDN – 145 Sr.” . 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 ? “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines. ” . (Refer OISD-STD-106 ).0 kg / sq.OISD – GDN – 145 Sr. C surface temperature have safety insulation ? f) Whether continuity jumpers provided between flange joints for LPG. 2. ATF etc.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. OWS line connection & manhole location for the furnace be considered safe ? r) Whether the support structures are properly fire proofed ? 2. naphtha.Number:OISD/DOC/2013/172 Page No. 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. whether the set pressure is within design pressure ? “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines.7 PROCESS PIPING a) Whether expansion loops / expansion joints in working order ? b) Whether TSVs provided are periodically tested.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. 37 INTERNAL SAFETY AUDITS PROCEDURES -------------------------------------------------------------------------------------------------------------------------------------------------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. 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 ? “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines. within 15m radius i) Whether acoustic insulation has been provided on vents producing excessive noise ? j) Whether toxic vapors like SO2.Number:OISD/DOC/2013/172 Page No.minimum exit velocity of 15. phenol.” . 38 INTERNAL SAFETY AUDITS PROCEDURES -------------------------------------------------------------------------------------------------------------------------------------------------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 : .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. can it hold liquid discharge for 5 . 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 .0 m/second.discharge vertically upward through individual stack .OISD – GDN – 145 Sr. chlorine etc. . 39 INTERNAL SAFETY AUDITS PROCEDURES -------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK ------------------------------------------------------------------------------------------------------------------------------------------------o) Whether vapor depressurising system has been provided for emergency situations such as runaway reaction.? 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. exposure to fire etc. Note 3 “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines.” .OISD – GDN – 145 Sr.Number:OISD/DOC/2013/172 Page No. water gel blanket and explosive meter ? c) What is the accident record of the last two years ? d) All incidents requiring first aid should be recorded. 0 TANK FARM 41 2.0 INSPECTION & MAINTENANCE 46 6.Sr. 40 OISD – GDN – 145 INTERNAL SAFETY AUDITS PROCEDURES SAFETY AUDIT CHECKLIST No.0 OPERATING PROCEDURES 44 5.” .0 TANKS 42 3.OISD-GDN-145-05 OIL STORAGE AND MOVEMENT CONTENTS -------------------------------------------------------------------------------------------------------------------------------------SECTION DESCRIPTION PAGE NO.0 PIPING 43 4.0 ADDITIONAL CHECK LIST ITEMS 47 “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines. -------------------------------------------------------------------------------------------------------------------------------------1.Number:OISD/DOC/2013/172 Page No. OISD – GDN – 145 Sr.Number:OISD/DOC/2013/172 Page No. 41 INTERNAL SAFETY AUDITS PROCEDURES 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 ? “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines.” OISD – GDN – 145 Sr.Number:OISD/DOC/2013/172 Page No. 42 INTERNAL SAFETY AUDITS PROCEDURES ------------------------------------------------------------------------------------------------------------------------------------------------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 ? “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines.” OISD – GDN – 145 Sr.Number:OISD/DOC/2013/172 Page No. 43 INTERNAL SAFETY AUDITS PROCEDURES ------------------------------------------------------------------------------------------------------------------------------------------------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 ? “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines.” anchors.0 OPERATING PROCEDURES : a) Whether a copy of updated operating manual with operating instructions. 44 INTERNAL SAFETY AUDITS PROCEDURES ------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -----------------------------------------------------------------------------------------------------------------------------------------------b) Whether pipe supports. 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. MS. blending etc.” . 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. “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines. b) Whether there is any possibility of product contamination during tank line up/changeover.Number:OISD/DOC/2013/172 Page No. particularly of LPG. Naphtha etc. guides are in order ? c) Whether pipes carrying heavy products have been properly heat traced and insulated ? d) Whether proper color codings. k) Whether the redundant lines are kept positively isolated with all the ends plugged/blinded and actions are taken to get them removed ? 4. are available to all concerned and a copy available in the C/R.OISD – GDN – 145 Sr. piping etc. h) Whether cross checking of auto level gauge is done through manual gauge. what are the procedures & safety precautions taken. g) Whether any blending of DP product and NDP product is resorted to ? If so.Number:OISD/DOC/2013/172 Page No. lines are segregated from other lines with positive isolation during blending operation ? d) Whether periodical checks are made for locating any leakage on tank. and recorded for rectification. 45 INTERNAL SAFETY AUDITS PROCEDURES ------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------c) Whether the blending pumps.” .monsoon checks are carried out. i) Whether it is ensured during initial filling a flow velocity of maximum 1 m/sec is maintained for products like SKO. f) Whether pre.OISD – GDN – 145 Sr. e) Whether the roof drain valves of floating roof tanks are normally kept open . ATF ? j) Whether use of nylon rope for sampling was observed ? “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines. floating roof valves. while the tanks are under operation. relief valves.OISD – GDN – 145 Sr. f) Whether any documented procedure exists for tank cleaning ? What is the methodology to ensure strict adherence ? g) Whether the ladders.Number:OISD/DOC/2013/172 Page No. 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. breather valves. 46 INTERNAL SAFETY AUDITS PROCEDURES -------------------------------------------------------------------------------------------------------------------------------------------------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. 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. c) Whether any provision exists for static electricity discharge ? What is the frequency of inspection of earthing connections and whether records maintained.” . j) What are the schedules for painting of tanks ? “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines. flame arrestors ? Whether records are maintained in line with OISD STD-129.0 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. 47 INTERNAL SAFETY AUDITS PROCEDURES -------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------k) Whether Nitrogen blanketing system provided on any tank. & Organization OISD-GDN-145-01 Fire Fighting OISD-GDN-145-02 Layouts OISD-GDN-145-03 Electrical systems OISD-GDN-145-09 “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines.Number:OISD/DOC/2013/172 Page No. what is the frequency of inspection & whether records maintained ? 6.” .OISD – GDN – 145 Sr. If so.0 ADDITIONAL CHECKLIST ITEMS : For detailed checklist on individual areas refer other OISD checklists as follows : General Admn. -------------------------------------------------------------------------------------------------------------------------------------------------1.1.Number:OISD/DOC/2013/172 Page No.1 General 49 1.OISD-GDN-145-06 POL LOADING & UNLOADING A. TANK WAGONS CONTENTS -------------------------------------------------------------------------------------------------------------------------------------------------SECTION DESCRIPTION PAGE NO.3 House keeping 51 “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines. 48 INTERNAL SAFETY AUDITS PROCEDURES SAFETY AUDIT CHECKLIST No.1 Placement of rakes and loading 49 2.2 Sick wagons 51 2.1.2 Drainage 49 1.3 Miscellaneous 49 1.” .OISD – GDN – 145 Sr.4 Electrical 49 2.0 FACILITIES AND SYSTEMS 49 1.1.1 Tank Wagon Gantry 49 1.0 OPERATING PROCEDURES AND PRACTICES 49 2.1. 1.1.2 Drainage Whether concrete flooring has been provided below rail track and with proper slope ? 1.3 Miscellaneous Whether No-shunting device / caution boards are provided to avoid movement of wagons while filling / decantation is in progress ? 1.Number:OISD/DOC/2013/172 Page No.1.1 TANK WAGON GANTRY 1. Whether proper facilities have been provided for handling sick wagons ? b.1 a.0 FACILITIES AND SYSTEMS 1.1 General a. PLACEMENT OF RAKES AND LOADING Whether the type used are : of loco -diesel -steam -electric “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines.” .4 Electrical a.1.0 OPERATING PROCEDURES AND PRACTICES 2. Whether the diesel shunter used is equipped with spark arrestors and proper cooling of engine exhaust ? 2. TANK WAGONS -------------------------------------------------------------------------------------------------------------------------------------------------AUDITOR'S REMARKS -------------------------------------------------------------------------------------------------------------------------------------------------1. Whether the rail sleepers are of concrete / metallic construction ? 1.Sr.0 POL LOADING & UNLOADING-TANK WAGONS A. Whether the rail tracks are provided bonding strips and connected to maintained earthing system ? with well b. 49 OISD – GDN – 145 INTERNAL SAFETY AUDITS PROCEDURES OISD-GDN-145-06 SAFETY AUDIT CHECKLIST 6. Whether the TXR staff check / inspect each wagon and issue a formal certificate prior to loading ? g.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. 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.fill pipes (if exists) are properly capped .OISD – GDN – 145 Sr. Whether the wagons are placed with master valve closed and bottom sluice valve and cover plate normally in opened position ? e. 50 INTERNAL SAFETY AUDITS PROCEDURES -------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------b. in case of open type wagons. Whether checks are made for any left over materials. 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. loading arms/hoses do not hit the incoming rake ? d. Whether Railways are informed in writing about wagons found defective during loading ? i.” . Whether wagons declared defective are shown on tally sheets and also marked on the wagons ? h. Whether. Whether replacement check is carried out to ensure that platform . previous product & fitness of wagons by operating staff on placement ? f.pre-fabricated fill pipes are available for use ? k.Number:OISD/DOC/2013/172 Page No. Whether the following are ensured after completion of loading : .) is maintained ? n Whether necessary caution boards are displayed while loading / unloading in progress ? “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines. railway tracks etc.3 House keeping a Whether the gantry floor. ? c Whether Rly. 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.Number:OISD/DOC/2013/172 Page No. fittings ? “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines.” . tracks / sliding is free from unused T. 51 INTERNAL SAFETY AUDITS PROCEDURES -------------------------------------------------------------------------------------------------------------------------------------------------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.W.OISD – GDN – 145 Sr. Number:OISD/DOC/2013/172 Page No. -------------------------------------------------------------------------------------------------------------------------------------------------1.1 Placement of trucks 53 2.” .0 VEHICLE CREW AND CHECK 54 “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines.0 OPERATING PROCEDURES AND PRACTICES 53 2. OISD GDN-145-06 POL LOADING & UNLOADING B.2 Loading operations 53 3.OISD – GDN – 145 Sr.1 Headers & loading hoses 53 2.0 FACILITIES & SYSTEMS 53 1. 52 INTERNAL SAFETY AUDITS PROCEDURES SAFETY AUDIT CHECKLIST No. TANK TRUCKS CONTENTS -------------------------------------------------------------------------------------------------------------------------------------------------SECTION DESCRIPTION PAGE NO. 0 OPERATING PROCEDURES AND PRACTICES 2. 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 “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines. TANK TRUCKS -------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR'S REMARKS -------------------------------------------------------------------------------------------------------------------------------------------------1.2 LOADING OPERATIONS a Whether it is ensured that the trucks.TANK TRUCKS B.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. 53 INTERNAL SAFETY AUDITS PROCEDURES SAFETY AUDIT CHECKLIST 6.0 POL LOADING & UNLOADING .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.OISD – GDN – 145 Sr.” .Number:OISD/DOC/2013/172 Page No. emergency procedures.OISD – GDN – 145 Sr. 54 INTERNAL SAFETY AUDITS PROCEDURES -------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------3.” . 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 ? “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines. Tool Box and Emergency Lighting ? j Whether there are any sources of ignition like candles.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. 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.Number:OISD/DOC/2013/172 Page No. have been provided ? w Whether all junction boxes are sealed properly ? x Whether electrical equipments like generator switches. 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 ? “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines. 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.Number:OISD/DOC/2013/172 Page No. in bold letters at least 7 cm high and on a back ground of sharp contrasting color.OISD – GDN – 145 Sr. 55 INTERNAL SAFETY AUDITS PROCEDURES -------------------------------------------------------------------------------------------------------------------------------------------------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.” . 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. 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. (The word "flammable " and name of product are required to be marked ) as per UN code. 0 FACILITIES & SYSTEMS 57 1. COMMON CHECKLIST FOR LOADING AND UNLOADING OF TWs & TTs CONTENTS -------------------------------------------------------------------------------------------------------------------------------------------------SECTION DESCRIPTION PAGE NO.1 Pump house 57 1.Number:OISD/DOC/2013/172 Page No.4 Training 61 2.Sr.3 Headers and loading arms 58 1.5 Miscellaneous 59 1.2 Structure & platforms 57 1.4 Drainage 59 1.” . -------------------------------------------------------------------------------------------------------------------------------------------------1.3 House keeping 61 2.0 FIRE PROTECTION FACILITIES 62 4.1 Inspection & maintenance 61 2.6 Electrical 59 2.2 Work Permit Systems 61 2.0 OPERATING PROCEDURES AND PRACTICES 60 2.5 Miscellaneous 62 3. 56 OISD – GDN – 145 INTERNAL SAFETY AUDITS PROCEDURES OISD-GDN-145-06 REVISION I SAFETY AUDIT CHECKLIST OISD GDN-145-06 POL LOADING AND UNLOADING C.0 ADDITIONAL CHECKLIST 63 “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines. have been blinded off? j) Whether P. 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.0 POL LOADING AND UNLOADING C.” .D. COMMON CHECKLIST FOR LOADING AND UNLOADING OF TWs & TTs -------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR'S REMARKS ------------------------------------------------------------------------------------------------------------------------------------------------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. 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 ? “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines. not in use for long time. 57 INTERNAL SAFETY AUDITS PROCEDURES SAFETY AUDIT CHECKLIST 6.0 FACILITIES AND SYSTEMS 1.OISD – GDN – 145 Sr.Number:OISD/DOC/2013/172 Page No. rubber pads and other safety features to avoid frictional spark ? g) Whether handrails are provided on the platform ? 1.Number:OISD/DOC/2013/172 Page No. security chain.OISD – GDN – 145 Sr. if so how many ? h) i) Whether proper arrangement has been provide for securing the hose nozzle with manhole and properly secured after loading (T/T & T/W)? Whether vacuum breaker is provided on the loading arm ? “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines. 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.” .3 a) b) HEADERS & LOADING ARMS Comment as to how the loading velocities are maintained within safe limits ? 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. 58 INTERNAL SAFETY AUDITS PROCEDURES -------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------c) Whether the swing ladders are provided with counter weight. Number:OISD/DOC/2013/172 Page No. quality and condition & meets BIS norms? Whether the idle loading headers/ loading arms not in use for long time are blinded off ? 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.OISD – GDN – 145 Sr. installed the smoking booths. 59 INTERNAL SAFETY AUDITS PROCEDURES -------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------j) k) 1. 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 ? “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines.” .4 Whether the rubber hose are of proper diameter. lighting provisions.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. are well maintained ? 1.6 in ELECTRICAL a) Whether all electrical fittings. welding apparatus receptacles. etc. length. 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. 60 INTERNAL SAFETY AUDITS PROCEDURES -------------------------------------------------------------------------------------------------------------------------------------------------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.Number:OISD/DOC/2013/172 Page No. and earth test done every year and records maintained.0 OPERATING PROCEDURES AND PRACTICES a) Check and comment on earthing and bonding practices during loading / unloading. j) Whether structure is earthed as per std.OISD – GDN – 145 Sr. 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 ? “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines. Is the catwalk antiskid ? k) Whether earthing bosses with flexible cable and robust clamping device have been provided adjacent to loading points ? 2.” . or light hydrocarbons are used ? c) Whether the gantry floor are regularly washed to avoid oil accumulation ? Any visible oil accumulation in the area ? “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines. arms/hoses.3 a) HOUSE KEEPING 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.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.OISD – GDN – 145 Sr. etc.Number:OISD/DOC/2013/172 Page No. till the filling pipe is completely submerged and thereafter at the rate not exceeding 6 M/Sec ? 2. 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. ? 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. 61 INTERNAL SAFETY AUDITS PROCEDURES -------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------h) Whether initial loading is done at a rate not exceeding 1 M/Sec. PA system provided and are working ? g) Whether the communication system.) 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. long range water/foam monitors are provided on both sides of gantry and are they safely located ? d) Whether all hydrants. 62 INTERNAL SAFETY AUDITS PROCEDURES -------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------d) Whether the drain channels are cleaned & well maintained ? 2.4 TRAINING (REFER OISD 154 STD. 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 ? “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines.OISD – GDN – 145 Sr.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.Number:OISD/DOC/2013/172 Page No. monitors are easily accessible ? e) Whether proper approach roads exist for Fire Tenders and Fire Fighting Equipment ? f) Whether communication system like Fire Alarms.” . ” .OISD – GDN – 145 Sr. organization Fire fighting Layouts Electrical Systems OISD-GDN-145-01 OISD-GDN-144-02 OISD-GDN-145-03 OISD-GDN-145-09 “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines.0 ADDITIONAL CHECK LIST ITEMS a) For comprehensive check lists on individual areas also refer OISD check lists as indicated below: b) General admn.Number:OISD/DOC/2013/172 Page No. 63 INTERNAL SAFETY AUDITS PROCEDURES -------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------j) Whether a copy of Fire Fighting manual is available in the gantry control room ? 4. 0 BULK STORAGE AREA 65 2. -------------------------------------------------------------------------------------------------------------------------------------------------1.0 TANK WAGON GANTRY AREA 68 4.0 PUMPS/ COMPRESSORS AREA 67 3.0 TRAINING 72 6.0 TANK TRUCK GANTRY AREA 70 5.OISD-145-07 LPG BULK LOADING & UNLOADING CONTENTS -------------------------------------------------------------------------------------------------------------------------------------------------SECTION DESCRIPTION PAGE NO.” .OISD – GDN – 145 Sr.Number:OISD/DOC/2013/172 Page No. 64 INTERNAL SAFETY AUDITS PROCEDURES SAFETY AUDIT CHECKLIST No.0 ADDITIONAL CHECKLIST ITEMS 72 “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines. 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. If so. c) Whether general house keeping in the area is satisfactory ? d) Whether storage vessels are insulated. 65 INTERNAL SAFETY AUDITS PROCEDURES SAFETY AUDIT CHECKLIST 7. e) Whether five year hydraulic test records are available ? 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 isolation 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 ? “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines.0 BULK STORAGE AREA: 1.Number:OISD/DOC/2013/172 Page No.0 LPG BULK LOADING & UNLOADING -------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR'S REMARKS -------------------------------------------------------------------------------------------------------------------------------------------------1.OISD – GDN – 145 Sr.” . what is the condition of insulation. 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 “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines.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.OISD – GDN – 145 Sr.” .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.Number:OISD/DOC/2013/172 Page No. 66 INTERNAL SAFETY AUDITS PROCEDURES -------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------1. lighting fittings etc.Number:OISD/DOC/2013/172 Page No.2 ELECTRICAL: a) Whether all the motors and other electrical equipments such as terminal/junction boxes.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.OISD – GDN – 145 Sr. 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. 67 INTERNAL SAFETY AUDITS PROCEDURES -------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------proofed? f) Whether periodical checks are done with explosive meters to detect any gas leaks? 1.1 FACILITIES: a) Whether the layout of the area meets statutory requirements in terms of safety distance from storage vessels. 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 ? “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines. g.Number:OISD/DOC/2013/172 Page No. of fire extinguishers have been provided? 3.1 FACILITIES: a) Whether the layout of the gantry meets statutory requirements? b) Whether the design.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. `NO SMOKING'.2 LOADING HEADERS AND ARMS: a) Whether quick isolation valve/MOV has been provided on the loading header and is operative? Whether independent isolation valve provided on each loading point? b) “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines.) d) Whether all maintenance tools used in the area are non sparking type? 2. `MEN AT WORK' etc. 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? 3.0 TANK WAGON GANTRY AREAS: 3. material selection and installation of the gantry platform. have been done as per standard engineering norms adopting proper safety guidelines of established norms. loading header.OISD – GDN – 145 Sr. 68 INTERNAL SAFETY AUDITS PROCEDURES -------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------2.” . loading hoses etc.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. long range water monitors have been provided ? c) Whether gas detector system have been provided with alarm in the control room ? -------------------------------------------------------------------------------------------------------------------------------------------------“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines. 69 INTERNAL SAFETY AUDITS PROCEDURES -------------------------------------------------------------------------------------------------------------------------------------------------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. fire hydrants.OISD – GDN – 145 Sr.” .? 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.Number:OISD/DOC/2013/172 Page No. 70 INTERNAL SAFETY AUDITS PROCEDURES ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------3.” . refer to OISD-STD-144? 4.OISD – GDN – 145 Sr.Proper earthing connection are made . before commencement of loading operation? d) Whether the following are ensured before loading ? .0 TANK TRUCK GANTRY AREAS 4. "O" rings. thermometer etc. 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.All hot jobs in the area are stopped . any corrosion on tanker.Number:OISD/DOC/2013/172 Page No. physical damage.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.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. safety valve.All engines nearby are switched off .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. of trucks parked at the gantry area is restricted? “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines. uncovered battery terminals etc. 71 INTERNAL SAFETY AUDITS PROCEDURES -------------------------------------------------------------------------------------------------------------------------------------------------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? . .Number:OISD/DOC/2013/172 Page No.fittings as per CCE such as flame arrestor.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. fire screen etc. Whether gas detection system has been provided in the area & working satisfactory 4.” .OISD – GDN – 145 Sr. fire hydrants.Valid licenses . 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 ? “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines.3 FIRE PROTECTION AND SAFETY a) Whether water sprinkler system has been provided and working satisfactorily? b) Whether adequate nos.safety instruction booklet g) Elimination of ignition sources like loose wires. ref.” .0 ADDITIONAL CHECKLIST ITEMS For detailed checklist on specific areas refer other OISD check lists as follows : General (Organization Admn. 72 INTERNAL SAFETY AUDITS PROCEDURES -------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------5.) For detailed checklist for loading TT pl . oxygen content etc.to OISD-STD-144.r.t. have been issued to all concerned employees ? b) How it is ensured that loading operations such as hose connection etc.Number:OISD/DOC/2013/172 Page No.0 TRAINING a) Whether pocket size instruction booklets/manuals in widely understood languages. 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.OISD – GDN – 145 Sr. 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. “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines. ” .0 SUGGESTED INSPECTIONS MAINTENANCE CHECKS 82 “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines. -------------------------------------------------------------------------------------------------------------------------------------------------1.0 CYLINDER STORAGE AREA 75 4. 73 OISD – GDN – 145 INTERNAL SAFETY AUDITS PROCEDURES SAFETY AUDIT CHECKLIST No.0 CYLINDER LOADING 79 7.0 NEW AND DEFECTIVE CYCLINDERS 78 6.0 GENERAL ORGANISATION AND ADMINISTRATION 74 2.0 SAFETY AND FIRE PROTECTION 79 8.0 MANPOWER AND TRAINING 75 3.Sr.OISD GDN-145-08 LPG BOTTLING AND DISPATCH CONTENTS -------------------------------------------------------------------------------------------------------------------------------------------------SECTION DESCRIPTION PAGE NO.Number:OISD/DOC/2013/172 Page No.0 BOTTLING SHED 76 5.0 ADDITIONAL CHECKLIST ITEMS 81 9. Filling of LPG cylinders b) Whether inter distances from/to admn.” . c) Whether plant approach/access roads are well maintained & at least one emergency exit is provided. filling shed. of escape routes/staircases available around each of the facilities viz. g) Whether frisking of employees. j) k) l) Whether updated P&ID drawings & layouts & other facilities available? Whether records of Daily Safety Check reports are reviewed and corrective action taken? Is the general housekeeping okay? Any specific comments. maintenance offices. “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines.Number:OISD/DOC/2013/172 Page No. 74 INTERNAL SAFETY AUDITS PROCEDURES SAFETY AUDIT CHECKLIST LPG BOTTLING AND DISPATCH -------------------------------------------------------------------------------------------------------------------------------------------------AUDITOR'S REMARKS -------------------------------------------------------------------------------------------------------------------------------------------------1. d) Whether adequate no. contractor. check & change rooms.Storage of LPG cylinders . . are meeting safety requirement.Storage of LPG . - LPG Operations Manual S&EP Manual Emergency/Disaster Control Plan Operation/Inspection/Repair Manual of epuipment supplied by vendor. .OISD – GDN – 145 Sr. 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. 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.. offices.0 GENERAL ORGANISATION AND ADMINISTRATION a) Check for valid licenses of CCE pertaining to the locations.OISD Standards. smoking booths etc. Regular Staff . (English/Hindi/local language)? f) Whether important Do's and Dont's displayed prominently in operating areas? 3.Telescopic Conveyer/ Trolleys /Conveyers? Any dropping. for: .” .5 year testing due cylinders .Number:OISD/DOC/2013/172 Page No.Security Staff. Disaster Control/ Emergency handling? b) Whether Safety Officer is available and duly designated as safety officer. d) Whether operating manuals and standing instructions are provided to working personnel? e) Whether safety booklets distributed to all including contractor employees. 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 .Other defective cylinders d) Whether cylinders stacked in vertical position in tiers as per the norms? “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines.0 MANPOWER & PLANNING a) Whether supervisory/managerial cadre staff fully trained in all aspects of LPG Plant operations.Tank Truck Operators/drivers .Contractor Workmen .0 CYLINDER STORAGE AREA a) Whether Transfer of cylinders from/to truck is done through . 75 INTERNAL SAFETY AUDITS PROCEDURES -------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------2. rolling.OISD – GDN – 145 Sr. 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. OISD – GDN – 145 Sr. Unit filling Machines. c. 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. 76 INTERNAL SAFETY AUDITS PROCEDURES -------------------------------------------------------------------------------------------------------------------------------------------------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. Conveyers b. j) Check for accumulation of vapors in “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines. Carousel units (bonding of filling guns). filed and gas free cylinders? j) Whether the daily stocks of cylinders (empty/filled/defective) are displayed? 4. Evacuation units. d.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.Number:OISD/DOC/2013/172 Page No.” . 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. u) Whether tagging of overfilled/underfilled cylinders done? v) Check for leakage from carousel filling guns.To check for conveyors .To check 'O' Ring .2. r) Whether bung leak/body leak checks are done through in-line water bath for both 14. Kg. evacuation unit. 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) “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines.” . valve change shed is provided and in working condition? .Whether standby blower is available? . cylinders? s) Whether capping/sealing facilities are provided .Number:OISD/DOC/2013/172 Page No.OISD – GDN – 145 Sr.To check defective cylinders .Al foil/PVC seal? t) Check for neck labels plastic/paper. and 19 Kg.To check weight correction. 77 INTERNAL SAFETY AUDITS PROCEDURES -------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------recess/pits in the area with the explosimeter k) Whether vapor extraction system with suction points at carousel.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: . .” . 78 INTERNAL SAFETY AUDITS PROCEDURES -------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------y) Whether Movement of cylinders is done through floor conveyers/trolleys? statistical checks include .Valve leak . due for retesting .No. found defective.Bung leak .2 meter above the roof edge? d) Whether Cold Repair facilities are available? If so.Total No.Weight variation (under filling) . of cylinders filled. of cylinders checked at random.2 kg.OISD – GDN – 145 Sr.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 .Remarks if any.Defective "O" Ring (by CVT Test) .Total No. .% of cyls.'Pressure Control valve' Filling procedure .Cyls."O" Ring missing . found defective. of cyls. 5. 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 +/.)? “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines. .Other minor defects . in last month . Mt.Weight variation (Over filling) .Number:OISD/DOC/2013/172 Page No. 0 SAFETY & FIRE PROTECTION a) Whether Contingency Plans are available and updated for tackling major emergencies? vertically “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines.OISD – GDN – 145 Sr.Number:OISD/DOC/2013/172 Page No.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 without protrusions? d) Whether explosimeter checks are done before releasing the truck? e) Whether Loading/unloading of cylinders is done in safe manner? 7.” . 79 INTERNAL SAFETY AUDITS PROCEDURES -------------------------------------------------------------------------------------------------------------------------------------------------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. of hydrants. valve change shed. & sprinkler system. 80 INTERNAL SAFETY AUDITS PROCEDURES -------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------b) Whether fire organisation chart is prepared upto date and displayed? c) Whether important telephone nos.Number:OISD/DOC/2013/172 Page No. . Also whether in critical areas like carousel evacuation unit. 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.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. long range monitors etc.OISD – GDN – 145 Sr. Meters area. m) Whether gas monitoring system having sensors to monitor gas leak near carousel. DCP Mobile unit per shed.” . of state Fire Services/Police/Dist. meters)? l) Whether portable DCP Fire Extinguishers are provided at appropriate location? -2 Nos. DCP FE per 200 Sq. Admn. risers/monitors -yellow. 10 Kg. 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. valve “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines. / Hospitals / other offices etc. evacuation unit. 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. 100/70 Kg.1 No. OISD – GDN – 145 Sr.Whether working satisfactorily? . 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 “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines. 81 INTERNAL SAFETY AUDITS PROCEDURES -------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------change shed provided? if so: .” .0 ADDITIONAL CHECK LIST ITEMS For detailed checklist on specific areas refer other OISD check lists as follows: General (Organisation Admn.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.Number:OISD/DOC/2013/172 Page No. b) Water draining from filters of check scales & filling gun. air service units. CVT etc.2. 9. Air Service Units. g) Checking the sensitivity of check scales h) Conducting test run/test filling to see the performance of filling-gun. filling guns. CVT etc. ejction device. CVT etc.Central column .Carousel Driving unit.Number:OISD/DOC/2013/172 Page No.” . d) Checking/control of oil level in check scale & filling gun. e) Zero checking of Introduction Device/Ejection Device. “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines. check scales. c) Air leak control from check scale. f) Calibrations/Adjustments of devices indicated in above.1 DAILY MAINTENANCE a) Cleaning the cover plate of introduction device. c) Cleaning of the bearings and suspensions of Filling machines d) Greasing & leakage control of Introduction system & Ejection System. b) Oil topping in dampers of in-line check scales and calibration with standard weights. e) Greasing/lubrication of : .OISD – GDN – 145 Sr. introduction/ejection devices. 82 INTERNAL SAFETY AUDITS PROCEDURES ----------------------------------------------------------------------------------------------------------------------ITEMS AUDITORS REMARKS ------------------------------------------------------------------------------------------------------------------------------------------- SUGGESTED INSPECTION & MAINTENANCE CHECKS 9. WEEKLY MAINTENANCE a) Oil topping in Air service unit/cleaning of Air Filters. central column & driving units. e) Inspection & adjustment for proper functioning of Differential Pressure valve.Number:OISD/DOC/2013/172 Page No. ropes & pulley inspections. introduction/ejection system. b) Checking the filling hoses for stiffness and replacement. c) Inspection of Gun hanger.4 ANNUAL MAINTENANCE a) Overhauling of machines & replacement of defective parts of filling machines.3 QUARTERLY MAINTENANCE a) Earthing strip tightness of equipment like in-line control Check Scale & Filling Machine. if necessary. d) Inspection of rails of conveyer system for setting &tightening of fish plate. c) Inspection of ejection system for wear & tear. e) Calibration of filling machines with standard weights. d) Inspection of wear & tear for knife edges & bearing. b) Inspection of power cylinder of introduction system & cleaning. “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines. f) Checking the level of Introduction system & Ejection system.OISD – GDN – 145 Sr.” . 9. check scales. 83 INTERNAL SAFETY AUDITS PROCEDURES -------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------9. ” . -----------------------------------------------------------------------------------------------------------------------------------------------1.0 SUBSTATION (EQUIPMENT & BUILDING) 86 3. 84 OISD – GDN – 145 INTERNAL SAFETY AUDITS PROCEDURES SAFETY AUDIT CHECKLIST NO.0 CAPTIVE GENERATION 94 9.0 ELECTRICAL HEAT TRACING 96 11.0 PORTABLE APPARATUS/ MOBILE EQUIPMENT (ELECTRICAL /BATTERY OPERATED) 97 “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines.0 SPECIAL REQUIREMENTS 85 2.0 LIGHTING INSTALLATIONS 92 7.Number:OISD/DOC/2013/172 Page No.0 EARTHING & BONDING 92 8.0 BATTERY CHARGER/ UPS 95 10. OISD GDN-145-09 ELECTRICAL SYSTEM CONTENTS -------------------------------------------------------------------------------------------------------------------------------------------------SECTION DESCRIPTION PAGE NO.Sr.0 SWITCHYARD AND OUTDOOR EQUIPMENT 89 4.0 CABLE NETWORK TERMINATIONS & JOINTS 89 5.0 MOTORS CONTROL STATIONS 91 6. ) and the electrical equipment was accordingly replaced to conform to revised classification? h) Whether the suggested remedial measures given in the Accident Investigation Reports. Rule No.” . 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.E.OISD – GDN – 145 Sr.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. if any. 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. 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. as per approved schedule (Review the inspection records)? “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines. 85 INTERNAL SAFETY AUDITS PROCEDURES SAFETY AUDIT CHECKLIST ELECTRICAL SYSTEM -------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR'S REMARKS -------------------------------------------------------------------------------------------------------------------------------------------------1.Number:OISD/DOC/2013/172 Page No.) As per I. 3) and displayed? j) Whether inspection of electrical equipment is carried out. E. Rule 51? c) Are all the substation equipment provided with double earthing connections? “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines. 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.0 SUBSTATION (EQUIPMENT & BUILDINGS) a) Is the substation equipment freely accessible for Operation. 86 INTERNAL SAFETY AUDITS PROCEDURES -------------------------------------------------------------------------------------------------------------------------------------------------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. Inspection and Maintenance? b) Are the minimum clearances around the equipment maintained as per I. Motors.OISD – GDN – 145 Sr. carried out? s) Whether CO2 fire electric fires? t) Whether sand-buckets provided? extinguishers provided for 2.Number:OISD/DOC/2013/172 Page No. Transformers & Busducts etc.oil drums. clothes. are vermin proof? r) Whether preventive Maintenance Schedules as per OISD-STD-137 etc. Relays.” . painting at regular intervals etc) m) Whether the substations / power plant rooms/control room /MCC rooms 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. are used as storage area for scraps.) and junction / terminal boxes etc. OISD – GDN – 145 Sr. 87 INTERNAL SAFETY AUDITS PROCEDURES -------------------------------------------------------------------------------------------------------------------------------------------------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. 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? “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines. Yellow.Number:OISD/DOC/2013/172 Page No.” . ” . & L. 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. 88 INTERNAL SAFETY AUDITS PROCEDURES -------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------r) Are all the power (H.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.Number:OISD/DOC/2013/172 Page No. 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? “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines.free of tripping hazards? bb) Whether the switchgear rooms located in the hazardous area are pressurized? (if not.T. 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.OISD – GDN – 145 Sr. H. 89 INTERNAL SAFETY AUDITS PROCEDURES -------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------3.0 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? “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines.0 SWITCHYARD AND OUTDOOR EQUIPMENT.H. Switches and circuit breakers D/O and H/G Fuses Poles/switches/insulator pins/stay clamps .Number:OISD/DOC/2013/172 Page No.OISD – GDN – 145 Sr.B.switch.” .Operating handle of the A.E. a) Are the following components individually earthed with two separate earthleads ( No. conductors are maintained as per I. is it being followed? h) Whether the doors of the gate are rusted and need to be painted? 4. 8 SWG copper or equivalent)? - Metal Frameworks A. 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. Rule (79)? c) Are the earth electrodes provided in sufficient number? Whether earth pits are properly maintained and tests carried out as per schedule? the d) Whether the lightning arrestors are connected after the A.B. 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.B. switch b) Whether the vertical and horizontal clearances from O. ” .Number:OISD/DOC/2013/172 Page No.OISD – GDN – 145 Sr. 90 INTERNAL SAFETY AUDITS PROCEDURES -------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------b) Whether the underground cables in excavated trenches are laid at designed depth with sand filling. what is the arrangement? l) Whether one run of earthing strip fixed through the entire length of cable Tray (wherever cable tray is used) ? “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines. 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. 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. 91 INTERNAL SAFETY AUDITS PROCEDURES -------------------------------------------------------------------------------------------------------------------------------------------------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.” .OISD – GDN – 145 Sr.Number:OISD/DOC/2013/172 Page No.) 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? “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines. and conduits earthed? p) Are all conduit ends for cables sealed at both ends? 5. pipes (conduits) used for cable entries (sleeves) sealed at both ends.I.) on the flameproof motors/control stations / terminal boxes? ( to accommodate XLPE cable termination etc. OISD – GDN – 145 Sr. 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. EARTHING & BONDING a) Is the earthing carried out as per IS:3043? b) Is the earth leakage protection wherever provided functioning satisfactorily? “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines.Number:OISD/DOC/2013/172 Page No. is it functioning satisfactorily? (test this) d) Whether the body of lighting fixtures are separately earthed in addition to cable armor earthing? 7. 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. 92 INTERNAL SAFETY AUDITS PROCEDURES -------------------------------------------------------------------------------------------------------------------------------------------------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.0 LIGHTING INSTALLATIONS a) Whether separate distribution for lighting system adopted from main switchboard.” . Number:OISD/DOC/2013/172 Page No. vessels. process piping.” . metallic structures / sheds and buildings and fencing etc.OISD – GDN – 145 Sr. 93 INTERNAL SAFETY AUDITS PROCEDURES -------------------------------------------------------------------------------------------------------------------------------------------------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. steel columns. 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? “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines. 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? “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines.OISD – GDN – 145 Sr. 94 INTERNAL SAFETY AUDITS PROCEDURES ------------------------------------------------------------------------------------------------------------------------------------------------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.Number:OISD/DOC/2013/172 Page No. 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.” . equipped with all protections ( short circuit.Number:OISD/DOC/2013/172 Page No. 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 ? “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines. and earthfault)? m) If synchronized with grid.OISD – GDN – 145 Sr.” . LSHS are used additional safety precautions should be taken. overcurrent. whether effective measures are available to prevent backfeeding? n) For Prime Mover where fuels like Naphtha. 95 INTERNAL SAFETY AUDITS PROCEDURES ------------------------------------------------------------------------------------------------------------------------------------------------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. Number:OISD/DOC/2013/172 Page No.) are available? g) Is the operation of UPS satisfactory? (Test for critical services) h) Whether trickle charger working and checked properly. 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.0 ELECTRIC HEAT TRACING a) Whether all indication lamps are functioning properly in the panel to ensure healthiness of tracer circuits. 96 INTERNAL SAFETY AUDITS PROCEDURES ------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------d) Are the cell voltage. c) Are there damages to insulation / traces? d) Is the system water tight? “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines. acid proof hand gloves etc. 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.OISD – GDN – 145 Sr. 10. g) Whether ELCB provided for portable equipment? h) Are the portable equipment.OISD – GDN – 145 Sr. switchboards 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. torches. 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. and test instruments and tools inspected regularly? “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines.Number:OISD/DOC/2013/172 Page No.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. including the electrical system in the mobile equipment / vehicles (Battery Operated). (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.. etc. 97 INTERNAL SAFETY AUDITS PROCEDURES ------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------11. generators. ” . of Portable tools/Mobile equipment (Electrically operated) in the last 2 years? (if so.OISD – GDN – 145 Sr.Number:OISD/DOC/2013/172 Page No. 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? by “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines. 98 INTERNAL SAFETY AUDITS PROCEDURES -------------------------------------------------------------------------------------------------------------------------------------------------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 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. -------------------------------------------------------------------------------------------------------------------------------------------------1) COATING CONDITION 100 2) CATHODIC PROTECTION 100 3) POWER SUPPLY TO CP STATION 101 4) ULTRASONIC THICKNESS SURVEY 101 5) INTERNAL CORROSION 102 6) PIGGING 102 7) INHIBITOR INJECTION 102 8) CPL/EWP SURVEY 103 9) SOIL TESTING 103 10) MAINLINE VALVE 103 11) HYDROSTATIC TESTING 103 12) PIPELINE PATROLLING 103 13) TELECOMMUNICATION & TELEMETRY 104 14) SINGLE BUOY MOORING SYSTEM 106 15) CONTINGENCY PLANS 107 16) DOCUMENTATION 107 “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines. 99 OISD – GDN – 145 INTERNAL SAFETY AUDITS PROCEDURES SAFETY AUDIT CHECKLIST 10.Number:OISD/DOC/2013/172 Page No.Sr.0 CROSS-COUNTRY PIPELINE CONTENTS -------------------------------------------------------------------------------------------------------------------------------------------------SECTION DESCRIPTION PAGE NO.” . . 2..” .1 After revisioning of coating whether PSP readings are recorded and monitored to observe improvements Yes/No 2...4 Dielectric strength of Insulation Joints Satisfactory/ Not satisfactory 2.7 Condition of test led points 2.) 2.5 Is schedule made for inspection of insulation joints/couplings (yearly) Yes/No 2..3 Number of insulating joints .1 Is rolling plan for pearson.6 No.P..Nos.. Nos.Sr. 2.9 If 'yes' the findings 2. (To check PSP profile graphs in conjunction with CP station reports) (b) Is any stretch of pipeline left cathodically unprotected for a period more than one year Good/Bad Yes/No Satisfactory/ Not Satisfactory Yes/No Satisfactory / Not Satisfactory Not Satisfactory Yes/No “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines. 100 OISD – GDN – 145 INTERNAL SAFETY AUDITS PROCEDURES SAFETY AUDIT CHECKLIST ELECTRICAL SYSTEM -------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR'S REMARKS -------------------------------------------------------------------------------------------------------------------------------------------------1. Stations .2 Periodic calibration of AC & DC volt meter/Ammeter and PSP Meter of CP Units Yes/No 2..Number:OISD/DOC/2013/172 Page No. 2.0 CATHODIC PROTECTION: (No....4 Type of coating and its application method . of C....3 Coating Condition (Survey report to be checked Satisfactory / not Satisfactory 1.10 If 'not satisfactory.Nos.0 COATING CONDITIONS: 1.. of test lead points for PSP Survey ..11 (a) Effectiveness of C. coating conductance and current drainage surveys made? Yes/No 1.8 Is schedule made for PSP survey (PSP readings at feeding points) (PSP readings at Test lead points quarterly) 2.P.2 If 'yes' is the schedule maintained Yes/No 1. any action plan drawn for correcting the deficiencies on short term and long term basis? 2. if any... average 3.hrs./day Satisfactory/ Not Satisfactory 4.Sr. .1 Inspection of source 3..1.3 If 'NOT SATISFACTORY'.3 Condition of back up power supply.1 Is schedule made and followed for thickness survey of mainline at : 4.16 Are all the C.4. any action plan for correcting the deficiencies drawn Yes/No 4...P. 101 OISD – GDN – 145 INTERNAL SAFETY AUDITS PROCEDURES ------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------2. the findings Satisfactory/ Not satisfactory 4.0 ULTRASONIC THICKNESS SURVEY 4.2 If 'Yes".13 If 'YES' any action taken/plan drawn for correcting the deficiencies Yes/No 2. units provided with the lightening arrestors Yes/No 2.. transformer oil checked ? Yes/No 3. unit connected with the earthing electrode ? 2.18 Safety aspects for fault condition due to AC/DC power system ------- 2. Is two yearly schedule made for thickness survey of unprotected pipeline section from I/F to scrapper launcher/receiver Yes/No “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines.Number:OISD/DOC/2013/172 Page No.20 Is the di-electric strength of C.15 Is the earthing resistance of C.P.P.P.2 Sharp pipe bends/Riser bends Yes/No 4. .19 Is the ground bed circuit resistance record maintained ? Yes/No 2.1 Exposed section of Pipelines Yes/No 4.17 Whether Lightening arrestor grid and Equipment Earthing grids are segregated Yes/No 2..0 POWER SUPPLY TO CP STATION 3.1.2 Power availability of CP stations. earthing electrode taken & record maintained Yes/No Yes/No 2....14 Is the C..” . . 102 OISD – GDN – 145 INTERNAL SAFETY AUDITS PROCEDURES -------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------5..” ..0 INTERNAL CORROSION 5. % by mass c) pH value d) Acidity.2.1 Is schedule made for pigging ? Yes/No 6..3 Is pig residue/dirty product analysis carried out? Yes/No If yes.2...2 6.0 Intelligent Pigging 6..5 Based on pig residue analysis internal condition of pipeline 6..Sr.2. any action plan has been drawn to implement the recommendations Satisfactory/Not satisfactory Satisfactory /Not satisfactory Yes/No 7.. 6. ..Number:OISD/DOC/2013/172 Page No. 6. corrosion rate < 1 MPY 1 to 4. any schedule made for carrying out the survey (once in five years).0 PIGGING 6.2 And. what is the value of a) Fe 0 % by mass b) Water.1..9 MPY 5.3 6.4 If yes..1. If not satisfactory.. findings of the survey.1. corrosion rate ? ..4 If the survey has been carried out.0 Descaling 6. .3 Whether Electrical Resistance probes are installed Yes/No 5.1.4 6.1 Is inhibitor injection being done and records maintained Yes/No “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines..2.2 If yes.0 INHIBITOR INJECTION 7.1 Is any IPS survey carried out ? Yes/No If no.9 MPY/ > 4. (To check the reports).1. ..1.2.is followed Yes/No 6. mg KOH/gm... Yes/No 6..1 Whether coupons are installed Yes/No 5... .. said sample tested to determine the efficacy of the existing coating of the pipe lines..2 Whether sufficient number of pipe lengths.141&API 1110 11.” .4 MOV working 11. OF MAINLINE VALVES .) 10.0 CPL/EWP SURVEY 8. Average dosing of corrosion inhibitor injection .1 Is any CPL/EWP SURVEYS CARRIED OUT Yes/No 8.Sr.2 If No. Yes/No 9.4 If not satisfactory.PPM/day 8.4 Variations observed in soil resistivity . schedule followed and valves operating freely.3 Supply to Motor Operated Valves (MOV) available Yes/No 10.2 If `yes'.. 10.0 MAINLINE VALVE (NO.2.1 Whether all repaired piping system are being tested in accordance with OISD . NOS.0 SOIL TESTING 9.1 Soil samples within ROW being tested once in five years. Yes/No 10. any schedule made for Carrying out the survey (once in five years) Yes/No 8..2 Is there any industrial affluent flowing over the ROW Yes/No 9.0 Locally/Remotely HYDROSTATIC TESTING 11. what are the findings (To check the report) Satisfactory/Not Satisfactory 8.3 If `yes'. Yes/No 9... pretested and kept at vulnerable locations for replacement if required Yes/No Yes/No “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines.. any action plan has been drawn to implement the recommendations.Number:OISD/DOC/2013/172 Page No..1 Is schedule made for maintenance of mainline valve Yes/No 10.3 If the survey has been carried out. 103 OISD – GDN – 145 INTERNAL SAFETY AUDITS PROCEDURES -------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------7. Yes/No 9. 1..2 Helicopter surveillance once in a month 12.0 PIPELINE PATROLLING (Total length of Pipeline .” .Sr.1.0 TELECOMMUNICATION & TELEMETRY (NO. whether various reports filled/ monitored regularly and proper checks on line patrolman exercised ..4 Inspection of Pipeline crossings at 12.3 Right of way inspection and maintenance of above ground structures along ROW once in a year Yes/No Yes/No Yes/No 12.OF REPEATER STN.a Rail/Road Bridge and suspended crossing (exposed pipeline) quarterly Yes/No 12.b Road/Highway crossing quarterly Yes/No 12..NOS) 13.c Submerged river crossing before and after monsoon Yes/No 12.1..1. (other than load shedding) corrective action taken Yes/No Whether all the lights and fans are working ? Yes/No State Electricity Board Energy Meter working ? Yes/No 13.5 Energy Meter Readings being noted Yes/No 13.2 If no.4.6 All the Radio Parameters as per 13.Number:OISD/DOC/2013/172 Page No. 13.1 Availability of Power supply Yes/No 13..4 “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines.1..4.1.1 Is the schedule made for 12.3 13.2 If reply to the above is yes. 104 OISD – GDN – 145 INTERNAL SAFETY AUDITS PROCEDURES -------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------12..km) 12.4.1 Ground Patrolling by Patrolman each segment twice in a week by physical walking. 12.1.. 13.G.11 13. of fire buckets/ extinguishers adequate and in working order ? Yes/No Whether aviation tower lights are in working condition ? Yes/No Whether twilight switches are in working condition ? Yes/No Whether the tower painting is done as per rolling plan ? Yes/No 13.9 Whether Engineering order wire (E.20 13.W) working. number of faulty units .” . Nos. if any...13 Sick cells.15 13.25 Check the resistance of lightning “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines. 105 OISD – GDN – 145 INTERNAL SAFETY AUDITS PROCEDURES ------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------format are being checked Yes/No 13.12 Whether all the Battery voltages are (should be above 2 volts)being checked Yes/No 13. Yes/No 13.16 13.7 Whether all the Radio Units are in working condition ? Yes/No 13.21 13.Sr.24 13.Number:OISD/DOC/2013/172 Page No. Yes/No Whether Rooms are in dust free condition Yes/No Whether all the parameters of charger are properly working.17 Auto change over working ? Yes/No 13.O.22 13.14 13. Yes/No 13.10 13. are being identified and corrective action taken Yes/No Whether specific Gravity of all the cells recorded in a register Yes/No Sufficient reserve of distilled water available Yes/No Check for the proper running of D.8 If no.19 Whether Diesel Tank of DG set is full Yes/No Whether all the alarms are in working order ? Yes/No Whether no.18 Is it free from leakages ? Yes/No 13.23 13. Set carried out. 27 13.” .1 Whether the following items are being inspected daily and records kept ? Free floatation of buoys Draft Free movement of rotating assembly Yes/No Yes/No Yes/No 14.3 Whether visual inspection of buoys and equipments for external corrosion is carried out on monthly basis ? Yes/No 14. Yes/No Whether Unauthorized Entry Alarm / Signal system is in working condition? Yes/No 14.Number:OISD/DOC/2013/172 Page No.Navigational aids Yes/No Yes/No Yes/No 14.29 13. 106 OISD – GDN – 145 INTERNAL SAFETY AUDITS PROCEDURES ------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------arrestor (better than 2 ohms) 13.28 13.Batteries .4 Whether following item are being inspected on quarterly basis ? - Anchor chains of buoys for wear tear and tension Fenders for damage Yes/No Yes/No “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines.32 Whether Telecommunication link VHF/UHF/Microwave/Fiber optics is available ? Yes/No Whether all the desired telesupervisory signals are passed on to master control station through remote terminal Unit (RTU) and data monitored? Yes/No Functional test of telecommunication/ telemetry system are being carried out daily Yes/No Telecommunication / Telemetry equipments are being inspected as per manufacturer's recommendations Yes/No Pressure/Temperature/Flow recorder charts are in working order and are being checked for its safe limits Yes/No Maintenance and inspection of safety instrumentation are being followed as per OISD-153.2 Whether following items are being inspected weekly and records kept ? .Sr.30 13.Mooring ropes and ancillary equipments .26 13.0 SINGLE BUOY MOORING SYSTEM 14.31 13. Sr. length.4 Is the list of Mainline emergency equipments/tools available ? Yes/No 15.Number:OISD/DOC/2013/172 Page No. 107 OISD – GDN – 145 INTERNAL SAFETY AUDITS PROCEDURES ------------------------------------------------------------------------------------------------------------------------------------------------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 14.1 Is there updated contingency plans for emergencies at ? - Installations Mainlines Off-shore facilities Yes/No Yes/No Yes/No 15.0 CONTINGENCY PLANS: 15.3 Are all the employees familiar with it ? Yes/No 15.3 Whether list of various codes to which Pipeline and SBM systems ? “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines. are available in Pipeline installation ? Yes/No 16.2 Is the contingency plans(s) displayed in conspicuous place ? Yes/No 15.0 DOCUMENTATION 16.5 Are the mainline emergency equipments/ tools stacked separately and marked for easy identification ? Yes/No 16.1 Whether the basic datas and parameters of the Pipelines/SBM system layout.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. diameter etc.” .6 Whether inspection of Hoses are being done as per the requirements of OISD-STD-135 Yes/No 15.5 Whether following items are being inspected annually ? - Expansion joints Oil swivel seals Yes/No Yes/No 14. (Lab bench or near ground level) 8. Is the condition of the utility lines healthy. 10. 11. Is vacuum system adequate and working properly. Whether fire extinguishers are adequately positioned. “OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines. Check the condition of Test benches & cupboards.” . Whether entry to the Laboratory area is restricted. 9. 18. Whether the drainage system has been provided with a oil trap. Whether any emergency siren button provided in the Lab.OISD – GDN – 145 Sr. 14. 4. Whether emergency lighting available. 6. 13. Whether system exists for switching off all equipments at the end of the day.Number:OISD/DOC/2013/172 Page No. Whether samples of Class 'A' petroleum products in air tight containers. 7. 17. Are all Gas Cylinders kept outside buildings and kept properly secured. Whether the on-site emergency plan includes possibility of a fire in the Lab. Whether the switches/plug sockets for various equipments intrinsically safe. Whether the height of the chimney in the fume chamber is sufficient. Whether important instructions. emergency procedures displayed. 5. Whether proper ventilation/exhaust system exists in the fume chamber area. 3. 108 INTERNAL SAFETY AUDITS PROCEDURES ANNEXURE CHECKLIST FOR SAFETY IN LABORATORIES -------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------1. Whether fittings in storehouse for returnable petroleum samples are of flameproof nature. 15. 12. Whether ELCB/ECB installed in the main power switch board. 16. 2.