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 and Natural Gas
1
OISD - GDN - 145 Revision - I July, 1995 Amended September 2001
Edition,
FOR RESTRICTED CIRCULATION ONLY
GUIDELINES ON INTERNAL SAFETY AUDITS (PROCEDURE AND CHECKLISTS)
Prepared by:
COMMITTEE ON “ INTERNAL SAFETY AUDITS”
OIL INDUSTRY SAFETY DIRECTORATE 2ND FLOOR, “KAILASH” 26, KASTURBA GANDHI MARG New Delhi - 110 001.
2
NOTES
OIL INDUSTRY SAFETY DIRECTORATE publications are prepared for use in the Oil and gas industry under Ministry of Petroleum and Natural Gas. These are the property of Ministiry of Petroleum and Natural Gas and shall not be reproduced or copied and loaned or exhibited to others without written consent from OISD. Though every effort has been made to assure the accuracy and reliability of data contained in these documents, OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from their use. These documents are intended only to supplement and not replace the prevailing statutory requirements.
Note
3
in
superscript
modification/changes/addition
indicates based
on
the the
amendments approved in the 19th Safety Council meeting held in September, 2001July, 1999
3
FOREWORD Safety Audits have been conducted in the oil/gas industry in one form or other. Generally, Safety Audits are of two types viz. Internal Safety Audits and External Safety Audits. While methodology to be adopted for carrying out the External Safety Audits is separately dealt with, this document contains guidelines for conducting Internal Safety Audits in a professional manner and is expected to assist the industry further in maintaining and improving the Safety. Different aspects of the Internal Safety Audits starting from the need of such Audits, methodology, preparation of reports, follow up actions on the recommendation of the Audit Reports have been covered in Section I of this document- "Internal Safety Audit Procedures". In addition, comprehensive Check Lists are given in Section II of the Document covering typical areas in the oil/ gas industry. These Check Lists would be useful tool for undertaking in-depth and systematic Internal Safety Audits and would go a long way in accelerating audits to ensure that no aspect is overlooked while carrying out such audits. The present document on Internal Safety Audits (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 2nd Floor, “Kailash” 26, Kasturba Gandhi Marg New Delhi - 110 001.
4
INTRODUCTION
This is the second edition of the OISD Guidelines on `Internal Safety Audits' (Procedure and Checklists), first edition of which was published in October, 1989. The first edition was prepared by OISD and did not have a regular Functional Committee. A Functional Committee for the objective of revising the same was therefore constituted. The original document has been now revised to include a new chapter on Internal Audit of cross-country pipelines in order to make it broad based and thoroughly updated with the experience gained during the first round of External Safety Audits of refineries, gas processing plants, Marketing terminals/LPG Bottling Plants etc. As during the interim period a number of new OISD Standards/ Guidelines have been published, reference to the same has also been provided wherever required. With the issuance of this edition, the guidelines contained in earlier edition stands revised.
5
SCOPE These guidelines are applicable for refineries/on-shore gas processing units(excluding all oil-field operations)/ and marketing installations. Items which may not be applicable in Marketing have been separately identified by an asterisk (*) mark. However, it should be clearly understood that in addition to check points contained in these guidelines locations may like to further improve the checklist in order to meet any specific requirements of the respective safety policy of the concerned organisation. In the case of terminals where no pipeline transfer is taking place, chapters 1,2,3,5,6 and 9 would be applicable. In the case of terminals where pipeline transfer is taking place, chapters 1,2,3,5,6,9 and 10 will be applicable. OISD-STD-144 on “ LPG Bottling Plant Operations” has recommended a periodicity of once a year for Internal Safety Audit of individual LPG Plant (Marketing). The inspection and Maintenance System as well as Electrical Safety Audits are to be carried out based on Internal Audit Checklists as stipulated in OISD-STD-144. The OISD-145 guidelines are exhaustive and therefore be adopted for carrying out a comprehensive Internal Safety Audit of LPG Bottling Plants (Marketing) for which chapters 1,2,3,7,8 will be applicable
6
COMMITTEE ON `INTERNAL SAFETY AUDITS' REVISION-I -------------------------------------------------------------------------------------------------------------------------------------NAME ORGANISATION -------------------------------------------------------------------------------------------------------------------------------------LEADER Shri Barath Balan
Hindustan Petroleum Corporation Ltd. (Marketing)
MEMBERS Shri M.N. Ahmed
Indian Oil Corporation Ltd. (R&P Division - Pipelines)
Shri S.K. Ray
Ex-Official Bharat Petroleum Corporation Ltd. ( Marketing )
Shri T.S.Charvethia
Bharat Petroleum Corporation Ltd. ( Refinery )
Shri S.N.Rao
Indian Oil Corporation Ltd. (Refineries & Pipelines Division)
Shri G.C.Sharma
Bongaigaon Refinery & Petrochemicals Ltd
Shri M.Bhaskar Rao
Hindustan Petroleum Corporation Ltd. ( Refineries )
Shri I.J.Shroff
Hindustan Petroleum Corporation Ltd. ( Refineries )
Shri C.T.Ananthakrishnan
Indian Oil Corporation Ltd. (Marketing Division)
Shri K.Madhusudanan
Cochin Refineries Ltd.
Shri D.Madhukar Rao
Gas Authority of India Ltd.
MEMBER CO-ORDINATOR Shri S.C. Gupta
Oil Industry Safety Directorate
-------------------------------------------------------------------------------------------------------------------------------------In addition to the above, several other experts from Industry contributed on the preparation, review and finalisation of this document.
7
OISD - GDN - 145 REVISION-I
GUIDELINES ON INTERNAL SAFETY AUDITS
SECTION - 1
SECTION - 2
INTERNAL SAFETY AUDIT PROCEDURE
INTERNAL SAFETY AUDITS CHECKLISTS
8
SECTION - 1
INTERNAL SAFETY AUDITS PROCEDURES
9
-------------------------------------------------------------------------------------------------------------------------------------SECTION DESCRIPTION PAGE NO. -------------------------------------------------------------------------------------------------------------------------------------1.0 INTRODUCTION
2.0
OBJECTIVES OF SAFETY AUDITS
3.0
SCOPE OF SAFETY AUDITS
4.0
TYPES OF SAFETY AUDITS
5.0
METHODOLOGY OF INTERNAL SAFETY AUDITS 5.1 Frequency of Audits 5.2 Formulation of multi-disciplinary
Audit Teams
5.3 Duration of Audits 5.4 Use of Safety Audit Check Lists 5.5 Preparation before Site Visits for Safety Audits 5.6 Briefing 5.7 Site Inspections 5.8 Discussions 5.9 Study of Documents 6.0
PREPARATION OF AUDIT REPORTS
7.0
FOLLOW UP OF AUDIT REPORTS
8.0
IMPLEMENTATION OF RECOMMENDATIONS
--------------------------------------------------------------------------------------------------------------------------------------
10
INTERNAL SAFETY AUDITS PROCEDURES 1.0
INTRODUCTION Identification of vulnerable areas and specific potential hazards, is one of the prime function of loss prevention in oil industry. Safety audit is an important tool in undertaking this function.
2.0
OBJECTIVES OF SAFETY AUDITS While the basic aim of safety audits is to identify the areas of weaknesses and strengths, safety audits are undertaken to meet different specific objectives viz.1.
To identify any design deficiencies and also any weaknesses which might have cropped up during modifications / additions of facilities.
2.
To ensure that fire protection facilities and safety systems are well maintained.
3.
To ensure that operating / maintenance procedures, work practices are as per those stipulated in the manuals and standards, which might have degraded with time.
4.
To check on security, training, preparedness disaster management etc.
5.
To check the compliance of statutory regulations, standards, codes, etc.
6.
As a social objective to cater to public opinion and concern environment. This also improves public relation of the organization.
for
handling emergencies and
for safe
3.0 SCOPE OF SAFETY AUDITS A Safety Audit subjects various areas of a company's activities to a systematic critical examination with the objective of minimizing loss. This includes all the components of the system viz. management policy, attitudes, training, design (Process, Mechanical, Electrical, etc.) aspect, layout and construction of the plant, operating Inspection & Maintenance procedures, emergency plans, personal protection standards, accident records.
4.0 TYPES OF SAFETY AUDITS Two types of Safety Audits are proposed to be carried out as below : I) Internal Safety Audit ii) External Safety Audit
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Audit conducted by Internal Audit teams of the organisation is categorized as Internal Safety Audit.The methodology for carrying out such Internal Safety Audit is described in greater detail under paras 5.0 to 8.0. Internal Safety Audits will be coordinated by local management under the overall direction from the Corporate Office. External Safety Audits will be carried out by outside teams consisting of technical experts from other organizations in oil industry, professional bodies and statutory authorities under the overall coordination of OISD.
5.0 METHODOLOGY OF INTERNAL SAFETY AUDITS 5.1 FREQUENCY OF AUDITS: All the facilities in a particular Refinery/Installation should be covered minimum once every year. In case of LPG bottling plants the internal safety audit should be conducted minimum once a year as per OISD-STD-144. However, facilities' design can be audited every 3 years or after any major modification or additions. For this purpose, the individual organisation/ installation should draw up a calendar in advance for carrying such audits for every calendar year which should be made known to all the Departments and concerned Area Managers. The areas to be audited should be clearly identified and logically grouped. The suggestive groupings in case of a Refinery Installation are given below. Similar groupings can be done for other types of Installations. However, this could be modified depending upon layout and complexity of the individual installation. Group -I
All LPG Storage, filling &
dispatch
facilities.
Group – II
All dispatch facilities like Tank-Wagon loading Tank - lorry loading, Bitumen filling and dispatch facilities.
Group - III
Oil Movement & Storage (OM&S) (Rest of all the facilities other than those covered under Group I & II, including TEL blending)
Group - IV
PROCESS UNITS :
Sub Groups IV - A Atmospheric / Vacuum Units IV - B Visbreaking,
Coking,
Bitumen Blowing Units.
IV - C Secondary Processing Unit like FPU / Units.
FCCU/HCU & H2 along with Treating
IV - D Naphtha HDS, Cat-Reforming, Kero / Diesel HDS etc. IV - E N2 & Others. Group - V
Power House, Electrical Sub-stations, Water Block, Utilities, Effluent Treatment.
Group - VI
Miscellaneous other facilities such as Workshops, Warehouse Laboratories etc.
Group - VII
General Audit, Fire Fighting and Safety, Layouts etc.
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5.2 FORMATION OF MULTI-DISCIPLINARY AUDIT TEAMS: The Internal Audits should be carried out through multidisciplinary audits teams. The composition of the Internal Safety Audit may vary depending on the Group and areas to be audited, however, person(s) concerned should have necessary experience and background to undertake in-depth audit in a particular discipline. A team of 4 to 5 experienced officers from various disciplines viz. Process / Production, Maintenance / Inspection, Electrical, Instrumentation, Fire & Safety and with the activity involvement of concerned Plant / Area Manager is suggested. One of the team members should be nominated as the leader of the audit team. In multi-unit organizations, the team members could also be drawn from the Head Office / Corporate Office and other operating Units under its control.
5.3 DURATION OF AUDIT Depending on the nature of audit and type / complexity of the installations in the selected group, the duration of internal safety Audit can be fixed. This may vary from 2 to 7 working days for facilities under each group. 5.4 USE OF SAFETY AUDIT CHECK LISTS Check lists are the most useful tool for undertaking systematic Safety Audit. Even for a skilled and well qualified engineer a good check list would be necessary as a guide. Like a code of practice, a Check List is a means of pooling the knowledge and hard won experience and ensures that no important aspect is overlooked or forgotten. Such check lists help maintaining uniformity and speeding up the audits. In Section-II of this document, detailed model Checklist covering important areas are given. It is suggested that oil industry members should adopt these model check lists for carrying out Internal Safety Audits.
5.5 PREPARATION BEFORE SITE VISITS FOR INTERNAL SAFETY AUDITS: Before the safety Audit team visits any particular facility for carrying out Safety Audit, it would be essential to study all relevant documents as below to get complete picture : - Layouts - P & IDs - Operating Manuals - Maint. / Inspection Manuals - Fire and Safety Manuals, etc. Depending upon the nature of audit more emphasis can be given to study specific documents. All the audit team members should study these documents in advance to know the details of the installation.
5.6 BRIEFING: Before beginning of each audit, all concerned persons of the area/installation be briefed by the team leader about the purpose of the audit. No impression should be left that audit will throw bad light on them.
5.7 SITE INSPECTIONS: Most of the information could be gathered through site inspection using ready-made check lists. The auditors should enter their observations under the remarks column and not simply state "yes" / "no". Wherever necessary, observations should be recorded in separate sheet. Inspection should be carried out accompanied by Installation / Plant Manager or the assigned officials.
10
5.8 DISCUSSIONS: Further information can also be gathered through discussions (formal & informal), with site personnel and Installation / Plant Manager, who is in-charge of the area or other site officers. The audit team should interact with persons from various disciplines such as Production, Maintenance, Electrical, Instrumentation, etc.. Formal discussions could be in the form of brief periodical sessions while informal discussions could be over a cup of tea with personnel working in the area.
5.9 STUDY OF DOCUMENTS: In addition to the documents which are already studied before inspection of the facilities, other documents, such as Operating Instructions, Standing Orders, Log Books, Log sheets, Accident Records, Minutes of Safety Committee Meetings etc. may also be studied as required.
6.0 PREPARATION OF AUDIT REPORTS The work of the Internal Safety Audit item should be presented in the form of a Safety Audit Report for each group which should contain observations & recommendations and also in brief the modalities adopted in conducting audit and the names of the audit team members. Before finalizing the report, the Safety Audit Team can give a presentation as feedback to the Operating / Management personnel of the Area / Installation. Additions or deletions could be made in the draft report based on the discussions and comments received during the presentation. This approach is always constructive and does not undermine the technical competence of the audit team.
7.0 FOLLOW UP OF AUDIT REPORTS Generally, the Internal Safety Audit Reports are submitted to the concerned authority who appoints the audit team for undertaking needful follow up actions. Only the appointing authority should exercise judgement in rejecting any of the recommendations. The appointing authority shall be of senior management level ( General Manager and above ). The crux of the safety audits lie in removing the weakness identified during the audit. Sometimes audit reports identify only the problem / weakness, but not the solution. In such cases, it would be necessary to undertake a detailed study of the specific area and to identify the rectification measures. Wherever the necessary in-house expertise is not available for detailed studies, help of consultants / professional bodies should be sought for.
8.0 IMPLEMENTATION OF RECOMMENDATIONS The final and most important phase is the implementation of recommendations. A senior person should be nominated for coordinating implementation of all accepted recommendation under a time bound program. Senior management should review the progress of implementation of recommendations periodically through Management Safety Committee meetings and other review meetings.
11
SECTION : 2 INTERNAL SAFETY AUDITS CHECKLISTS
12
SECTION : 2 INTERNAL SAFETY AUDIT CHECKLIST CONTENTS ----------------------------------------------------------------------------------------------------------------------Sr.
CHAPTER
SAFETY AUDIT PAGE NOS. CHECK LIST NO. ------------------------------------------------------------------------------------------------------------------------------------------------1. GENERAL SAFETY AUDITS OISD-GDN-145-01 6 - 11 2.
FIRE PROTECTION
OISD-GDN-145-02
12 - 18
3.
LAYOUTS
OISD-GDN-145-03
19 - 23
4.
PROCESS PLANTS
OISD-GDN-145-04
24 - 33
5.
OIL STORAGE AND MOVEMENT
OISD-GDN-145-05
34 - 38
6.
POL LOADING AND UNLOADING
OISD-GDN-145-06
39 - 51
7.
LPG BULK LOADING / UNLOADING
OISD-GDN-145-07
52 - 59
8.
LPG BOTTLING AND DISPATCH
OISD-GDN-145-08
60 - 68
9.
ELECTRICAL SYSTEM
10.
CROSS - COUNTRY PIPELINES
OISD-GDN-145-09 OISD-GDN-145-10
69 - 79 80 - 87
ANNEXURE 88 ---------------------------------------------------------------------------------------------------------------------------------------
13
OISD-GDN - 145-01 REVISION I
SAFETY AUDIT CHECKLIST No.OISD-GDN-145-01
GENERAL SAFETY AUDITS CONTENTS --------------------------------------------------------------------------------------------------------------------------SECTION DESCRIPTION PAGE NO. -----------------------------------------------------------------------------------------------------------------------1.0 ORGANISATION AND ADMINISTRATION 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8
Management Philosophy Procedures Safety Audits Safety Committee Meetings Safety consciousness & Propagation Work Permit System Contingency/ Disaster Plan Plant Security
2.0 INDUSTRIAL HAZARD CONTROL 2.1 2.2 2.3 2.4 2.5 2.6 2.7
House Keeping Machine Guarding General Safety features Maintenance of Tools and Tackles Materials handling Personnel Protective Equipment Toxic Materials and Occupational Health
3.0 EMPLOYEE TRAINING 4.0 FIRES, ACCIDENTS AND NEAR MISSES 4.1 4.2 4.3 4.4 4.5
Reporting formats Reporting Procedures Follow up of Recommendations Maintenance of Records & Data Review of Accidents Data
14
OISD-GDN-145-01 SAFETY AUDIT CHECKLIST 1.0 GENERAL SAFETY AUDITS ------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR REMARKS ------------------------------------------------------------------------------------------------------------------------1.0 ORGANIZATION AND ADMINISTRATION: 1.1 MANAGEMENT PHILOSOPHY a)
Whether the declared safety policy is made available to all concerned in written form ?
b)
When updated last ?
c)
Does the employees contribution towards safety form a part of the appraisal system ?
1.2 PROCEDURES
a)
Whether procedures are well defined and manuals are available & accessible plant / facility wise for the following functions ? - Operation - Inspection and maintenance - Electrical - Mechanical - Instruments - Civil - Fire fighting & Safety - Emergency and disaster management plans
b)
When were these documents updated last ?
1.3 SAFETY AUDITS a)
When was last External/Internal Safety Audit carried out ?
b)
Whether accepted safety audit recommendations are implemented with time bound schedules ?
1.4 SAFETY COMMITTEE MEETINGS Whether Safety Committee Meetings are held regularly ?
15
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK ------------------------------------------------------------------------------------------------------------------------------------------------1.5 SAFETY CONSCIOUSNESS & PROPAGATION a)
Whether following items have been taken care of ? Display of (in languages widely understood) - sequence of operations where critical / batch operations are performed.
- Safety posters/slogans. - Safety precautions at strategic points through sign boards. b
Whether fire & safety training programs are conducted periodically and are in line with OISD-STD-154 ?
c)
Whether Safety awareness competitions are held periodically ? - Type - Frequency - Participants Any other Motivation scheme exists ?
1.6 WORK PERMIT SYSTEM Whether work permit system meet the requirements of OISD Standards 105/137 ? 1.7 CONTINGENCY/DISASTER PLAN a)
Whether disaster management plans are available for different possible types of scenarios?
b) Whether all the concerned personnel are given their individual copies? c) Whether these copies are available at place, 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?
--------------------------------------------------------------------------------------------------------------------------------------------------
16
ITEM AUDITOR’S REMARK ------------------------------------------------------------------------------------------------------------------------------------------------1.8 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, visitors and contractors personnel for admission to restricted areas? d)How it is ensured that visitors/contractor personnel do not trespass into non permitted areas? e)Whether frisking is done for contractor personnel / visitors / employees; if so, how much percentage is covered under each category? f) Whether Crisis Management Scheme for BOMB Threat exists? g) Whether watch towers exist? 2.0 INDUSTRIAL HAZARD CONTROL 2.1 HOUSE KEEPING
-
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 -
-
-
- Rotary equipment in operating areas - Workshops - Others -
-
2.2 MACHINE GUARDING
2.3 GENERAL SAFETY FEATURES Check For: - unprotected Floor openings protected - Slippery defective floors - Stairway surfaces --------------------------------------------------------------------------------------------------------------------------------------------------
17
ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------- Inadequate illumination - Ventilation - Cross-overs over piping - Platforms/Hand rails - Walk ways in tank farm area - All intrinsic safety devices (For refinery,ref.to 1.7 of OISD145-04) *Ratings:(Notation Followed) 1: Not meeting requirement 2: Meeting requirements satisfactorily 2.4 MAINTENANCE OF TOOLS AND TACKLES
*
Whether all lifting tools and tackles are tested as per statutory requirements and record maintained?
2.5 MATERIALS HANDLING( Mechanised/ manual) Whether safe lifting methods and proper protective equipment are used? 2.6 PERSONNEL PROTECTIVE EQUIPMENT a) Whether requirements are identified as per operating manuals / standards? b) Are these readily available at the time need? c) How periodically these are inspected and records maintained? d) Whether personnel are trained for effective use?
2.7 TOXIC MATERIALS AND OCCUPATIONAL HEALTH a) Are there any toxic materials in use ? b) Whether relevant personnel protective equipment is available (Ref. Section 2.6) as per requirement? c) Is storage of toxic materials proper? d) Is disposal of containers of toxic materials safe ? --------------------------------------------------------------------------------------------------------------------------------------------------
18
ITEM AUDITOR’S REMARK ------------------------------------------------------------------------------------------------------------------------------------------------e) Is there display of Do's and Dont's for handling of toxic chemicals? f) How the Health monitoring is done. Whether records are maintained ? g) Is First Aid available for toxic chemicals handled? h) Whether proper communication system exists? i) Is there any monitoring of work environment for toxic chemicals /gases etc. and records maintained thereof? Whether material safety data sheet displayed Note 3 3.0 EMPLOYEE TRAINING a) Whether the training given for all employees (operators / technicians / engineers) is in line with OISD- STD-154 w.r.t following items : -
syllabi course materials class room/field on job training on job fire and safety
b) Whether Refresher courses are conducted for technical personnel? c) What is the evaluation and qualifying system? d)
How employees performance?
are
Motivated
for
safety
e) How the contractor personnel are trained/briefed w.r.t safety procedures? f)
Whether the T/T crew are trained as per the C.M.V.Rule 9 ?
4.0 FIRES, ACCIDENTS AND NEAR MISSES 4.1 REPORTING FORMATS Whether reporting formats as per OISD-GDN-107 are available for (preferably separate)? - fires and explosions - accidents causing injuries to personnel and damage to equipments and products (without the explosion/ fire) - Near misses
19
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK ------------------------------------------------------------------------------------------------------------------------------------------------4.2 REPORTING PROCEDURES a) Whether responsibilities are clearly defined as regards to preparation of the reports? b) Who receives the reports? c) Whether all minor incidents and near misses as reported to Safety Dept/Concerned authority? 4.3 FOLLOW UP OF RECOMMENDATIONS 4.3.1 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? 4.3.2
Dissemination
a)
Whether the procedures /systems are established & streamlined for dissemination of information?
b)
What is the MIS upto Chief Executives level w.r.t information on fires, accidents and near misses?
4.4 MAINTENANCE OF RECORDS & DATA a) Accident statistics of last how many years are available ? b) If required, how fast any case history could be located? - w.r.t specific case - based on particular area/type 4.5 REVIEW OF ACCIDENTS DATA a) Is there any system to periodically review the trends of accidents for taking necessary actions ?
20
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK ------------------------------------------------------------------------------------------------------------------------------------------------b) Whether any review is under taken at top management/ corporate level periodically, to review the safety performance and new goals are set up?
21
OISD-GDN-145-02 REVISION I
SAFETY AUDIT CHECKLIST FIRE PROTECTION CONTENTS --------------------------------------------------------------------------------------------------------------------------SECTION DESCRIPTION PAGE NO. -----------------------------------------------------------------------------------------------------------------------1.0
PHILOSOPHY AND STANDARDS
13
2.0
FACILITIES
13
2.1
Fire water
13
2.2 2.3 2.4 2.5 2.6 2.7 2.8
Fire Hydrant System Foam System Fire Station Fire Extinguishers Fire Hoses and Accessories Protective/ Safety Equipment Others
14 14 15 15 15 15 15
3.0
PROCEDURES
16
3.1 3.2 3.3 3.4 3.5
Organisations Disaster Management Plan Inspection and Testing facilities Training Checklist for DMP
16 17 17 17 18
22
OISD-GDN-145-02 SAFETY AUDIT CHECKLIST 2. FIRE PROTECTION
-------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR'S REMARKS --------------------------------------------------------------------------------------------------------------------------------------In order to evaluate the adequacy of fire fighting facilities and procedures, answers should be obtained for the following four basic queries: 1. Are the facilities adequate for anticipated fires ?
and
reliable
2.Is manpower available and effectively trained to handle the fire fighting equipment. 3.Are emergency control procedures adequately established. Since the scope under each query is too broad and it is difficult to give simple answers, these are divided into a number of simpler items/ questions which could be evaluated/answered with reasonable clarity. 1.0
PHILOSOPHY AND STANDARDS
Does basic philosophy for designing the fire fighting facilities follow OISD 116 (for Refinery),OISD 117(for Marketing-POL) and OISD 144 (LPG bottling plants) as necessary ? 2.0
FACILITIES
Whether following facilities are provided adequately and have the necessary efficacy. 2.1
FIRE WATER
2.1.1
Fire water storage
a.What is the capacity & how was it determined b.Is it sufficient ? Is the storage AG/UG or other wise ? c.What are replenishment source ? adequate ?
Are they
d.What's the internal replenishment rate ? --------------------------------------------------------------------------------------------------------------------------------------------------
23
ITEM 2.1.2
AUDITOR’S REMARK
Fire Water Pump :
a. Is location away (from hazardous area) ? b. What's the power source ? How many are diesel & elect driven ? c. What's the stand by philosophy ? d. What's the capacity of each pump and at what head ? e. What's the priming system? f. Is there any jockey pump ? g. What's the capacity ? What's set pressure? h. What's fire water pump starting system manual/auto ? I. What's the condition of battery of diesel engine ? j. What's the diesel fuel tank capacity (hrs) ? k How frequently does jockey pump start ? How long it runs ? l. Are the fire water pumps/engines started & observations logged as per OISD Std. 116/ 117/144. 2.2
FIRE HYDRANT SYSTEM
Check and comment on the hydrant system layout design position of hydrants/monitors, flow rate pressure at the farthest point, condition of pipeline etc. Please comment on the system as per the following. 2.2.1
Network - Grid type/Closed type/Any other
2.2.2
Mains
a.
What's the material of construction of pipes ? 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
b. c. d. e. f. g.
2.3
FOAM SYSTEM
a. b.
What are the types of foam available? What are the dilution potential and the quantities ? What are the storage arrangements and its accessibility
c.
--------------------------------------------------------------------------------------------------------------------------------------------------
24
ITEM AUDITOR’S REMARK ------------------------------------------------------------------------------------------------------------------------------------------------d.
Do the coverage and application rate for floating roof/fixed roof tanks meet OISD norms ?
e.
Are foam branch pipes, nozzles, wheeled equipments available and adequate as per OISD Stnadard ?
f.
Proportioning equipment - suitability proper pick up
2.4
FIRE STATION
a.
Is the location away from hazardous areas ? Are the no. and variety of fire vehicles sufficient ? Facilities on fire vehicles capacity, pressure, flow proportioning system etc. Daily starting of vehicles and other check logs.?
b. c.
2.5
FIRE EXTINGUISHERS
a.
Are portable extinguishers meeting OISD requirements ? Are they BIS approved ?
b.
Whether periodical inspection, maintenance and testing of fire extinguisher are promptly carried out and proper records maintained in line with OISD Std.?
c.
Are replacement of extinguishers on shell failure or hydrotest ensured and necessary records available ?
d.
Are quantity of cartridge and powder sufficient at work site and spares available in store in line with OISD Std. ?
e.
What is the monthly cartridge and product ?
f.
Fire Extinguishers attached to all the vehicles / position at various sites shall be numbered and date of testing shall be written on them Note 3
g.
Fire Extinguishers attached to TTs should also bear the TT number Note 3 .
2.6
FIRE HOSES AND ACCESSORIES
a.
Are no of hoses sufficient w.r.t. no. of hydrants in the system ?
consumption
25
of
b. c.
Are the hose boxes strategically placed ? Are the hoses easily removable during an emergency ?
26
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK ----------------------------------------------------------------------------------------------------------------------------------------------d. Are the hoses periodically tested/ checked and replaced? e. Are the hose boxes painted fire red Note 3 as per OISD Standard.? f. Are adequate sand drums / buckets available ? g. Are all various types of nozzles/foam branch pipes etc. provided as per OISD STD.? h.
Are the hoses BIS Approved Note 3 ?
2.7
PROTECTIVE/SAFETY EQUIPMENT Are safety appliances available in line with OISD 116/117/144 Standard? ADDITIONAL ITEMS : FACILITIES AT PORT
Are the fire fighting facilities (fixed as well as portable) provided at the port meeting requirement as per OISD-STD- 156 ? 2.8
OTHERS Whether the fire siren and fire alarm are provided at strategic locations and are audible up to the desired range ? Whether siren codes are identified for different types of fire/emergencies ?
2.8.1
Fire siren and fire alarm network (Electrical/ mechanical/ hand operated) Satisfactory working. Differentiation between different types fires / emergencies.?
of
Check the locn./range and report - Within and to outside. - Normal and emergency. - Condition of radio communication equipment. - Availability of alternate power supply during normal supply failure - Inspection and maintenance schedule - Training of the users. 2.8.2
Ambulance/Other means of transport and First-Aid services with complete kit Note 3. -
Contingency Plan for medical emergency.
27
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK ------------------------------------------------------------------------------------------------------------------------------------------------- Evacuation, etc. - First Aid training to personnel on shift. 2.8.4
Availability of critical areas.
2.8.5
Availability of special fire fighting components aprons / suits / emergency flood lights, power megaphones, etc.
3.0
PROCEDURES
3.1
ORGANIZATION
a.
Whether the organogram of fire fighting and other supporting services well defined ? Is periodic fire drill conducted, shortcomings observed and necessary action initiated ?
b.
c.
emergency,
lights
in
Does location have well defined fire order ? Whether organogram has provision to meet emergency situation during idle shift / sundays and holidays.
d.
Whether relevant fire order is displayed at various work stations indicating station employees role during fire / emergency ?
e.
Whether following documents are updated and displayed as reqd. - Organogram - Fire hydrants layouts and P & ID diagrams - Fire fighting procedures / manual
f.
Whether layouts and organogram displayed ?
3.2
DISASTER MANAGEMENT PLAN (Ref.to new checklist for DMP)
a.
Whether mutual aid schemes are made with neighboring industries, local fire brigades, etc.
b.
Whether resource requirements are worked out
28
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK ------------------------------------------------------------------------------------------------------------------------------------------------3.3 INSPECTION AND TESTING FACILITIES Whether periodic inspection and maintenance / testing is done and proper records maintained for following : a. Pumps - Is flow vs. pressure meeting the requirement ? - Is lubrication periodically carried out ? b.
Hydrants - Are pressure and flow at different points adequate enough ? - Are all valves easy to operate ?
c.
How effective is the fire water spray system ?
d.
Is foam proportioning equipment in working order ?
e.
Whether hydrotesting and regular inspection of fire gate mains undertaken and records maintained ?
f.
Whether various checks & records of periodical running of Diesel engines carried out?
g.
FIRE HOSE AND ACCESSORIES - Are hoses , nozzles, adapters, hose holders, wrenches etc. inspected regularly ?
h.
Foam concentrate - What is the inventory ? Are the procurement / expiry date record maintained? - Whether protein foams churned regularly and record maintained ?
3.4 TRAINING Whether training provided fire crew / other employees / CISF etc. is in line with OISD std. 154?
29
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK ------------------------------------------------------------------------------------------------------------------------------------------------3.5 CHECKLIST FOR DMP 1. What is the frequency of DMP drill ? When was it last conducted ? Whether the short comings observed during drills were analyzed and action taken to prevent repetition ? 2.Whether mutual aid schemes are planned with neighboring units local fire brigade etc. ? Is the scheme periodically discussed with members ? Are they trained to fight fire in oil / gas installation / 3. Whether the resources of the operating location and the mutual aid members properly tabulated ? Whether assessment of necessary man power and equipment studied and action taken for the shortfall ? 4. Whether organogram of various co-ordinators, succession charts showing alternate persons and sub-organisation chart well displayed ? 5. Are responsibilities of various neighboring industrial units, discussed and recorded ? Whether the duties of various coordinators and team members well defined ? 6. Are the following information included in the DMP ? Name, address, telephone numbers (Off.and Res. ) of anchorages / key persons are to be clearly shown. a. b. c. d. e.
f.
Mutual aid members Police, fire and district authorities. Hospitals and doctors Medical shops, ambulance, blood bank, blood donors, Water supply dept. water transporter, elect. boards, railways, port trust, telephone exchange. Generator hire service, transport hire service , welfare bodies, social organization and catering services.
7.
Is emergency control centre planned properly furnished / fitted to meet requirement ?
and the
8.
Whether DMP is based on MCA and analysis ?
risk
30
OISD-GDN-145-03 REVISION I
SAFETY AUDIT CHECK LIST No. OISD GDN-145-03
LAYOUTS CONTENTS -------------------------------------------------------------------------------------------------------------------------------------SECTION DESCRIPTION PAGE NO. ------------------------------------------------------------------------------------------------------------------------------------------
1.0
TOPOGRAPHY OF INSTALLATION
20
2.0
SURROUNDING OF THE INSTALLATION
20
3.0
INTER - DISTANCES
20
4.0
TANKFARMS
20
4.1 4.2 4.3
Grouping of tanks Dykes LPG storage
20 20 20
5.0
PROCESS UNITS
21
5.1 5.2 5.3
Location Control room Field
21 21 21
6.0
OTHER FACILITIES AND EQUIPMENT
21
6.1 Electrical power lines 21 6.2 Electrical switchgear 21 6.3 Roads 22 6.4 Administrative buildings/ workshops/canteen 22 6.5 Boiler plants 22 6.6 Gantries 22 6.7 Waste water facilities 22 6.8 Water cooling towers 22 6.9 Elevated platforms 22 6.10 Piping 22 6.11 Rail spurs 23 6.12 Fire hydrants/ monitors/ safety showers/ hose etc. 23 6.13 Compressors 23 6.14 Miscellaneous 23 -------------------------------------------------------------------------------------------------------------------------------------------------
OISD-GDN-145-03
31
SAFETY AUDIT CHECKLIST LAYOUTS ------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR'S REMARKS ------------------------------------------------------------------------------------------------------------------------------------------------1.0 TOPOGRAPHY OF INSTALLATION - Susceptibility for flooding - Location of process units and tank farms in undulating areas. 2.0 SURROUNDING OF THE INSTALLATION - Flammables / Toxics/ Ignition sources up/ down wind 3.0 INTER-DISTANCES Code / standard/ regulations followed /deviated (Ref.OISD-STD-118/144). - Equipment/block/facility to boundary walls - Block/facility to block/facility - Equipment to Equipment switch in a block / facility. 4.0 TANKFARMS 4.1 GROUPING OF TANKS - Mixing of different class products in POL tank farm -
Accessibility of tanks for fire fighting.
4.2 DYKES - Aggregate capacity of tanks in each Dyke / enclosure - Capacity of Dykes with respect relevant group
to
- Construction and dimensions of dyke wall - Routing / Cris- crossing of process / fire hydrant lines inside dyked tank farm - Provision of fire walls.
32
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK ------------------------------------------------------------------------------------------------------------------------------------------------4.3 LPG STORAGE - Orientation w.r.t. wind direction - General state of terrain without depression / large ditches - No of vessels in each group and the capacities
aggregate
-Provisions of slope and spill collection shallow pumps. - Vapour trap 5.0 PROCESS UNITS 5.1 LOCATION - Consolidated / Scattered - Separation from tank farm/concentration of people - Down wind from ignition sources 5.2 CONTROL ROOM - Design for minimum occupancy - Electrical area /equipment classification - Upwind from sources of flammables / toxic materials - Easy approach to entrance and to fire fighting facilities - Safety of control room from any blast situation - Emergency Light during power failure at Process Control room. Note 3 5.3 FIELD - Positioning of process equipment without stacking - Segregation of equipment handling hazardous / materials - Adequacy of accessways for the movement of equipment and people. - Strategic location of fire fighting equipment - Over head clearances for passage of heavy equipment like cranes - Adequate provision of oily water sewers and catch pits.
water
and storm
- Packing and grinding of susceptible leaky areas
33
34
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK ------------------------------------------------------------------------------------------------------------------------------------------------6.0 OTHER FACILITIES AND EQUIPMENT 6.1 ELECTRICAL POWER LINES - Rooting below / above ground - Passing over critical facilities - Separation from elevated structures which may fall across power lines - Location of power receiving station & layout hazard 6.2 ELECTRICAL SWITCHGEAR - Upwind from flammable sources - High ground in flooding areas - Routes of overhead power cable and instrument cable trays and their fire protection/ fire proofing 6.3 ROADS - Road widths and turning radii for movement of large fire fighting vehicles . -
Separate entry points product movement
for
employees
and
- Layout of the roads for minimum truck traffic in grass - Accessibilities to each process unit/tank - Crossing of pipe alleys - Concreted / asphalted (condition) - Process Plants and facilities shall have access roads for fire tenders from at least two sides. Note 3 6.4 ADMINISTRATIVE BUILDINGS /WORKSHOPS/ CANTEENS -
Peripheral locations Separation from hazardous areas Upwind from sources of flammable / toxics
6.5 BOILER PLANTS Upwind and separation from flammable materials
35
sources of
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK ------------------------------------------------------------------------------------------------------------------------------------------------6.6 GANTRIES - Peripheral location - Downwind from ignition sources - Separation from main line of rail / road 6.7 WASTE WATER FACILITIES - Peripheral locations - Down wind from concentrations of people
ignition
sources /
- Any treatment facility to dischargeable water for pollution control 6.8 WATER COOLING TOWERS - Down wind from ignition sources/ concentration of people 6.9 ELEVATED PLATFORMS - Permanent platforms for all operating points - Alternate routes for descent - Landing at grade in safe locations 6.10 PIPING - Head bumpers, shin splitters and tripping hazards - Personnel protection from hot lines - Fire proofing of pipe racks. 6.11 RAIL SPURS - Clearance for derailments - No facility opposite the end of the spur. 6.12 FIRE HYDRANTS / MONITORS / SAFETY SHOWERS / HOSE ETC. - No obstruction for approach. Good path for retreat
36
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -----------------------------------------------------------------------------------------------------------------------------------------------6.13 COMPRESSORS - Not in closed buildings - Down wind from rest of unit 6.14 MISCELLANEOUS - Location of fire station and fire pump - Location of smoke booths - Display of Layout drawing and display of P & I DRAWING -Check piping layout for minimum piping - Greenscaping area - Flood light towers & security towers - Grading of various block facilities - Storm water drains & easy drainage - Height of flares is adequate - TTL gantry and easy exit through the product movement gate - Provision of Truck parking area
37
OISD-GDN-145-04 REVISION I
SAFETY AUDIT CHECKLIST No.OISD GDN-145-04 PROCESS PLANTS CONTENTS --------------------------------------------------------------------------------------------------------------SECTION DESCRIPTION PAGE NO. ---------------------------------------------------------------------------------------------------------------1.0
GENERAL
25
1.1
Layout and Drainage
25
1.2
Fire Protection facilities
25
1.3
Housekeeping
26
1.4
Training
26
1.5
Inspection & Maintenance
26
1.6
Electrical
27
1.7
Instrumentation
27
2.0
PROCESS SUB-SYSTEMS
27
2.1
Control room
27
2.2
Pump House
28
2.3
Compressor house
29
2.4
Heat exchangers/ condensers/ coolers
29
2.5
Process vessels and columns
30
2.6
Process furnaces
30
2.7
Process piping
31
2.8
Relief and Disposal System
32
2.9
First aid
33
38
SAFETY AUDIT CHECKLIST 4.0 PROCESS PLANTS ----------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITORS REMARKS -----------------------------------------------------------------------------------------------------------------------------------------1.0 GENERAL 1.1 LAYOUT AND DRAINAGE a)
OIDF-STD-118 ? (deviations, if any to be specified)
b)
Whether the location of the control room & furnace meets the OISD-STD-118
c)
Whether proper approach roads to the plant have been provided ?
d)
Whether ladders, platforms provided are as per standard engineering practices and can be considered adequate ?
e)
Whether oil water sewers are adequately sized and the manholes on these sewers covered properly ?
f)
Whether the plant surface drainage systems are adequately sized and properly maintained ?
g)
Whether a closed blow down been provided for draining of from the vessels / equipments pump out arrangement from tank ?
1.2
FIRE PROTECTION FACILITIES
a)
Whether the fire water network provided is well designed (Ring type) and covers all sides of the plant ? refer OISD116.
b)
Whether the hydrants, water monitors are provided from all sides of the plant ?And are they located more than 15 meters away from nearest hazard ?
c)
Whether steam lancers have been provided and are adequate ?
d)
Whether all hydrants, monitors, hose boxes are easily accessible ?
e)
Whether adequate number of portable fire extinguishers have been provided all over
39
system has hydrocarbon with proper underground
the plant as per the OISD-116 ?
40
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------f)
Whether communication systems, fire alarms and p.a. system have been provided ? Are they working ?
g)
Whether a copy of fire fighting manual is available in the plant control room ?
h)
Whether safety committee meetings are conducted at plant level ? Is the frequency adequate?
1.3.
HOUSEKEEPING :
a)
Whether the plant floors particularly in pump house, heat exchanger areas are regularly washed to avoid Oil Accumulation ? Any visible Oil Accumulation on the floor, drains found ?
b)
Are redundant pipes/valves/ pump foundations /insulation debris removed from process area ?
c)
Whether the general housekeeping in the area can be considered as ; - adequate - not adequate
1.4
TRAINING
a)
Are copies of updated operating manual, fire & safety manual, disaster control manual, standing instructions available in the control room ?
b)
Are the working personnel in the area given thorough training on operations, safety and fire fighting at the induction stage ?
c)
Whether subsequent refresher training programs are organized-periodically?
d)
Whether contractor employees are given basic training on hazards of petroleum products & safe practices ?
e)
Whether the workers are using proper personnel protective clothing such as hand gloves, safety shoes, helmet, face shield etc. ?
41
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK ------------------------------------------------------------------------------------------------------------------------------------------------1.5
INSPECTION & MAINTENANCE
a)
Whether inspection of equipments/ tanks /piping /safety valves etc. are carried out as per schedules? Are history cards maintained ? Refer OISD129 / OISD-127.
b)
Whether all the modification works are undertaken only with approved engineering drawings ?
c)
Whether a well designed work permit system exists for the following and is rigidly followed ; Refer OISD-105. - Hot/Cold work - Energizing and de-energizing of electrical Equipment. - Excavation - Vessel Entry - Entry of Vehicle into battery area.
1.6. ELECTRICAL a)
Whether all motors, electrical fittings in the plant are as per area classification ? Is area classification drawing available ?
b)
Whether equipments properly earthed ? readings taken periodically ? Are records maintained ?
c)
Whether illumination can be considered adequate ?
d)
Whether emergency lighting system has been provided ?
e)
Whether any interlocks bypassed and recorded ?
1.7
INSTRUMENTATION:
a)
Whether electronic instrumentation provided are as per area classification?
b)
Whether minimum safety instrumentation provided for furnace, vessels, compressors etc. and is well maintained ?
42
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK ------------------------------------------------------------------------------------------------------------------------------------------------c) Whether any schedule exists for checking up of various interlocks, shutdown systems ? Are such schedules followed and recorded ? d)
Whether any process interlock bypassed and recorded ?
e)
Whether smoke / heat / gas / hydrocarbon detectors are provided and are working ?
2.0
PROCESS SUB-SYSTEMS
2.1
CONTROL ROOM
a)
Whether fire protection provided and considered adequate ?
b)
Whether updated P & I diagram available ?
c)
Whether emergency shutdown controls are available ?
d)
Whether requisite PPE & first aid kit available ?
e)
Whether control room is blast proof, if it is hazardous area ?
f)
Whether the cable entry in the control room is properly sealed ?
g)
Whether control room pressurization has been provided and working satisfactorily ?
2.2
PUMP HOUSE :
a)
Whether the location of the pump house with respect to furnace is as per OISD 118 ?
b)
Whether hot pump have been segregated from pump handling lighter hydrocarbons ?
c)
Whether hot pumps are properly located so as to prevent fire due to spillage of hydrocarbon from over head ?
d)
Whether piping arrangement w.r.t. personnel's movement satisfactory ?
e)
Whether hot pumps are properly insulated ? (including the associated piping) ?
43
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK ------------------------------------------------------------------------------------------------------------------------------------------------f) Whether the hot pumps are provided with warm up lines ? g)
Are vents / drains of hot pumps cooled before discharge ?
h)
Whether reciprocating pumps have proper safety release system, if discharge is blocked ?
i)
Are the threaded joints on the pump vents / drain lines found corroded?
j)
Whether all pump drains are connected to CBD and OWS ? Any of the drains found congealed ?
k)
Does the pump house floor drain have a proper water seal to prevent propagation of fire from OWS to pump house ?
l)
Are the auto start / stop of the pumps (where applicable) checked as per schedule and recorded ? Check at random ?
2.3
COMPRESSOR HOUSE
a)
Whether the location is well ventilated ?
b)
Whether the following are in working condition ? -
Vibration monitoring system Anti surge device Speed control system Shut down system Lubrication system
c)
Whether various alarms and signaling systems are in working condition ?
d)
Are the safety valves on the discharge side of the compressor checked as per schedule ?
e)
Whether suction strainer is periodically cleaned ?
f)
Whether the compressor has a proper depressurising system ? Is venting system proper ?
g)
Whether there is a condensate collection system at suction / discharge of the compressor ? if so, is it functional ?
44
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK ------------------------------------------------------------------------------------------------------------------------------------------------h) Whether the compressor has nitrogen inerting system ? if so,is it functional ? i)
Do compressor safety valve atmospheric vents have nitrogen / steam purging especially for hydrogen rich gases ?
2.4.
HEAT EXCHANGERS/CONDENSERS/COOLERS
a)
Are adequate nos. of high vents / low points drains with proper isolation provided ?
b)
Whether provision for thermal relief/ thermal expansion has been provided ? Are TSVs on line ?
c)
Whether the insulation / cladding is fully covering the exchanger ? Is earthing proper ? Are supports fire proofed ?
d)
Does sacrificial anode exist for coolers / condensers where different metals are in contact ?
e)
Whether the operating parameters and test pressures have been tagged on the equipment and is being operated within that?
f)
Whether the over head condenser platform is within reach for fire fighting and does the overhead condenser platform have two sets of staircases at either end ?
2.5
PROCESS VESSELS AND COLUMNS: (REFER OISD STD-152)
a)
Whether relief valves are periodically tested and records maintained ?
b)
Whether all the utility connections are in working condition ?
c)
Whether the vessel has been provided with adequate safety instrumentation ?
d)
Are the nozzles, nipples on idle drains and vents capped / blinded ?
e)
Whether vessel supports are fire proofed and it is in proper condition ?
f)
Whether insulation / painting is proper ?
45
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK ------------------------------------------------------------------------------------------------------------------------------------------------g) Do all columns have two sets of level indicators ? 2.6
PROCESS FURNACES; (REFER OISD-STD-111)
a)
Whether the pass flows are provided with recorder and controller and are properly working ?
b)
Whether skin temperature and bridge temperatures are recorded ?
c)
Whether each main burner has a pilot burner ?
d)
Whether electric igniters are provided for each burner and are they well maintained?
e)
Whether fuel oil supply header is properly steam traced and insulated ?
f)
Whether both oil and gas lines have proper blinding facilities at the battery limit ?
g)
Whether the furnace has a trip system / flame out protection system ? Whether on line testing of the same is done ?
h)
Whether furnace has step ladder & monkey ladders to reach each platform ? Is alternative escape ladder available from burner-valves platform ?
i)
Whether safety wears such as safety goggles, face shield etc. are used by operators regularly while adjusting / viewing burners ?
j)
Whether the location of the explosion door can be considered safe ?
k)
Is the snuffing and purging steam valve manifold easily accessible ? Is it away from fire radiation risk zone ? Is the coil purging steam facility in line with OISD-111 Annexure -1 ?
l)
Whether the damper control system is satisfactory ? Is position of damper readable from ground level ?
m)
Whether the control system for drop out doors opening can be tested on line ?
46
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK ------------------------------------------------------------------------------------------------------------------------------------------------n) Whether the location and height of FD fan air intake can be considered safe ? o)
Whether the furnace has a decoking system which is operative ?
p)
Whether noise level near the furnace is within permissible limit ? Is it monitored atleast once a year ?
q)
Can the condensate draining, OWS line connection & manhole location for the furnace be considered safe ?
r)
Whether the support structures are properly fire proofed ?
2.7
PROCESS PIPING
a)
Whether expansion loops / expansion joints in working order ?
b)
Whether TSVs provided are periodically tested, records maintained ?
c)
Whether pipe supports (sliding / spring supports ) guides and anchors are in order ?
d)
Does the piping slope towards drain points / knockout pots ?
e)
Whether all piping above 60 deg. C surface temperature have safety insulation ?
f)
Whether continuity jumpers provided between flange joints for LPG, naphtha, ATF etc, (Refer OISD-STD-106 ).
2.8
RELIEF AND DISPOSAL SYSTEM
a)
Whether the relief valves have been set at 10% over normal operating pressure ?
b)
Whether difference between set pressure and the normal operating pressure is maintained minimum 2.0 kg / sq.cmg ?
c)
Whether safety valve has been installed directly on the protecting equipment / on the connected piping without any isolation valve ?
d)
Whether multiple safety valves have been used ? if so, whether the set pressure is within design pressure ?
47
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK ------------------------------------------------------------------------------------------------------------------------------------------------e) Whether any spare safety valves have been used with isolation valves ? if so what is the safe guard against inadvertent closing of isolation valves of operating safety valves ? f)
Whether any relief valve on hydrocarbon / toxic gas services relieves to atmosphere ? if so whether the following points are considered : - discharge vertically upward through individual stack - minimum exit velocity of 15.0 m/second. - snuffing steam provided ?
g)
Whether use of common atmosphere vent stack for several relief valves is observed ?
h)
Whether any vent stack is observed discharging at an elevation of less than 3m above the tallest structure, within 15m radius
i)
Whether acoustic insulation has been provided on vents producing excessive noise ?
j)
Whether toxic vapors like SO2, phenol, chlorine etc. are disposed through closed system ?
k)
Whether isolation valves with spectacle blinds have been provided at the battery limits of the plant ? if so whether their stems are pointing downward to avoid accidental closure ?
l)
Whether unit knock out drums have been provided ? if so , can it hold liquid discharge for 5 - 10 minutes from a single contingency ?
m)
Whether pumps with auto start / stop at high / low level have been provided to pump out the contents ?
n)
Whether high / low level alarms for the knock out pots have been provided in the control room ?
48
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK ------------------------------------------------------------------------------------------------------------------------------------------------o) Whether vapor depressurising system has been provided for emergency situations such as runaway reaction, exposure to fire etc.? 2.9
FIRST AID
a)
What is the percentage of shift employees trained in first aid ? how many can provide artificial resuscitation ?
b)
Does every control room including pump houses possess a first aid box, water gel blanket and explosive meter ?
c)
What is the accident record of the last two years ?
d)
All incidents requiring first aid should be recorded. Note 3
49
SAFETY AUDIT CHECKLIST No.OISD-GDN-145-05 OIL STORAGE AND MOVEMENT CONTENTS -------------------------------------------------------------------------------------------------------------------------------------SECTION DESCRIPTION PAGE NO. -------------------------------------------------------------------------------------------------------------------------------------1.0 TANK FARM 35 2.0
TANKS
35
3.0
PIPING
36
4.0
OPERATING PROCEDURES
37
5.0
INSPECTION & MAINTENANCE
38
6.0
ADDITIONAL CHECK LIST ITEMS
38
50
SAFETY AUDIT CHECKLIST 5.0
OIL STORAGE AND MOVEMENT
----------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR'S REMARKS ----------------------------------------------------------------------------------------------------------------------------------------1.0 TANK FARM : 1.1
GENERAL :
a)
Whether the location, layouts interspacing in the tank farm meet OISD-STD-118/statutory requirements?
b)
Whether Dyke / fire walls meet OISD-118 / statutory requirements ?
c)
Whether the roads are available around the tank farm for movement for fire tenders ?
d)
Whether piping in the dyke farm is kept minimum ?
e)
Whether any piping not connected with the tanks to any individual dyke is passing through it ?
f)
Whether any hydrocarbon detection system has been provided ? If so, is it working satisfactorily ?
g)
Whether house keeping in the area is satisfactory and it is free of any dry vegetation.
h)
Whether communication system is available in the tank farm areas.
i)
Whether illumination in the area is adequate / inadequate
j)
What is the procedure adopted for recovery and disposal of the tank bottom sludges ?
51
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK --------------------------------------------------------------------------------------------------------------------------------------------------
k)
Whether leaded gasoline sludge if any, buried into the tank farm with clear demarcation ?
1.2
SEWERS :
a)
Whether the tank farm closed drains, drains are clear ?
b)
Whether provision exists to divert tank farm drainage either to storm water or to oily water sewer ?
2.0
TANKS :
a)
Whether tanks properly painted and important specifications, are marked on the tank ?
b)
Whether all nozzles of 2" and above sizes have been provided with reinforcing pads with tell - tale holes ?
c)
Whether all tanks are provided with circumferential railings ?
d)
Whether the roof drain of floating roof tanks is provided with a check valve ?
e)
Whether any alternative arrangement to read / record level in the tanks have been provided ?
f)
Whether the tanks with steam heating / blanketing are provided with high temp., high pressure indicator and alarms ?
g)
Whether any product is stored above its flash point ? If yes what are the additional safety consideration?
h)
Whether the breather valves provided matches the pumping in / pumping out requirements of the tank ?
i)
Whether any depression due to tank settlement observed on the tank pad along the circumference ?
46
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------j)
Whether steam coils provided have any flange connections inside the tank ? Whether provision exists to check oil leak through condensate outlet line ?
k)
Whether the tanks on ATF, Naphtha, chemicals services are internally coated ?
l)
Whether fixed/semi-fixed foam system are provided on all tanks storing A class and B class products (18 M and above for floating roofs ) and also tanks storing C class products of more than 40 m dia (floating/fixed roof tanks) ?
m)
Whether sprinkler systems are provided on all fixed roof tanks as per OISD norms ?
n)
Whether Halon system is provided on any tank. If so, whether periodically the Halon system is checked and records maintained ?
o)
Whether the tanks are properly painted and numbered ?
p)
Whether flame arrestors are provided on fixed roof storage tanks which are likely to have explosive mixture in the vapor space ?
q)
Whether goose neck type vent connections are provided with suitable wire mesh to avoid birds entry /formation of nests ?
r)
Whether oil of proper viscosity is used in oil breather valves ?
3.0
PIPING :
a)
Whether pipe alleys properly graded to ensure that no oil/water gets accumulated below ?
47
------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -----------------------------------------------------------------------------------------------------------------------------------------------b) Whether pipe supports, anchors, guides are in order ?
c)
Whether pipes carrying heavy products have been properly heat traced and insulated ?
d)
Whether proper color codings, products identification marks have been provided ?
e)
Whether low point drains and high point vents have been provided with proper caps ?
f)
Whether the tanks are having proper manifolds and are located outside the dyke ?
g)
Whether Hammer blinds are provided on the tank manifolds and are operable ?
h)
Whether the floor under the manifold are paved, have curb walls and drains connected to OWS ?
i)
Whether steam traps of tracer lines are functioning properly ?
j)
Whether any bolt is found missing on flanges of hydrocarbon lines, particularly of LPG, MS, Naphtha etc.
k)
Whether the redundant lines are kept positively isolated with all the ends plugged/blinded and actions are taken to get them removed ?
4.0
OPERATING PROCEDURES :
a)
Whether a copy of updated operating manual with operating instructions, blending etc. are available to all concerned and a copy available in the C/R.
b)
Whether there is any possibility of product contamination during tank line up/changeover.
48
------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------c)
Whether the blending pumps, lines are segregated from other lines with positive isolation during blending operation ?
d)
Whether periodical checks are made for locating any leakage on tank, floating roof valves, piping etc. and recorded for rectification.
e)
Whether the roof drain valves of floating roof tanks are normally kept open .
f)
Whether pre- monsoon checks are carried out.
g)
Whether any blending of DP product and NDP product is resorted to ? If so, what are the procedures & safety precautions taken.
h)
Whether cross checking of auto level gauge is done through manual gauge, while the tanks are under operation.
i)
Whether it is ensured during initial filling a flow velocity of maximum 1 m/sec is maintained for products like SKO, ATF ?
j)
Whether use of nylon rope for sampling was observed ?
49
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------k)
How it is ensured that side entry mixers are operated only when liquid level is above the blades ? (Wherever applicable )
5.0
INSPECTION & MAINTENANCE :
a)
What are the schedules of inspection of tanks (floating / fixed) and whether records maintained in-line with OISD STD-129.
b)
What is the frequency of inspection of PV vents, relief valves, breather valves, flame arrestors ? Whether records are maintained in line with OISD STD-129.
c)
Whether any provision exists for static electricity discharge ? What is the frequency of inspection of earthing connections and whether records maintained.
d)
Whether the pontoon covers are in place and are in good condition ?
e)
Whether foam/neoprene seals are checked regularly for perfect sealing and record maintained.
f)
Whether any documented procedure exists for tank cleaning ? What is the methodology to ensure strict adherence ?
g)
Whether the ladders, stairways are in good condition ?
h)
Whether the pipeline relief valves are kept relieving to tanks or to outside ?
i)
Whether any inspections are carried out on repaired tanks before taking them into operation ? Whether inspection schedule of radar gauges provided on storage tanks have been followed. Note 3
j)
What are the schedules for painting of tanks ?
50
51
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------k) Whether Nitrogen blanketing system provided on any tank. If so, what is the frequency of inspection & whether records maintained ?
6.0 ADDITIONAL CHECKLIST ITEMS : For detailed checklist on individual areas refer other OISD checklists as follows : General Admn. & Organization
OISD-GDN-145-01
Fire Fighting
OISD-GDN-145-02
Layouts
OISD-GDN-145-03
Electrical systems
OISD-GDN-145-09
52
SAFETY AUDIT CHECKLIST No.OISD-GDN-145-06
POL LOADING & UNLOADING A. TANK WAGONS
CONTENTS -------------------------------------------------------------------------------------------------------------------------------------------------SECTION DESCRIPTION PAGE NO. -------------------------------------------------------------------------------------------------------------------------------------------------1.0
FACILITIES AND SYSTEMS
40
1.1
Tank Wagon Gantry
40
1.1.1
General
1.1.2
Drainage
40
1.1.3
Miscellaneous
40
1.1.4
Electrical
40
2.0
OPERATING PROCEDURES AND PRACTICES
40
2.1
Placement of rakes and loading
2.2
Sick wagons
41
2.3
House keeping
41
40
53
40
OISD-GDN-145-06 SAFETY AUDIT CHECKLIST 6.0
POL LOADING & UNLOADING-TANK
WAGONS
A. TANK WAGONS -------------------------------------------------------------------------------------------------------------------------------------------------AUDITOR'S REMARKS -------------------------------------------------------------------------------------------------------------------------------------------------1.0 FACILITIES AND SYSTEMS 1.1 TANK WAGON GANTRY 1.1.1 General a.
Whether proper facilities have been provided for handling sick wagons ?
b.
Whether the rail sleepers are of concrete / metallic construction ?
1.1.2 Drainage Whether concrete flooring has been provided below rail track and with proper slope ? 1.1.3 Miscellaneous Whether No-shunting device / caution boards are provided to avoid movement of wagons while filling / decantation is in progress ? 1.1.4 Electrical a.
Whether the rail tracks are provided bonding strips and connected to maintained earthing system ?
with well
b.
Whether the diesel shunter used is equipped with spark arrestors and proper cooling of engine exhaust ?
2.0 OPERATING PROCEDURES AND PRACTICES 2.1 a.
PLACEMENT OF RAKES AND LOADING Whether the type used are :
of
loco
-diesel -steam -electric
54
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------b.
If steam /diesel loco is used for placement /removal of wagons whether safe distance from first loading point is maintained by use of dummy wagons ?
c.
Whether replacement check is carried out to ensure that platform , loading arms/hoses do not hit the incoming rake ?
d.
Whether the wagons are placed with master valve closed and bottom sluice valve and cover plate normally in opened position ?
e.
Whether checks are made for any left over materials, previous product & fitness of wagons by operating staff on placement ?
f.
Whether the TXR staff check / inspect each wagon and issue a formal certificate prior to loading ?
g.
Whether wagons declared defective are shown on tally sheets and also marked on the wagons ?
h.
Whether Railways are informed in writing about wagons found defective during loading ?
i.
Whether the tightness of Master valve is checked by TXR staff during this initial filling and in case of leak declared as SICK WAGON ?
j.
Whether, in case of open type wagons,pre-fabricated fill pipes are available for use ?
k.
Whether the following are ensured after completion of loading : - fill pipes (if exists) are properly capped - Top covers are properly closed and sealed -
Bottom sluice valves fully closed Bottom cover plates are boxed up with proper gaskets
l
Whether any loose shunting is done ?
m
Whether the shunting speed of 10 kmph (Max.) is maintained ?
n
Whether necessary caution boards are displayed while loading / unloading in progress ?
55
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------2.2 Sick wagons Whether the following are ensured before removing the defective / sick wagons : -
Top lid covers closed bottom cover plate is kept loose and hanging Checks made for any left out product
2.3 House keeping a Whether the gantry floor, drain channels are well maintained and tracks are regularly washed to avoid oil accumulation ? Any visible oil accumulation in the area ? b Whether sand spreading is being done on slippery working areas, railway tracks etc. ? c
Whether Rly. tracks / sliding is free from unused T.W. fittings ?
56
SAFETY AUDIT CHECKLIST No. OISD GDN-145-06 POL LOADING & UNLOADING B. TANK TRUCKS CONTENTS -------------------------------------------------------------------------------------------------------------------------------------------------SECTION DESCRIPTION PAGE NO. -------------------------------------------------------------------------------------------------------------------------------------------------1.0 FACILITIES & SYSTEMS 43 1.1
Headers & loading hoses
43
2.0
OPERATING PROCEDURES AND PRACTICES
43
2.1
Placement of trucks
43
2.2
Loading operations
43
3.0
VEHICLE CREW AND CHECK
43
4.0
ADDITIONAL CHECKLIST ITEMS
51
57
SAFETY AUDIT CHECKLIST 6.0 POL LOADING & UNLOADING - TANK TRUCKS B. TANK TRUCKS -------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR'S REMARKS -------------------------------------------------------------------------------------------------------------------------------------------------1.0 FACILITIES AND SYSTEM 1.1 HEADERS & LOADING HOSES Whether proper arrangement has been provided for securing the hose nozzle with truck manhole ? a
Whether facility is provided to drain overfilled truck to a closed system with proper pump out arrangement ?
2.0 OPERATING PROCEDURES AND PRACTICES
2.1 PLACEMENT OF TRUCK a
Whether any system exists to regulate number of trucks coming at a time to loading area ?
b
Whether any parking / place has been provided for the trucks near the loading area ?
c
Whether the placement of trucks in the gantry is allowed only on production of filling advice ?
d
Whether any safety checks are carried out on the trucks before issuing loading advice ?
2.2 LOADING OPERATIONS a
Whether it is ensured that the trucks, loading hoses are properly connected to earthing system before commencing loading ?
b
Whether decantation of any over filled truck done to closed system (for DP) and with close supervision ?
c
Whether the following are ensured after completion of loading :
-
Fill pipes properly capped Top covers are properly closed and sealed
58
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------3.0 VEHICLE AND CREW CHECK a
Whether the vehicles design has been approved by CCE ?
b
Whether license and explosives certificates are available in the vehicle ?
c
Whether the vehicle is in good condition and the RTO has issued a fitness certificate?
d
Whether the vehicle has non-sparking electrical fitting and external wiring through conduits ?
e
Whether the vehicle has a cut off master switch for electrical system ?
f
Whether there is facility to shut off the drain valves in case of emergency ?
g
Whether the vehicle has two fire extinguishers ?
h
Whether the gross and tare weight painted on the vehicle tally with the permit
i
Whether the vehicle has First Aid Box, Tool Box and Emergency Lighting ?
j
Whether there are any sources of ignition like candles, etc in the vehicles ?
k
Whether the vehicle has atleast a driver and a cleaner as its crew member ?
l
Whether the driver has a valid driving license ?
m
Whether the crew is trained for hazardous nature of petroleum products, emergency procedures, emergency communication etc ?
n
Whether the driver has a copy of standing instruction and TREM Card ?
o
Whether the exhaust is wholly in front of tank truck and has ample clearance from Fuel oil system and combustible material ?
59
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------p Whether approved quality spark arrestors provided on the engine exhaust and Muffler / Silencer is not cut off from the exhaust ? q
Whether each compartment of Tank is fitted with independent PV vents with minimum opening of 3 sq. cms. ?
r
Whether vent openings are covered with two layers of wire-mesh of size not less than 11 mesh per centimeter ?
s
Whether Tank Truck is conspicuously marked on each side and rear, in bold letters at least 7 cm high and on a back ground of sharp contrasting color. (The word "flammable " and name of product are required to be marked ) as per UN code.
t
Whether effective spark arrestors fitted on air intake system of the engine ?
u
Whether electric wiring is of heavily insulated quality and adequate carry maximum loads ?
v
Whether suitable over current protection in the form of fuses / automatic circuit breakers etc. have been provided ?
w
Whether all junction boxes are sealed properly ?
x
Whether electrical equipments like generator switches, fuses and circuit breakers are located inside the cabin or engine compartment ?
y
Whether battery is in easily accessible position with a heavy duty switch close by, to cut off the battery in emergency ?
z
Whether battery terminals have protective rubber covers ?
aa)
Whether vehicle's cabin is checked for presence of any flammable/explosive substance being carried by the crew ?
60
OISD-GDN-145-06 REVISION I
SAFETY AUDIT CHECKLIST OISD GDN-145-06 POL LOADING AND UNLOADING C. COMMON CHECKLIST FOR LOADING AND UNLOADING OF TWs & TTs CONTENTS -------------------------------------------------------------------------------------------------------------------------------------------------SECTION DESCRIPTION PAGE NO. -------------------------------------------------------------------------------------------------------------------------------------------------1.0 FACILITIES & SYSTEMS 1.1
Pump house
1.2
Structure & platforms
1.3
Headers and loading arms
1.4
Drainage
1.5
Miscellaneous
1.6
Electrical
2.0
OPERATING PROCEDURES AND PRACTICES
2.1
Inspection & maintenance
2.2
Work Permit Systems
2.3
House keeping
2.4
Training
2.5
Miscellaneous
3.0
FIRE PROTECTION FACILITIES
4.0
ADDITIONAL CHECKLIST
61
SAFETY AUDIT CHECKLIST 6.0 POL LOADING AND UNLOADING C. COMMON CHECKLIST FOR LOADING AND UNLOADING OF TWs & TTs -------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR'S REMARKS ------------------------------------------------------------------------------------------------------------------------------------------------1.0 FACILITIES AND SYSTEMS 1.1 PUMP HOUSE a)
Whether the pumps are numbered/name of product handled written ?
b)
Whether white oil and black oil pumps are segregated ?
c)
In case of common service pumps whether these are properly grouped keeping product quality (flash point) in view ?
d)
Whether the hot pumps and the associated piping are heat traced and properly lagged ?
e)
Whether delivery to suction bypass line / recirculation line to storage tank has been provided ?
f)
Whether adequate ventilation exists (in case of covered pump house) ?
g)
What is the system of communication between pump house, gantry and control room during normal operation/emergency ?
h)
Whether all the drains are routed to OWS and the system has water seal to act as fire barrier ?
i)
Whether the idle loading headers, not in use for long time, have been blinded off?
j)
Whether P.D. meters (if provided) have proper electrical fittings as per area classification ?
1.2
STRUCTURE & PLATFORMS
a)
Whether easy access available to the platform from both sides of the gantry ?
b)
Whether escape ladders provided along the platforms are adequate ?
62
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------c) Whether the swing ladders are provided with counter weight, security chain, rubber pads and other safety features to avoid frictional spark ? Are these in good working condition ? d)
Whether the supporting columns are fire proofed ?
e)
Whether the gantry shed is covered with asbestos sheet and has side protection ?
f)
Whether the ladders from platform to the top of the vehicles are provided with railings/security chain, rubber pads and other safety features to avoid frictional spark ?
g)
Whether handrails are provided on the platform ?
1.3 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, 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 ?
63
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------j)
k)
1.4
Whether the rubber hose are of proper diameter, length, 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 ?
1.5
MISCELLANEOUS
a)
Whether road barriers have been provided in the gantry area to restrict entry of unauthorized persons/vehicles ?
b)
Whether smoking booths with CODE approval have been provided for the area at safe locations ?
c)
Whether the electric lighters, installed the smoking booths, are well maintained ?
1.6
in
ELECTRICAL
a)
Whether all electrical fittings, welding apparatus receptacles, lighting provisions, etc. are as per hazard area classification ?
b)
Whether illumination in the gantry & pump house is adequate ?
c)
Whether ground level illumination is provided and found adequate ?
64
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------d) Whether the loading arms/hoses are having proper electrical continuity provision and earthing connection ? e)
Whether the loading headers/other pipes laid on the rack are properly earthed ?
f)
How frequently are the tests of bonding / earthing carried out ? Any records maintained ?
g)
Whether the No. of earthing pits are adequate and they are inter connected ?
h)
Whether condition of FLP fittings are periodically checked and records maintained ?
i)
Whether the motors are provided with proper earthing.
j)
Whether structure is earthed as per std. and earth test done every year and records maintained. Is the catwalk antiskid ?
k)
Whether earthing bosses with flexible cable and robust clamping device have been provided adjacent to loading points ?
2.0 OPERATING PROCEDURES AND PRACTICES a)
Check and comment on earthing and bonding practices during loading / unloading.
b)
Whether initial filling is done at a slow rate for safeguard against hazard off static charges ?
c)
Whether established communication system exists between gantry & pump house to control loading rates / pumping rate ?
d)
Whether the loading operation is done under the close supervision ?
f)
Whether operator's constant attention is there while the loading points have been opened ?
g)
Whether it is ensured that "no vehicle entry" in the gantry area is permitted during loading and unloading operations ?
65
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------h)
2.1
Whether initial loading is done at a rate not exceeding 1 M/Sec, till the filling pipe is completely submerged and thereafter at the rate not exceeding 6 M/Sec ? INSPECTION & MAINTENANCE
a)
Whether any schedules exist for lubrication for loading valves/swivel joints and records are maintained ?
b)
Whether schedules exist for inspection the loading headers, arms/hoses, etc. ? Whether records are maintained ?
c)
Whether adequate inventories are maintained for prompt replacement of passing valves and damaged hoses ?
c)
Whether all modification jobs are undertaken only with approved engineering standards ?
2.2
WORK PERMIT SYSTEM
a)
Whether as per OISD 105 (for Hot/Cold works and OISD 137 for Electrical Equipment being followed.
b)
Whether display boards have been provided at strategic locations covering key safety instructions ?
c)
Whether Emergency and Disaster Control Plans for the area is available with written procedures ?
2.3 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, or light hydrocarbons are used ?
c)
Whether the gantry floor are regularly washed to avoid oil accumulation ? Any visible oil accumulation in the area ?
66
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------d) Whether the drain channels are cleaned & well maintained ? 2.4
TRAINING (REFER OISD 154 STD.)
a)
Whether subsequent refreshed training programs are also organized periodically ?
b)
Whether contract employees (if any) are given basic training on hazards of petroleum products and safe practices ?
c)
Whether the workers are using required personal protective wears ?
2.5
MISCELLANEOUS
a)
Whether Operating Manuals/Standing Instructions are available at site ?
3.0
FIRE PROTECTION FACILITIES
a)
Whether the fire water network Provided is well designed (Ring type)
b)
Whether isolation valves exist for isolation of each section maintenance
c)
Whether hydrants, long range water/foam monitors are provided on both sides of gantry and are they safely located ?
d)
Whether all hydrants, monitors are easily accessible ?
e)
Whether proper approach roads exist for Fire Tenders and Fire Fighting Equipment ?
f)
Whether communication system like Fire Alarms, PA system provided and are working ?
g)
Whether the communication system, sprinklers are periodically checked and records maintained ?
h)
Whether any mock drills are conducted for fire fighting ?
i)
Whether adequate number of portable extinguishers have been provided all along the gantry ?
67
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------j) Whether a copy of Fire Fighting manual is available in the gantry control room ? 4.0
ADDITIONAL CHECK LIST ITEMS
a)
For comprehensive check lists on individual areas also refer OISD check lists as indicated below:
b)
General admn. organization Fire fighting Layouts Electrical Systems
OISD-GDN-145-01 OISD-GDN-144-02 OISD-GDN-145-03 OISD-GDN-145-09
68
SAFETY AUDIT CHECKLIST No.OISD-145-07
LPG BULK LOADING & UNLOADING CONTENTS -------------------------------------------------------------------------------------------------------------------------------------------------SECTION DESCRIPTION PAGE NO. -------------------------------------------------------------------------------------------------------------------------------------------------1.0 BULK STORAGE AREA 53 2.0
PUMPS/ COMPRESSORS AREA
55
3.0
TANK WAGON GANTRY AREA
56
4.0
TANK TRUCK GANTRY AREA
58
5.0
TRAINING
59
6.0
ADDITIONAL CHECKLIST ITEMS
59
69
SAFETY AUDIT CHECKLIST 7.0 LPG BULK LOADING & UNLOADING -------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR'S REMARKS -------------------------------------------------------------------------------------------------------------------------------------------------1.0 BULK STORAGE AREA: 1.1 GENERAL: a)
Whether the layout, area classification drawings have been duly approved by CCE ?
b)
Whether any new facilities (permanent or temporary natural) have been installed Area they considered to be safe.
c)
Whether general house keeping in the area is satisfactory ?
d)
Whether storage vessels are insulated. If so, what is the condition of insulation.
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 ?
70
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------1.3 DRAINING a)
Whether water drain chamber has been provided away from shadow of sphere ?
b)
Whether the area under the sphere is having concrete pavement with proper slope ?
c)
Whether antifreeze valve provided on the drain line
d)
Whether double block valves have been provided on water draining line (quick shut off type near the chamber and the other a globe valve) ?
e)
Whether safety instructions for draining operations have been prominently displayed?
f)
Whether draining is done under constant supervision ?
g)
Whether sampling points are provided with duplicate valves?
1.4
INSTRUMENTATION:
a)
Whether level gauge of two types have been provided for direct level measurement and counter checking?
b)
Whether monitoring of levels of all the vessels are done ?
c)
Whether High Level alarms have been provided in storage vessels and are in working conditions ?
d)
Whether remote operated valves (ROVs) have been provided on liquid outlets/inlets and are checked for proper operations ?
1.5
FIRE AND SAFETY:
a)
Whether gas detection system is provided in the area and is working satisfactorily?
b)
Whether capacity of fire water pumps and header are adequately designed?
c)
Whether sprinkler/Deluge system are provided on all the vessels and are periodically tested for satisfactory operation ?
d)
Whether the sprinkler/Deluge Valve are remote operated and are located 15M away from storage vessels?
e)
Whether the supports of the vessels are fire
71
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------proofed? f)
Whether periodical checks are done with explosive meters to detect any gas leaks?
1.6
ELECTRICAL:
a)
Whether bonding strips have been used across the flanges for electrical continuity ?
b)
Whether all the electrical fittings in the area meet area classification requirement?
c)
Whether earthing connections are provided and are properly maintained?
d)
Whether illumination in the area is adequate?
2.0
PUMPS/COMPRESSORS AREA:
2.1
FACILITIES:
a)
Whether the layout of the area meets statutory requirements in terms of safety distance from storage vessels, roads and other facilities?
b)
Whether the pumps have double mechanical seals to minimize leakage? Are the seals in good condition?
c)
Whether recirculation line to storage vessels have been provided?
d)
Whether the venting is done through high rise vents? Whether steam connections are provided for atmospheric vents ?
e)
Whether the drains/vents/sample points have double isolation valves and are provided with caps?
f)
Whether Gas Detection system has been provided in the area and working satisfactorily?
2.2
ELECTRICAL:
a)
Whether all the motors and other electrical equipments such as terminal/junction boxes, lighting fittings etc. are weather proof/ flameproof and are as per hazard area classification requirements?
b)
Whether the motors are provided with proper earthing?
c)
Whether illumination is adequate in the area ?
72
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------2.3 GENERAL: a)
Whether all the equipments in the area are properly painted?
b)
Whether an established communication system exists between the loading area and the pump area during normal operation/emergency?
c)
Whether safety instructions have been displayed? (e.g. `NO SMOKING', `MEN AT WORK' etc.)
d)
Whether all maintenance tools used in the area are non sparking type?
2.4
FIRE PROTECTION:
a)
Whether long range monitors/sprinkler system have been installed to cover the area and are in good working condition?
b)
Whether adequate nos. of fire extinguishers have been provided?
3.0
TANK WAGON GANTRY AREAS:
3.1
FACILITIES:
a)
Whether the layout of the gantry meets statutory requirements?
b)
Whether the design, material selection and installation of the gantry platform, loading header, loading hoses etc. have been done as per standard engineering norms adopting proper safety guidelines of established norms.
c)
Whether loading arm swivel joint gas seals are periodically greased and maintained properly?
d)
Whether high vent flame arrestors are cleaned periodically?
e)
Whether facilities have been provided to handle leaky wagons in situ (Evacuation of T/Wagons)?
f)
Whether emergency stop push button for loading pumps exists in the gantry?
3.2
LOADING HEADERS AND ARMS:
a)
Whether quick isolation valve/MOV has been provided on the loading header and is operative? Whether independent isolation valve provided on each loading point?
b)
73
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------c)
Whether loading velocities are maintained within safe limits by providing restriction orifice on each loading point ?
d)
Whether loading headers are provided with proper earthing/bonding connections?
e)
Whether loading hoses not in use are stored properly and open end is kept blinded?
f)
Whether loading hoses are having any sign of kinks/wears etc.?
g)
Whether the following facilities are available on each loading point ? Excess flow check valve on the filling line
-
vapor return line with check valve back to storage vessel flexible hoses on filling vapor return line
h)
Whether depressurising system has been provided on the gantry header discharging to high vents/flare?
i)
Whether temperature and pressure gauges have been provided at convenient points ?
j)
Whether the loading header is provided with ISV relieving to high point vent ?
k)
Whether proper capacity weigh bridge has been provided on each spur of the gantry Any risk of gas accumulation observed in the pit ?
l)
Whether bonding strips as provided for continuity of rail tracks ?
m)
Whether bonding connectors (copper strips/wires are provided for piping ?)
3.3
FIRE PROTECTION AND SAFETY :
a)
Whether water sprinkler system has been provided and working satisfactorily ?
b)
Whether adequate nos. fire hydrants, long range water monitors have been provided ?
c)
Whether gas detector system have been provided with alarm in the control room ?
74
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------3.4 OPERATING PROCEDURE AND PRACTICES : a)
Whether updated operating manual with loading/unloading procedures is available In the control room and is well understood by the operating crew ?
b)
Whether the TXR staff check and issue fitness certificates in writing for fitness of tank wagons ?
c)
Whether checks are done for gaskets. "O" rings, physical damage, any corrosion on tanker, safety valve, thermometer etc. before commencement of loading operation?
d)
Whether the following are ensured before loading ? - All engines nearby are switched off - All hot jobs in the area are stopped - Proper earthing connection are made - All wagons are secured by hand brake
e)
Whether it is ensured that non sparking tools are used for connecting/disconnecting the hoses?
f)
Whether used of any synthetic fiber material was observed?
g)
Whether loading hoses are periodically hydraulic tested, discarded/replaced and records maintained?
h)
Whether all hoses carry test code & date?
i)
Whether constant supervision is ensured during loading/unloading operation?
j)
For detailed checklist for loading T/W pl. refer to OISD-STD-144?
4.0
TANK TRUCK GANTRY AREAS
4.1
FACILITIES
a)
Whether the truck loading facilities have been installed as per CCE approved drawings?
b)
Whether separate entry/exit gates exist for the tank trucks?
c)
Whether weigh bridge is available within the Installation and is calibrated periodically and maintained?
d)
Whether the no. of trucks parked at the gantry area is restricted?
75
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------e) Whether facility available for evacuation/ decantation of defective/leaky trucks with necessary high point vents with steam connections? f)
Whether the following random checks are done the tank trucks? - Valid licenses - fittings as per CCE such as flame arrestor, fire screen etc. - safety instruction booklet
g)
Elimination of ignition sources like loose wires, uncovered battery terminals etc. Whether gas detection system has been provided in the area & working satisfactory
4.2
OPERATION
a)
Whether the vehicle engine is always shut off during loading operations?
b)
Whether it is ensured that earthing connection is properly checked before connecting hoses to tank truck?
c)
Whether blank flanges are fitted on the truck inlet flange and to the end of hoses when not in use?
g)
Whether loading arm open and is blinded when not in use?
4.3
FIRE PROTECTION AND SAFETY
a)
Whether water sprinkler system has been provided and working satisfactorily?
b)
Whether adequate nos. fire hydrants, long range water monitors have been provided?
c)
Whether gas detector system has been provided with alarm in the control room?
d)
Whether provision to start water sprinklers from loading gantry/Control Room / Weigh Bridge exists?
e)
Whether water sprinkler system adequately covers T/T bullet ?
f)
Provision to stop pump from loading gantry / WB Cabin ?
76
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------5.0
TRAINING
a)
Whether pocket size instruction booklets/manuals in widely understood languages, have been issued to all concerned employees ?
b)
How it is ensured that loading operations such as hose connection etc. are always done by plant operators rather than tank truck crew ?
c)
Whether operating procedures have been displayed in vicinity of the tank loading bays ?
d)
Whether protective gloves are being used by the operating crew ?
e)
Whether the vehicle crew has been trained on hazardous nature of LPG and to handle emergency situation ?
6.0
ADDITIONAL CHECKLIST ITEMS For detailed checklist on specific areas refer other OISD check lists as follows :
General (Organization Admn. Training etc )
OISD-GDN-145-01
Fire fighting
OISD-GDN-145-02
Layouts
OISD-GDN-145-03
Gantry Operations
OISD-GDN-145-06
Electrical
OISD-GDN-145-09
BULK TT CHECKING : How it is made sure that only TT fit for loading are taken up for filling?(w.r.t. oxygen content etc.) For detailed checklist for loading TT pl .ref.to OISD-STD-144.
77
SAFETY AUDIT CHECKLIST No.OISD GDN-145-08 LPG BOTTLING AND DISPATCH CONTENTS -------------------------------------------------------------------------------------------------------------------------------------------------SECTION DESCRIPTION PAGE NO. -------------------------------------------------------------------------------------------------------------------------------------------------1.0 GENERAL ORGANISATION AND ADMINISTRATION 61 2.0
MANPOWER AND TRAINING
61
3.0
CYLINDER STORAGE AREA
62
4.0
BOTTLING SHED
63
5.0
NEW AND DEFECTIVE CYCLINDERS
64
6.0
CYLINDER LOADING
65
7.0
SAFETY AND FIRE PROTECTION
66
8.0
ADDITIONAL CHECKLIST ITEMS
67
9.0
SUGGESTED INSPECTIONS MAINTENANCE CHECKS
67
78
SAFETY AUDIT CHECKLIST LPG BOTTLING AND DISPATCH -------------------------------------------------------------------------------------------------------------------------------------------------AUDITOR'S REMARKS -------------------------------------------------------------------------------------------------------------------------------------------------1.0 GENERAL ORGANISATION AND ADMINISTRATION a)
Check for valid licenses of CCE pertaining to the locations. - Storage of LPG - Storage of LPG cylinders - Filling of LPG cylinders
b)
Whether inter distances from/to admn. offices, maintenance offices, check & change rooms, smoking booths etc. are meeting safety requirement.
c)
Whether plant approach/access roads are well maintained & at least one emergency exit is provided.
d)
Whether adequate no. of escape routes/staircases available around each of the facilities viz., filling shed, cylinder storage area?
e)
Whether fencing/boundary wall around the Plant is in proper condition?
f)
Whether truck parking area has been provided as per OISD-STD-144.
g)
Whether frisking of employees, contractor, personnel and visitors ensured?
h)
Whether work permit/clearance (for hot & cold jobs) procedures followed as per approval?
i)
Whether following manual/documents are available and updated. -
LPG Operations Manual S&EP Manual Emergency/Disaster Control Plan Operation/Inspection/Repair Manual of epuipment supplied by vendor. - OISD Standards.
j)
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.
79
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------2.0 MANPOWER & PLANNING a)
Whether supervisory/managerial cadre staff fully trained in all aspects of LPG Plant operations, Disaster Control/ Emergency handling?
b)
Whether Safety Officer is available and duly designated as safety officer. Does he possess fire/safety engineering qualifications and his duty list drawn clearly?
c)
Whether Training Programs are organized periodically in LPG Operations fire fighting/emergency handling etc. for: - Regular Staff - Tank Truck Operators/drivers - Contractor Workmen - Security Staff.
d)
Whether operating manuals and standing instructions are provided to working personnel?
e)
Whether safety booklets distributed to all including contractor employees. (English/Hindi/local language)?
f)
Whether important Do's and Dont's displayed prominently in operating areas?
3.0
CYLINDER STORAGE AREA
a)
Whether Transfer of cylinders from/to truck is done through - Telescopic Conveyer/ Trolleys /Conveyers? Any dropping, rolling, mishandling noticed?
b)
Whether Inspection/visual checks are done to detect leaky/defective cylinders to segregate spurious leaky/defective cylinder?
c)
Whether storage is segregated and marked for? - Spurious cylinders - 5 year testing due cylinders - Other defective cylinders
d)
Whether cylinders stacked in vertical position in tiers as per the norms?
80
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------e)
Whether stacking discipline with small lots of 4 rows and 25 cylinder lengths followed with a minimum access path of 1 M maintained on both sides of 4 rows.
f)
Whether cylinders stacking areas are periodically inspected for leakage with explosimeter or probable leak detector?
g)
Whether cylinder offload bay platform provided with proper buffers?
i)
Whether stacks of cylinder are identified by markers to show empties, filed and gas free cylinders?
j)
Whether the daily stocks of cylinders (empty/filled/defective) are displayed?
4.0
BOTTLING SHED
a)
Whether cylinder washing facility provided?
b)
Whether filling/loading/unloading/storage areas are adequately covered with mastic coating on floors and pillars to avoid accidental sparks?
c)
Check for condition of mastic flooring.
d)
Whether tare weight of the body is marked distinctly on the body of the cylinder?
e)
Whether empty cylinders are checked for 'o' ring presence?
f)
Whether filling is done based on gross weight?
g)
Whether AUTO CUT OFF facility exists on filling machines?
h)
Whether filling head gun hoses are of approved quality and periodically tested?
i)
Whether proper earthing provided to? a. Conveyers b. Carousel units (bonding of filling guns). c. Unit filling Machines. d. Evacuation units.
j) Check for accumulation of vapors in
81
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------recess/pits in the area with the explosimeter k)
Whether vapor extraction system with suction points at carousel, evacuation unit, valve change shed is provided and in working condition? - Whether standby blower is available? - Whether carousel unit is interlocked with vapor extraction system?
l)
Whether accuracy of check scales being checked daily and records maintained?
m)
Whether filling machine check scales are calibrated periodically and records maintained?
n)
Whether facilities are provided for 100% cross checking of weight of filled cylinders? Are they in use?
o)
Whether check weigh scales are calibrated periodically?
p)
Whether CVT checks done after filling for`O' ring and valve defects?
q)
Check for facilities: - To check for conveyors - To check defective cylinders - To check 'O' Ring - To check weight correction.
r)
Whether bung leak/body leak checks are done through in-line water bath for both 14.2. Kg. and 19 Kg. cylinders?
s)
Whether capping/sealing facilities are provided - Al foil/PVC seal?
t)
Check for neck labels plastic/paper.
u)
Whether tagging of overfilled/underfilled cylinders done?
v)
Check for leakage from carousel filling guns.
w)
Whether persons working on carousel wear hand gloves & safety shoes?
x)
Whether Statistical Quality Control checks (SQC) carried out & records maintained? (See foot notes)
82
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------y)
Whether Movement of cylinders is done through floor conveyers/trolleys? statistical checks include - Total No, of cylinders filled. - Total No. of cylinders checked at random. - No. of cyls. found defective. - % of cyls. found defective. in last month - Weight variation (Over filling) - Weight variation (under filling) - Valve leak - Bung leak - "O" Ring missing - Defective "O" Ring (by CVT Test) - 'Pressure Control valve' Filling procedure - Cyls. due for retesting - Other minor defects - Remarks if any.
5.0
NEW/DEFECTIVE/LEAKY CYLINDERS
a)
Whether Purging facilities are available for new/retested cylinders?
b)
Whether Facilities provided for evacuation of leaky/partially filled cylinder are working satisfactorily?
c)
Whether venting/cold flaring of LPG is done at safe height - 2 meter above the roof edge?
d)
Whether Cold Repair facilities are available? If so, are they at appropriate location?
e)
Whether wire mesh provided on cold flare line?
f)
Whether degassing facility provided in cold repair shed? Is it 15 M away?
g)
Whether cylinder repairs/valve change etc are supervised?
h)
Whether stock of leaky cylinders is below the stipulated limits?
i)
Whether Torque wrenches with proper settings are used for valve removal replacement (20 +/- 2 kg. Mt.)?
83
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------j)
Whether PTFE tape/paste used while fixing valves?
k)
Whether cylinders are checked for denting are declared defective?
l)
Whether records of defective cylinders maintained supplierwise?
m)
Whether records of leaky /defective cylinders (company wise) detected during filling/are maintained on daily basis with following particulars: -
Cylinders filled Valve leak Bung leak Body leak "O" ring defect Spurious cylinders
n)
Whether record of defective cylinders returned by distributors is maintained on daily basis?
o)
Whether spurious cylinders and cylinders declared as scrapes are destroyed by crushing properly and records maintained?
6.0
CYLINDERS LOADING INTO TRUCK
a)
Whether covered facilities/sheds provided for positioning of trucks 15 M away from storage shed for receipts / loading of cylinders with sprinkler protection and lighting?
b)
Whether cylinders are loaded into trucks through conveyers?
c)
Whether cylinders stacked without protrusions?
d)
Whether explosimeter checks are done before releasing the truck?
e)
Whether Loading/unloading of cylinders is done in safe manner?
7.0
SAFETY & FIRE PROTECTION
a)
Whether Contingency Plans are available and updated for tackling major emergencies?
vertically
84
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------b) Whether fire organisation chart is prepared upto date and displayed? c)
Whether important telephone nos. of state Fire Services/Police/Dist. Admn. / Hospitals / other offices etc. are displayed?
d)
Whether Fire/Emergency mock drills conducted periodically?
e)
Whether Fire Water Network provided around the facilities is as per prescribed norms and adequate?
f)
Whether Pressure and flow are adequate at farthest end?
g)
Is system painted as per standard norms (Hydrant pipelines - Red; risers/monitors -yellow; & sprinkler system- Blue)
h)
Whether hydrants/monitors are provided at a minimum distance of 15 meters from the sheds and provided for every 30 meters distance?
i)
Whether adequate No. of hydrants, long range monitors etc. are provided and periodically inspected and records maintained?
j)
Whether MV Spray Sprinkler System having remote / local operated deluge valves provided in the storage shed and in working condition. Also whether in critical areas like carousel evacuation unit, valve change shed, automatic detection of heat / flame for automatic operation of sprinkler system provided?
k)
Whether deluge valves are located 15 meters away from the limits of sheds and protected by fire walls (One deluge valve to cover an area of about 520 Sq. meters)?
l)
Whether portable DCP Fire Extinguishers are provided at appropriate location? -2 Nos. 10 Kg. DCP FE per 200 Sq. Meters area. - 1 No. 100/70 Kg. DCP Mobile unit per shed.
m)
Whether gas monitoring system having sensors to monitor gas leak near carousel, evacuation unit, valve
85
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------change shed provided? if so: - Whether working satisfactorily? - Whether periodically inspected and records maintained? n)
Whether fire alarm/manually operated fire siren and communication system consisting paging system / flameproof telephones is available & adequate?
o)
Whether 'No smoking' and other cautions sign in Hindi/English/local language displayed at prominent places?
p)
Whether Emergency lighting system provided in strategic locations and is working satisfactorily?
q)
Whether Flame proof torches available?
8.0 ADDITIONAL CHECK LIST ITEMS For detailed checklist on specific areas refer other OISD check lists as follows: General (Organisation Admn. Training etc)
OISD-GDN-145-01
Fire Fighting
OISD-GDN-145-02
Layouts
OISD-GDN-145-03
Gantry Operations
OISD-GDN-145-06
Electrical
OISD-GDN-145-09
86
----------------------------------------------------------------------------------------------------------------------ITEMS AUDITORS REMARKS -------------------------------------------------------------------------------------------------------------------------------------------
SUGGESTED INSPECTION & MAINTENANCE CHECKS 9.1
DAILY MAINTENANCE
a)
Cleaning the cover plate of introduction device, ejction device, air service units, filling guns, CVT etc.
b)
Water draining from filters of check scales & filling gun.
c)
Air leak control from check scale.
d)
Checking/control of oil level in check scale & filling gun.
e)
Zero checking of Introduction Device/Ejection Device, Air Service Units, CVT etc.
f)
Calibrations/Adjustments of devices indicated in above.
g)
Checking the sensitivity of check scales
h)
Conducting test run/test filling to see the performance of filling-gun, check scales, introduction/ejection devices, CVT etc.
9.2.
WEEKLY MAINTENANCE
a)
Oil topping in Air service unit/cleaning of Air Filters.
b)
Oil topping in dampers of in-line check scales and calibration with standard weights.
c)
Cleaning of the bearings and suspensions of Filling machines
d)
Greasing & leakage control of Introduction system & Ejection System.
e)
Greasing/lubrication of : - Central column - Carousel Driving unit.
87
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------9.3 QUARTERLY MAINTENANCE a)
Earthing strip tightness of equipment like in-line control Check Scale & Filling Machine.
b)
Checking the filling hoses for stiffness and replacement, if necessary.
c)
Inspection of Gun hanger, ropes & pulley inspections.
d)
Inspection of wear & tear for knife edges & bearing.
e)
Calibration of filling machines with standard weights.
f)
Checking the level of Introduction system & Ejection system.
9.4
ANNUAL MAINTENANCE
a)
Overhauling of machines & replacement of defective parts of filling machines, check scales, introduction/ejection system, central column & driving units.
b)
Inspection of power cylinder of introduction system & cleaning.
c)
Inspection of ejection system for wear & tear.
d)
Inspection of rails of conveyer system for setting &tightening of fish plate.
e)
Inspection & adjustment for proper functioning of Differential Pressure valve.
88
SAFETY AUDIT CHECKLIST NO. OISD GDN-145-09 ELECTRICAL SYSTEM
CONTENTS -------------------------------------------------------------------------------------------------------------------------------------------------SECTION DESCRIPTION PAGE NO. -----------------------------------------------------------------------------------------------------------------------------------------------1.0 SPECIAL REQUIREMENTS 70 2.0 SUBSTATION (EQUIPMENT & BUILDING)
71
3.0 SWITCHYARD AND OUTDOOR EQUIPMENT
73
4.0 CABLE NETWORK TERMINATIONS & JOINTS
73
5.0 MOTORS CONTROL STATIONS
74
6.0 LIGHTING INSTALLATIONS
75
7.0 EARTHING & BONDING
75
8.0 CAPTIVE GENERATION
77
9.0 BATTERY CHARGER/ UPS
78
10.0 ELECTRICAL HEAT TRACING
78
11.0 PORTABLE APPARATUS/ MOBILE EQUIPMENT (ELECTRICAL /BATTERY OPERATED)
78
89
SAFETY AUDIT CHECKLIST ELECTRICAL SYSTEM -------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR'S REMARKS -------------------------------------------------------------------------------------------------------------------------------------------------1.0 SPECIAL REQUIREMENTS a)
Whether main single line diagrams of Electrical Power Distribution "updated" and "As-built"?
b)
Whether the Installations are duly approved by the Chief Electrical Inspectorate to Govt. for energisation? (DGMS for Oil Field Installations)
c)
Is there any unauthorized installation in operation including temporary construction power installations?
d)
Whether action taken on IE inspector visit report?
e)
Whether electrical installations/repairs to existing installations are being carried out through licensed electrical contractors under the supervision of Licensed Electrical Supervisor (approved by State Govt.) As per I.E. Rule No. 45)?
f)
Are the electrical equipment installed conforming to the Area Classification (IS:5572) approved by CCE?
g)
Whether there has been revision in the hazardous area classification from the original (due to modifications/expansions etc.) and the electrical equipment was accordingly replaced to conform to revised classification?
h)
Whether the suggested remedial measures given in the Accident Investigation Reports, if any, have been implemented? (Review the Accident Report of the last 5 years)?
i)
Whether the list of electrical "authorized persons" is being maintained (I.E. Rule No. 3) and displayed?
j)
Whether inspection of electrical equipment is carried out, as per approved schedule (Review the inspection records)?
90
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------k) Whether approved work Permit System is being followed? l)
Are the installations generally rust/corrosion protected effectively? (such as by using cadmium plated Bolts/nuts, painting at regular intervals etc)
m)
Whether the substations / power plant rooms/control room /MCC rooms etc. are used as storage area for scraps,oil drums, clothes, spares and such other foreign materials
n)
Are the flameproof features maintained intact for flameproof equipment? (Any damages or missing bolts /nut in the junction boxes/panel covers /terminal boxes etc. convert the equipment to non-flameproof)
o)
Whether flameproof telephones are used in the classified hazardous areas?
p)
Whether the Transformer & Switchyards are free of vegetation/dry grass?
q)
Whether all the electrical equipment( switchboards, Relays, Motors, Transformers & Busducts etc.) and junction / terminal boxes etc. are vermin proof?
r)
Whether preventive Maintenance Schedules as per OISD-STD-137 etc. carried out?
s)
Whether CO2 fire electric fires?
t)
Whether sand-buckets provided?
extinguishers provided for
2.0
SUBSTATION (EQUIPMENT & BUILDINGS)
a)
Is the substation equipment freely accessible for Operation, Inspection and Maintenance?
b)
Are the minimum clearances around the equipment maintained as per I.E. Rule 51?
c)
Are all the substation equipment provided with double earthing connections?
91
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------d)
Are the live parts of equipment made inaccessible from inadvertent contacts? (by barriers/shrouds)?
e)
Whether the rubber glove and mats with voltage test seals are provided in front of the switchboards and are in good condition?
f)
Whether the switchboards are dust / verminproof? Is pest control treatment given for substations?
g)
Are any unused cable entries left open?
h)
Have the protective relays been set at the recommended values (as per the design)?
i)
Whether the fuses used are of HRC Type and of ratings specified in the single line diagrams ?
j)
Whether each outgoing distinct circuit from the switchboard is separately controlled by a suitable linked switch fuse or circuit breaker of required capacity?
k)
Whether circuit identification marks/ tags are provided or not?
l)
Are the relays and meters tested for proper functioning/calibration as per approved schedule?
m)
Whether the bus bars are provided with distinct color identification ( Red, Yellow, Blue and Black)?
n)
Whether the conduits used for cable entry are sealed and earthed?
o)
Are the energized electrical equipment provided with caution notices?
p)
Is the substation building made water tight and all the openings in walls ( such as cable trench entry/ bus duct entry) sealed?
q)
Whether any water stagnation is there inside the cable trenches?
92
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------r) Are all the power (H.T. & L.T) and control cables in trenches properly segregated? s)
Are the cables near the terminations clamped?
t)
Is there any combustible material used for construction of substation building?
u)
Whether the cable trenches are provided with concrete slabs / chequered plates?
v)
Are the earth electrodes periodically tested and maintained properly?
w)
Are the earth resistance of the grid measured, checked and recorded periodically?
x)
Is the substation provided with Emergency Lighting?
y)
Is the substation provided with telephone?
z)
Is the trench sump pump ( for dewatering ) in working condition ( wherever provided ) ?
aa)
Are floors kept clean,free of tripping hazards?
bb)
Whether the switchgear rooms located in the hazardous area are pressurized? (if not, are these provided with flameproof equipment)?
cc)
Whether all panel doors are kept closed?
dd)
Whether all the indicating lamps in the Panel are in operating condition (i.e. not fused)?
ee)
Are the oil immersed starters filled with oil to the required level and of required dielectric strength?
ff)
Whether shock restoration chart & First Aid Box provided?
93
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------3.0 SWITCHYARD AND OUTDOOR EQUIPMENT. a)
Are the following components individually earthed with two separate earthleads ( No. 8 SWG copper or equivalent)? -
Metal Frameworks A.B. Switches and circuit breakers D/O and H/G Fuses Poles/switches/insulator pins/stay clamps - Operating handle of the A.B. switch b)
Whether the vertical and horizontal clearances from O.H. conductors are maintained as per I.E. Rule (79)?
c)
Are the earth electrodes provided in sufficient number? Whether earth pits are properly maintained and tests carried out as per schedule?
the
d)
Whether the lightning arrestors are connected after the A.B.switch, for the protection of transformer/circuit breaker?
e)
Whether a separate earth electrode of proper size is provided properly for the lightning arrestors?
f)
Is there O.H. shielding for lightning protection and whether it is properly maintained?
g)
Whether there is locking arrangement for the Transformer bay to prevent entry to the yard by unauthorized persons? If so, is it being followed?
h)
Whether the doors of the gate are rusted and need to be painted?
4.0 CABLE NETWORK/TERMINATIONS & JOINTS a)
Have the route markers and joint location indicators been provided in a permanent way throughout the Plant and Off site areas?
94
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------b) Whether the underground cables in excavated trenches are laid at designed depth with sand filling, brick protection? (check at on Random trial pit basis) Is u/g cable exposed at any location? c)
Are the cables provided with identification tags at intervals of every 30 mts? (On Random Trial Pit basis)
d)
Whether all the cables throughout their route protected mechanically from any external damages?
e)
Are the flameproof type terminations for cables carried out in the classified (Zone 1) areas?
f)
Are the cable joints staggered and having identification marks (when 2 or more cables laid in the same trench)?
g)
Is the oil seepage from process units getting drained through or collected in the cable trench/manholes?
h)
Whether the armour of cables exposed at the termination?
i)
Are the cables directly taken to the terminals without suitable cable glands/clamps/armour earthing?
j)
Are the cables above ground supported with proper clamps?
k)
Whether the cables : (telephone/ power / lighting cables) are taken through overhead system? (inside Refinery / Process / Areas)? If so, what is the arrangement?
l)
Whether one run of earthing strip fixed through the entire length of cable Tray (wherever cable tray is used) ?
95
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------m)
Whether proper mechanical protection and water sealing arrangement provided to cables especially at the following locations: -
Road crossings Railway installations Cathodically protected u/g piping Water logged areas Drainage & other u/g facilities RCC structures/brick walls Where cables rise above ground
n)
What are the fire protection arrangements adopted for cables laid above ground?
o)
Are the G.I. pipes (conduits) used for cable entries (sleeves) sealed at both ends, and conduits earthed?
p)
Are all conduit ends for cables sealed at both ends?
5.0
MOTORS CONTROL STATIONS
a)
Whether there is annunciation facility in case of failure of air supply ( wherever air purging is used for flame proofness )? Is it in working condition and monitored regularly?
b)
Is the approved inspection schedule followed ? Records maintained?
c)
Whether Terminal / junction Box properly sealed / covered?
d)
Is there any unauthorized modification carried out ( by way of local fabrication etc.) on the flameproof motors/control stations / terminal boxes? ( to accommodate XLPE cable termination etc.)
e)
Whether the insulation resistance values between phases and between phases and earth of the motors are within acceptable limits ? ( Select a few critical motors at random)
f)
Whether Emergency Isolating device for the motor is installed near the motor?
96
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------g)
Whether the double earthing provided are from two separate distinct earth connections of the grid?
h)
Are the motors (75KW) provided with spaceheater and local ammeters.
i)
Whether painting of motor body control station and supporting structure are in good condition?
j)
Whether there are motor guards provided to prevent inadvertent contact over the moving shaft?
k)
Are the nameplates of Motors worn out? Whether the inscriptions are visible?
l)
Whether the drive belts are antistatic fire resistant type?
6.0
LIGHTING INSTALLATIONS
a)
Whether separate distribution for lighting system adopted from main switchboard, through subdistribution/ fuse distribution & lighting panel final circuit boards?
b)
Whether lighting provided is sufficient? ( compare with IES chart for required levels of illumination at selected locations)?
c)
Is there auto changeover system provided for normal to emergency system and if so, is it functioning satisfactorily? (test this)
d)
Whether the body of lighting fixtures are separately earthed in addition to cable armor earthing?
7.
EARTHING & BONDING
a)
Is the earthing carried out as per IS:3043?
b)
Is the earth leakage protection wherever provided functioning satisfactorily?
97
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------c)
Are the earth electrodes being tested periodically? (Check the test records)
d)
What is the grid resistance (in ohms)? Is this periodically measured and recorded?
e)
Whether all 3 phase equipments double earthed and single phase equipment single earthed?
f)
Are all the loading arms earthed?
g)
Is there earth continuity between the flexible hoses and loading arms ?
h)
Are the tanks, vessels, process piping, steel columns, metallic structures / sheds and buildings and fencing etc. earthed?
I)
Are the hardware used free from rust or corrosion?
j)
Are the Rail Tracks within the gantry premises earthed and bonded?
k)
Are the earthing connections to lighting protection and electrical system protection ( Neutral earthing and body earthing) provided separately?
l)
Whether there is any discontinuity of earthing connections?
m)
Whether the flexible wire used for tanker body earthing ( TTL Gantry ) is soldered to crocodile clips?
n)
Whether crocodile clips have lost the spring action causing improper grip with the surface?
o)
Whether earth jumpers across the pipe flanges (of gantry piping) are provided?
p)
Is the buried underground earth conductors getting exposed at any location?
98
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------q)
Whether the earth pits with chambers are exposed and visible or is embedded inside the loose earth?
r)
Whether the earth strip connections on the earth electrode are loose / sheared off / tight?
s)
Are the weigh bridge (truck) platforms earthed?
t)
Whether the earth strip joints are having an overlapping equivalent to the width of the strip (minimum) and all the four sides are welded?
u)
Whether all product and utility pipelines earthed at every 25 meters apart and also at the point where it enters and leaves a shed, where volatile liquids and vapors are handled?
v)
Whether the earth strip runs continuously through conveyers and are the supporting structures also earthed?
w)
Whether all electronic equipments which stores electrical energy are properly earthed?
8.0
CAPTIVE GENERATION
a)
Is the neutral of the generator provided with an isolator?
b)
Whether the neutral of the generator is earthed by not less than two separate and distinct earth connections and whether the earthing is after the isolator?
c)
In case of High Voltage Generators (Voltage above 650 V) whether the neutral point is earthed by two separate and distinct connections with earth each having its own electrode?
d)
Whether the exposed wires near the Generator/Generator to switch board is in metallic conduit and the conduit earthed?
99
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------e)
Whether the control panel for the generator is earthed with two separate and distinct connections with earth?
f)
Whether the generator panels are made vermin proof?
g)
Whether more than one generator is provided, whether provision of individual breakers are kept for paralleling arrangement?
h)
Whether danger notice is provided for the generator enclosure?
i)
Whether location (where generator is installed ) is dry and dust free and nearer to the loads?
j)
Whether provided with fire and weather proof enclosure with ventilation?
k)
Whether the exhaust provision provided is away from the enclosure?
l)
Whether control panel is available near to the generator, equipped with all protections ( short circuit, overcurrent, and earthfault)?
m)
If synchronized with grid, whether effective measures are available to prevent backfeeding?
n)
For Prime Mover where fuels like Naphtha, LSHS are used additional safety precautions should be taken.
9.0
BATTERY / CHARGER/UPS
a)
What is the type of battery used?
b)
Whether the Battery room is clean and well ventilated? Are the floors acid proof?
c)
Whether exhaust fans provided ?
100
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------d)
Are the cell voltage, specific gravity of cell, and level of the electrolyte being checked and recorded as per approved schedules?
e)
Is there any corrosion on terminals / connectors?
f)
Whether all the safety equipment (Rubber apron, goggles, acid proof hand gloves etc.) are available?
g)
Is the operation of UPS satisfactory? (Test for critical services)
h)
Whether trickle charger working and checked properly.
10.0
ELECTRIC HEAT TRACING
a)
Whether all indication lamps are functioning properly in the panel to ensure healthiness of tracer circuits.
b)
What is the automatic control or protection provided for temperature raising above allowable limit? (Especially at hazardous areas) Is this being tested periodically for proper functioning.
c)
Are there damages to insulation / traces?
d)
Is the system water tight?
101
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------11.0
PORTABLE APPARATUS/MOBILE EQUIPMENT (ELECTRICAL BATTERY OPERATED)
a)
Is the electrical system of the portable apparatus/mobile equipment provided with Intrinsically safe / flameproof features when required to be taken to the classified hazardous areas? ( check test certificates)
b)
Are safe voltage (24 volts) being maintained for use of portable appliances such as hand lamps, torches, etc. (used for inspection / testing) especially in classified areas?
c)
Whether the flexible cables used for portable tools are free from damages and consisting of too many joints? Are the cables protected from mechanical damages ( by providing metallic sleeves etc.)?
d)
Whether the cables used for portable tools/equipment are 3 core for single phase and four core for three phase equipment respectively? Whether the 3rd / 4th core is used to earth the metallic body/screen covering of the cable?
e)
Are the power cables used for portable equipment such as welding machines, generators, switchboards etc., provided with 'armoring' and `gland' type terminations? Is the armoring bonded to earth?
f)
Are the portable tools/equipment being checked every time before use that there is no earth leakage? Is it ensured safe to use, by a "competent" person before issuing.
g)
Whether ELCB provided for portable equipment?
h)
Are the portable equipment, including the electrical system in the mobile equipment / vehicles (Battery Operated), and test instruments and tools inspected regularly?
102
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK --------------------------------------------------------------------------------------------------------------------------------------------i)
Whether all wiring and current carrying parts of an industrial electric truck, so constructed and enclosed as to protect from mechanical damages?
j)
Whether any uninsulated current carrying part is exposed especially on the outer surface of the truck?
k)
Whether all the components are accessible for maintenance/repairs?
l)
Whether the battery has the protection means of a non combustible enclosure?
m)
Are the Battery terminals provided with protective rubber gloves?
n)
Whether the battery enclosure is provided with sufficient ventilation to minimize the possibility of accumulation of explosive hydrogen air mixtures above the battery?
o)
Are there reported accidents due to improper maintenance / the wrong use/wrong selection etc. of Portable tools/Mobile equipment (Electrically operated) in the last 2 years? (if so, verify the accident investigation reports and compliance of recommendations)
p)
Whether connecting a welding machine the return path of the welding machine is directly connected to the work piece with proper insulation?
103
by
SAFETY AUDIT CHECKLIST 10.0 CROSS-COUNTRY PIPELINE CONTENTS -------------------------------------------------------------------------------------------------------------------------------------------------SECTION DESCRIPTION PAGE NO. -------------------------------------------------------------------------------------------------------------------------------------------------1)
COATING CONDITION
81
2)
CATHODIC PROTECTION
81
3)
POWER SUPPLY TO CP STATION
82
4)
ULTRASONIC THICKNESS SURVEY
82
5)
INTERNAL CORROSION
82
6)
PIGGING
82
7)
INHIBITOR INJECTION
83
8)
CPL/EWP SURVEY
83
9)
SOIL TESTING
84
10)
MAINLINE VALVE
84
11)
HYDROSTATIC TESTING
84
12)
PIPELINE PATROLLING
84
13)
TELECOMMUNICATION & TELEMETRY
84
14)
SINGLE BUOY MOORING SYSTEM
86
15)
CONTINGENCY PLANS
87
16)
DOCUMENTATION
87
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SAFETY AUDIT CHECKLIST ELECTRICAL SYSTEM -------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR'S REMARKS -------------------------------------------------------------------------------------------------------------------------------------------------1.0 COATING CONDITIONS: 1.1 Is rolling plan for pearson, coating conductance and current drainage surveys made?
Yes/No
1.2 If 'yes' is the schedule maintained
Yes/No
1.3 Coating Condition (Survey report to be checked
Satisfactory / not Satisfactory
1.4 Type of coating and its application method
.....
2.0 CATHODIC PROTECTION: (No. of C.P. Stations .....Nos.) 2.1 After revisioning of coating whether PSP readings are recorded and monitored to observe improvements
Yes/No
2.2 Periodic calibration of AC & DC volt meter/Ammeter and PSP Meter of CP Units
Yes/No
2.3 Number of insulating joints
.....Nos.
2.4 Dielectric strength of Insulation Joints
Satisfactory/ Not satisfactory
2.5 Is schedule made for inspection of insulation joints/couplings (yearly)
Yes/No
2.6 No. of test lead points for PSP Survey
..... Nos.
2.7 Condition of test led points 2.8 Is schedule made for PSP survey (PSP readings at feeding points) (PSP readings at Test lead points quarterly) 2.9 If 'yes' the findings
Good/Bad Yes/No Satisfactory/ Not Satisfactory
2.10 If 'not satisfactory, any action plan drawn for correcting the deficiencies on short term and long term basis?
Yes/No
2.11 (a) Effectiveness of C.P. (To check PSP profile graphs in conjunction with CP station reports)
Satisfactory / Not Satisfactory Not Satisfactory
(b) Is any stretch of pipeline left cathodically unprotected for a period more than one year
105
Yes/No
------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------2.13 If 'YES' any action taken/plan drawn for correcting the deficiencies
Yes/No
2.14 Is the C.P. unit connected with the earthing electrode ?
Yes/No
2.15 Is the earthing resistance of C.P. earthing electrode taken & record maintained
Yes/No
2.16 Are all the C.P. units provided with the lightening arrestors
Yes/No
2.17 Whether Lightening arrestor grid and Equipment Earthing grids are segregated
Yes/No
2.18 Safety aspects for fault condition due to AC/DC power system
-------
2.19 Is the ground bed circuit resistance record maintained ?
Yes/No
2.20 Is the di-electric strength of oil checked ? 3.0
C.P. transformer Yes/No
POWER SUPPLY TO CP STATION 3.1 Inspection of source
.....
3.2 Power availability of CP stations, average
........hrs./day
3.3 Condition of back up power supply, if any.
Satisfactory/ Not Satisfactory
4.0 ULTRASONIC THICKNESS SURVEY 4.1
Is schedule made and followed for thickness survey of mainline at :
4.1.1
Exposed section of Pipelines
Yes/No
4.1.2
Sharp pipe bends/Riser bends
Yes/No
4.2
If 'Yes", the findings
Satisfactory/ Not satisfactory
4.3 If 'NOT SATISFACTORY', any action plan for correcting the deficiencies drawn
Yes/No
4.4. Is two yearly schedule made for thickness survey of unprotected pipeline section from I/F to scrapper launcher/receiver
Yes/No
106
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------5.0 INTERNAL CORROSION 5.1 Whether coupons are installed
Yes/No
5.2 If yes, corrosion rate < 1 MPY 1 to 4.9 MPY/ > 4.9 MPY 5.3 Whether Electrical Resistance probes are installed
Yes/No
5.4 If yes, corrosion rate ?
.....
6.0 PIGGING 6.1.0
Descaling
6.1.1
Is schedule made for pigging ?
Yes/No
6.1.2
And,is followed
Yes/No
6.1.3
Is pig residue/dirty product analysis carried out?
Yes/No
If yes, what is the value of a) Fe 0 % by mass b) Water, % by mass c) pH value d) Acidity, mg KOH/gm,
..... ..... ..... .....
6.1.4
6.1.5
Based on pig residue analysis internal condition of pipeline
6.2.0
Intelligent Pigging
6.2.1
Is any IPS survey carried out ?
Yes/No
If no, any schedule made for carrying out the survey (once in five years).
Yes/No
6.2.2
6.2.3
6.2.4
Satisfactory/Not satisfactory
If the survey has been carried out, findings of the survey, (To check the reports).
Satisfactory /Not satisfactory
If not satisfactory, any action plan has been drawn to implement the recommendations
Yes/No
7.0 INHIBITOR INJECTION 7.1 Is inhibitor injection being done and records maintained
Yes/No
107
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------7.2. Average dosing of corrosion inhibitor injection
...PPM/day
8.0 CPL/EWP SURVEY 8.1 Is any CPL/EWP SURVEYS CARRIED OUT
Yes/No
8.2 If No, any schedule made for Carrying out the survey (once in five years)
Yes/No
8.3 If the survey has been carried out, what are the findings (To check the report)
Satisfactory/Not Satisfactory
8.4 If not satisfactory, any action plan has been drawn to implement the recommendations.
Yes/No
9.0 SOIL TESTING 9.1 Soil samples within ROW being tested once in five years.
Yes/No
9.2 Is there any industrial affluent flowing over the ROW
Yes/No
9.3 If `yes', said sample tested to determine the efficacy of the existing coating of the pipe lines.
Yes/No
9.4 Variations observed in soil resistivity
.....
10.0 MAINLINE VALVE (NO. OF MAINLINE VALVES .... NOS.) 10.1 Is schedule made for maintenance of mainline valve
Yes/No
10.2 If `yes', schedule followed and valves operating freely.
Yes/No
10.3 Supply to Motor Operated Valves (MOV) available
Yes/No
10.4 MOV working 11.0
Locally/Remotely
HYDROSTATIC TESTING
11.1 Whether all repaired piping system are being tested in accordance with OISD - 141&API 1110 11.2 Whether sufficient number of pipe lengths, pretested and kept at vulnerable locations for replacement if required
108
Yes/No
Yes/No
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------12.0 PIPELINE PATROLLING (Total length of Pipeline .....km) 12.1
Is the schedule made for
12.1.1 Ground Patrolling by Patrolman each segment twice in a week by physical walking.
Yes/No
12.1.2 Helicopter surveillance once in a month
Yes/No
12.1.3 Right of way inspection and maintenance of above ground structures along ROW once in a year
Yes/No
12.1.4 Inspection of Pipeline crossings at 12.1.4.a Rail/Road Bridge and suspended crossing (exposed pipeline) quarterly
Yes/No
12.1.4.b Road/Highway crossing quarterly
Yes/No
12.1.4.c Submerged river crossing before and after monsoon
Yes/No
12.2
If reply to the above is yes, whether various reports filled/ monitored regularly and proper checks on line patrolman exercised
...
13.0 TELECOMMUNICATION & TELEMETRY (NO.OF REPEATER STN...NOS) 13.1
Availability of Power supply
Yes/No
13.2
If no, (other than load shedding) corrective action taken
Yes/No
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
13.6
All the Radio Parameters as per
13.3
13.4
109
------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------format are being checked Yes/No 13.7
Whether all the Radio Units are in working condition ?
Yes/No
13.8
If no, number of faulty units
... Nos.
13.9
Whether Engineering order wire (E.O.W) working.
Yes/No
Whether Rooms are in dust free condition
Yes/No
Whether all the parameters of charger are properly working.
Yes/No
13.10
13.11
13.12
Whether all the Battery voltages are (should be above 2 volts)being checked Yes/No
13.13
Sick cells, if any, are being identified and corrective action taken
Yes/No
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.G. Set carried out.
Yes/No
13.17
Auto change over working ?
Yes/No
13.18
Is it free from leakages ?
Yes/No
13.19
Whether Diesel Tank of DG set is full
Yes/No
Whether all the alarms are in working order ?
Yes/No
Whether no. 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
13.14
13.15
13.16
13.20
13.21
13.22
13.23
13.24
13.25
Check the resistance of lightning
110
------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------arrestor (better than 2 ohms) 13.26
13.27
13.28
13.29
13.30
13.31
13.32
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.
Yes/No
Whether Unauthorized Entry Alarm / Signal system is in working condition?
Yes/No
14.0
SINGLE BUOY MOORING SYSTEM
14.1
Whether the following items are being inspected daily and records kept ? Free floatation of buoys Draft Free movement of rotating assembly
Yes/No Yes/No Yes/No
14.2 Whether following items are being inspected weekly and records kept ? - Mooring ropes and ancillary equipments - Batteries - Navigational aids
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
14.4 Whether following item are being inspected on quarterly basis ? -
Anchor chains of buoys for wear tear and tension Fenders for damage
111
Yes/No Yes/No
------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK ------------------------------------------------------------------------------------------------------------------------------------------------Draft of buoys Yes/No Hose configuration Yes/No Hose with respect to PLEM Yes/No Sacrificial anodes Yes/No Swivel joints and turn tables Yes/No 14.5 Whether following items are being inspected annually ? -
Expansion joints Oil swivel seals
Yes/No Yes/No
14.6 Whether inspection of Hoses are being done as per the requirements of OISD-STD-135
Yes/No
15.0 CONTINGENCY PLANS: 15.1 Is there updated contingency plans for emergencies at ? -
Installations Mainlines Off-shore facilities
Yes/No Yes/No Yes/No
15.2 Is the contingency plans(s) displayed in conspicuous place ?
Yes/No
15.3 Are all the employees familiar with it ?
Yes/No
15.4 Is the list of Mainline emergency equipments/tools available ?
Yes/No
15.5 Are the mainline emergency equipments/ tools stacked separately and marked for easy identification ?
Yes/No
16.0 DOCUMENTATION 16.1 Whether the basic datas and parameters of the Pipelines/SBM system layout, length, diameter etc. are available in Pipeline installation ?
Yes/No
16.2 Whether complete route strip map showing all the details of the passage of the pipeline and all isolation M/L valve locations are available on record in Pipeline installation?
Yes/No
16.3 Whether list of various codes to which Pipeline and SBM systems ?
112
ANNEXURE CHECKLIST FOR SAFETY IN LABORATORIES -------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------1. Whether fire extinguishers are adequately positioned. 2. Whether important instructions, emergency procedures displayed. 3. Whether fittings in storehouse for returnable petroleum samples are of flameproof nature. 4. Whether ELCB/ECB installed in the main power switch board. 5. Whether samples of Class 'A' petroleum products in air tight containers. 6. Whether emergency lighting available. 7. Whether the switches/plug sockets for various equipments intrinsically safe.(Lab bench or near ground level) 8. Whether system exists for switching off all equipments at the end of the day. 9. Whether any emergency siren button provided in the Lab. 10. Whether the on-site emergency plan includes possibility of a fire in the Lab. 11. Whether the drainage system has been provided with a oil trap. 12. Whether proper ventilation/exhaust system exists in the fume chamber area. 13. Whether the height of the chimney in the fume chamber is sufficient. 14. Whether entry to the Laboratory area is restricted. 15. Check the condition of Test benches & cupboards. 16. Is vacuum system adequate and working properly. 17. Are all Gas Cylinders kept outside buildings and kept properly secured. 18. Is the condition of the utility lines healthy.
113
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