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

indicates based on

the the

modification/changes/addition

amendments approved in the 19th Safety Council meeting held in September, 2001July, 1999

3

In addition. Kasturba Gandhi Marg New Delhi . methodology. marketing. 4 . This document will be reviewed periodically for improvements based on the new experiences and better understanding. 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. Generally. preparation of reports. 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. Different aspects of the Internal Safety Audits starting from the need of such Audits. pipelines and gas processing disciplines.110 001. follow up actions on the recommendation of the Audit Reports have been covered in Section I of this document. 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. While methodology to be adopted for carrying out the External Safety Audits is separately dealt with."Internal Safety Audit Procedures". Safety Audits are of two types viz. Suggestions from users/industry members may be addressed to: The Co-ordinator Committee on Internal Safety Audits Oil Industry Safety Directorate 2nd Floor.FOREWORD Safety Audits have been conducted in the oil/gas industry in one form or other. comprehensive Check Lists are given in Section II of the Document covering typical areas in the oil/ gas industry. “Kailash” 26. Internal Safety Audits and External Safety Audits. if implemented objectively will go a long way in improving the safety in the oil & gas industry. It is hoped that the provision of this document.

reference to the same has also been provided wherever required. the guidelines contained in earlier edition stands revised. With the issuance of this edition. 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. The first edition was prepared by OISD and did not have a regular Functional Committee. 1989. As during the interim period a number of new OISD Standards/ Guidelines have been published. A Functional Committee for the objective of revising the same was therefore constituted. Marketing terminals/LPG Bottling Plants etc. 5 .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.

9 and 10 will be applicable. 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-144.7.2.8 will be applicable 6 .SCOPE These guidelines are applicable for refineries/on-shore gas processing units(excluding all oil-field operations)/ and marketing installations.6 and 9 would be applicable.5. In the case of terminals where pipeline transfer is taking place.3.5. 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. Items which may not be applicable in Marketing have been separately identified by an asterisk (*) mark.2. chapters 1. 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.6. chapters 1.3. However.3. 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).2. In the case of terminals where no pipeline transfer is taking place.

Shri S.Bhaskar Rao Shri I. (Marketing Division) Cochin Refineries Ltd. Gupta Oil Industry Safety Directorate -------------------------------------------------------------------------------------------------------------------------------------In addition to the above.Sharma Shri M.Madhusudanan Shri D.Madhukar Rao MEMBER CO-ORDINATOR Shri S. several other experts from Industry contributed on the preparation.COMMITTEE ON `INTERNAL SAFETY AUDITS' REVISION-I -------------------------------------------------------------------------------------------------------------------------------------NAME ORGANISATION -------------------------------------------------------------------------------------------------------------------------------------LEADER Shri Barath Balan Hindustan Petroleum Corporation Ltd.S. (R&P Division .T.C.N. ( Refineries ) Indian Oil Corporation Ltd.Shroff Shri C.N. 7 . Gas Authority of India Ltd.J.K. Ray Shri T. review and finalisation of this document.Pipelines) Ex-Official Bharat Petroleum Corporation Ltd. ( Marketing ) Bharat Petroleum Corporation Ltd. (Refineries & Pipelines Division) Bongaigaon Refinery & Petrochemicals Ltd Hindustan Petroleum Corporation Ltd. Ahmed Indian Oil Corporation Ltd.Charvethia Shri S.C. ( Refinery ) Indian Oil Corporation Ltd.Ananthakrishnan Shri K.Rao Shri G. ( Refineries ) Hindustan Petroleum Corporation Ltd. (Marketing) MEMBERS Shri M.

GDN .2 INTERNAL SAFETY AUDITS CHECKLISTS 8 .OISD .1 INTERNAL SAFETY AUDIT PROCEDURE SECTION .145 REVISION-I GUIDELINES ON INTERNAL SAFETY AUDITS SECTION .

1 INTERNAL SAFETY AUDITS PROCEDURES 9 .SECTION .

0 TYPES OF SAFETY AUDITS METHODOLOGY OF INTERNAL SAFETY AUDITS 5.6 Briefing 5.5 Preparation before Site Visits for Safety Audits 5.1 Frequency of Audits 5.0 PREPARATION OF AUDIT REPORTS FOLLOW UP OF AUDIT REPORTS IMPLEMENTATION OF RECOMMENDATIONS -------------------------------------------------------------------------------------------------------------------------------------- 10 .0 7.4 Use of Safety Audit Check Lists 5.3 Duration of Audits 5.0 INTRODUCTION 2.2 Formulation of multi-disciplinary 5.9 Study of Documents Audit Teams 6.0 8.0 3.-------------------------------------------------------------------------------------------------------------------------------------SECTION DESCRIPTION PAGE NO.0 5.7 Site Inspections 5.8 Discussions 5. -------------------------------------------------------------------------------------------------------------------------------------1.0 OBJECTIVES OF SAFETY AUDITS SCOPE OF SAFETY AUDITS 4.

etc.0 TYPES OF SAFETY AUDITS Two types of Safety Audits are proposed to be carried out as below : I) Internal Safety Audit ii) External Safety Audit 11 . design (Process. safety audits are undertaken to meet different specific objectives viz.0 OBJECTIVES OF SAFETY AUDITS While the basic aim of safety audits is to identify the areas of weaknesses and strengths. training. for safe 3. 3. 4. To ensure that operating / maintenance procedures.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. 5. etc. emergency plans. work practices are as per those stipulated in the manuals and standards. personal protection standards. accident records. 4. Mechanical.INTERNAL SAFETY AUDITS PROCEDURES 1. codes. training.) aspect. To identify any design deficiencies and also any weaknesses which might have cropped up during modifications / additions of facilities. preparedness disaster management etc. Safety audit is an important tool in undertaking this function. operating Inspection & Maintenance procedures. which might have degraded with time. This includes all the components of the system viz. is one of the prime function of loss prevention in oil industry.1. To ensure that fire protection facilities and safety systems are well maintained.0 INTRODUCTION Identification of vulnerable areas and specific potential hazards. 2. layout and construction of the plant. for handling emergencies and 2. attitudes. 6. As a social objective to cater to public opinion and concern environment. This also improves public relation of the organization. management policy. To check on security. standards. Electrical. To check the compliance of statutory regulations.

.

External Safety Audits will be carried out by outside teams consisting of technical experts from other organizations in oil industry. All dispatch facilities like Tank-Wagon loading Tank . Miscellaneous other facilities such as Workshops. However. Coking.VII Power House. The areas to be audited should be clearly identified and logically grouped. professional bodies and statutory authorities under the overall coordination of OISD. Kero / Diesel HDS etc. However.0 METHODOLOGY OF INTERNAL SAFETY AUDITS 5. 5. Similar groupings can be done for other types of Installations.lorry loading.D Naphtha HDS. The suggestive groupings in case of a Refinery Installation are given below.C Secondary Processing Unit like FPU / Units.VI Group . Bitumen filling and dispatch facilities.E N2 & Others. IV . this could be modified depending upon layout and complexity of the individual installation. Warehouse Laboratories etc. In case of LPG bottling plants the internal safety audit should be conducted minimum once a year as per OISD-STD-144. Cat-Reforming. Internal Safety Audits will be coordinated by local management under the overall direction from the Corporate Office. Electrical Sub-stations. For this purpose. Layouts etc.B Visbreaking.A Atmospheric / Vacuum Units IV . 9 .IV Sub Groups - IV . filling & dispatch facilities. IV . 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. Water Block.1 FREQUENCY OF AUDITS: All the facilities in a particular Refinery/Installation should be covered minimum once every year.V Group . FCCU/HCU & H2 along with Treating IV .III Group .0 to 8. including TEL blending) PROCESS UNITS : Group . facilities' design can be audited every 3 years or after any major modification or additions.The methodology for carrying out such Internal Safety Audit is described in greater detail under paras 5.Audit conducted by Internal Audit teams of the organisation is categorized as Internal Safety Audit.0. Fire Fighting and Safety. Group -I Group – II All LPG Storage. General Audit. Bitumen Blowing Units. Utilities. Oil Movement & Storage (OM&S) (Rest of all the facilities other than those covered under Group I & II. Effluent Treatment. Group .

5. This may vary from 2 to 7 working days for facilities under each group. it would be essential to study all relevant documents as below to get complete picture : . a Check List is a means of pooling the knowledge and hard won experience and ensures that no important aspect is overlooked or forgotten. person(s) concerned should have necessary experience and background to undertake in-depth audit in a particular discipline. Maintenance / Inspection. the team members could also be drawn from the Head Office / Corporate Office and other operating Units under its control.2 FORMATION OF MULTI-DISCIPLINARY AUDIT TEAMS: The Internal Audits should be carried out through multidisciplinary audits teams. observations should be recorded in separate sheet.7 SITE INSPECTIONS: Most of the information could be gathered through site inspection using ready-made check lists.Operating Manuals . / Inspection Manuals . the duration of internal safety Audit can be fixed.Maint. 5. Process / Production. One of the team members should be nominated as the leader of the audit team. 5. detailed model Checklist covering important areas are given. A team of 4 to 5 experienced officers from various disciplines viz. It is suggested that oil industry members should adopt these model check lists for carrying out Internal Safety Audits. Wherever necessary. The auditors should enter their observations under the remarks column and not simply state "yes" / "no". Like a code of practice. In multi-unit organizations.Layouts . The composition of the Internal Safety Audit may vary depending on the Group and areas to be audited. Even for a skilled and well qualified engineer a good check list would be necessary as a guide. 5.5 PREPARATION BEFORE SITE VISITS FOR INTERNAL SAFETY AUDITS: Before the safety Audit team visits any particular facility for carrying out Safety Audit. Fire & Safety and with the activity involvement of concerned Plant / Area Manager is suggested.3 DURATION OF AUDIT Depending on the nature of audit and type / complexity of the installations in the selected group. In Section-II of this document.5. etc. Electrical. Inspection should be carried out accompanied by Installation / Plant Manager or the assigned officials.6 BRIEFING: Before beginning of each audit.Fire and Safety Manuals.4 USE OF SAFETY AUDIT CHECK LISTS Check lists are the most useful tool for undertaking systematic Safety Audit. No impression should be left that audit will throw bad light on them. All the audit team members should study these documents in advance to know the details of the installation. Depending upon the nature of audit more emphasis can be given to study specific documents. all concerned persons of the area/installation be briefed by the team leader about the purpose of the audit.P & IDs . Such check lists help maintaining uniformity and speeding up the audits. Instrumentation. 10 . 5. however.

0 FOLLOW UP OF AUDIT REPORTS Generally. Log Books. Log sheets. A senior person should be nominated for coordinating implementation of all accepted recommendation under a time bound program. 5. Maintenance. other documents. Electrical. Standing Orders.9 STUDY OF DOCUMENTS: In addition to the documents which are already studied before inspection of the facilities.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. This approach is always constructive and does not undermine the technical competence of the audit team.0 IMPLEMENTATION OF RECOMMENDATIONS The final and most important phase is the implementation of recommendations. 7. Senior management should review the progress of implementation of recommendations periodically through Management Safety Committee meetings and other review meetings. Before finalizing the report. with site personnel and Installation / Plant Manager. it would be necessary to undertake a detailed study of the specific area and to identify the rectification measures. 6. but not the solution. Accident Records. 11 . The crux of the safety audits lie in removing the weakness identified during the audit. Only the appointing authority should exercise judgement in rejecting any of the recommendations. Wherever the necessary in-house expertise is not available for detailed studies. the Safety Audit Team can give a presentation as feedback to the Operating / Management personnel of the Area / Installation.. Sometimes audit reports identify only the problem / weakness.5.8 DISCUSSIONS: Further information can also be gathered through discussions (formal & informal). Instrumentation. the Internal Safety Audit Reports are submitted to the concerned authority who appoints the audit team for undertaking needful follow up actions. such as Operating Instructions. may also be studied as required. In such cases. 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. 8. The appointing authority shall be of senior management level ( General Manager and above ). The audit team should interact with persons from various disciplines such as Production. who is in-charge of the area or other site officers. etc. help of consultants / professional bodies should be sought for. Additions or deletions could be made in the draft report based on the discussions and comments received during the presentation. Minutes of Safety Committee Meetings etc.

SECTION : 2 INTERNAL SAFETY AUDITS CHECKLISTS 12 .

9.87 ANNEXURE 88 --------------------------------------------------------------------------------------------------------------------------------------- 13 .51 52 .18 19 .COUNTRY PIPELINES 80 . FIRE PROTECTION LAYOUTS PROCESS PLANTS OIL STORAGE AND MOVEMENT POL LOADING AND UNLOADING LPG BULK LOADING / UNLOADING LPG BOTTLING AND DISPATCH ELECTRICAL SYSTEM OISD-GDN-145-02 OISD-GDN-145-03 OISD-GDN-145-04 OISD-GDN-145-05 OISD-GDN-145-06 OISD-GDN-145-07 12 . OISD-GDN-145-08 69 .79 60 .38 39 . CHECK LIST NO. 7. 6.59 CHAPTER 8. SAFETY AUDIT PAGE NOS.33 34 . 3. GENERAL SAFETY AUDITS OISD-GDN-145-01 6 . 4. 5. 10.11 2.68 OISD-GDN-145-09 OISD-GDN-145-10 CROSS . ------------------------------------------------------------------------------------------------------------------------------------------------1.SECTION : 2 INTERNAL SAFETY AUDIT CHECKLIST CONTENTS ----------------------------------------------------------------------------------------------------------------------Sr.23 24 .

3 4.6 1.4 2.1 2.5 Reporting formats Reporting Procedures Follow up of Recommendations Maintenance of Records & Data Review of Accidents Data 14 .6 2.3 2.OISD-GDN-145-01 GENERAL SAFETY AUDITS CONTENTS --------------------------------------------------------------------------------------------------------------------------SECTION DESCRIPTION PAGE NO.145-01 REVISION I SAFETY AUDIT CHECKLIST No.0 INDUSTRIAL HAZARD CONTROL 2.0 FIRES.5 2.2 2. -----------------------------------------------------------------------------------------------------------------------1.0 EMPLOYEE TRAINING 4.1 1.4 4.1 4.4 1.5 1.2 1.7 House Keeping Machine Guarding General Safety features Maintenance of Tools and Tackles Materials handling Personnel Protective Equipment Toxic Materials and Occupational Health 3.7 1.OISD-GDN .2 4.0 ORGANISATION AND ADMINISTRATION 1.3 1.8 Management Philosophy Procedures Safety Audits Safety Committee Meetings Safety consciousness & Propagation Work Permit System Contingency/ Disaster Plan Plant Security 2. ACCIDENTS AND NEAR MISSES 4.

Fire fighting & Safety .3 SAFETY AUDITS a) When was last External/Internal Safety Audit carried out ? Whether accepted safety audit recommendations are implemented with time bound schedules ? b) 1.2 PROCEDURES a) Whether procedures are well defined and manuals are available & accessible plant / facility wise for the following functions ? .OISD-GDN-145-01 SAFETY AUDIT CHECKLIST 1.1 MANAGEMENT PHILOSOPHY a) Whether the declared safety policy is made available to all concerned in written form ? When updated last ? Does the employees contribution towards safety form a part of the appraisal system ? b) c) 1.Operation .Electrical .Inspection and maintenance .0 ORGANIZATION AND ADMINISTRATION: 1.Mechanical .0 GENERAL SAFETY AUDITS ------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR REMARKS ------------------------------------------------------------------------------------------------------------------------1.4 SAFETY COMMITTEE MEETINGS Whether Safety Committee Meetings are held regularly ? 15 .Emergency and disaster management plans b) When were these documents updated last ? 1.Instruments .Civil .

Frequency . .Safety posters/slogans.sequence of operations where critical / batch operations are performed.5 SAFETY CONSCIOUSNESS & PROPAGATION a) Whether following items have been taken care of ? Display of (in languages widely understood) .7 CONTINGENCY/DISASTER PLAN a) Whether disaster management plans are available for different possible types of scenarios? c) 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 .6 WORK PERMIT SYSTEM Whether work permit system meet the requirements of OISD Standards 105/137 ? 1.Safety precautions at strategic points through sign boards.-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK ------------------------------------------------------------------------------------------------------------------------------------------------1. b Whether fire & safety training programs are conducted periodically and are in line with OISD-STD-154 ? Whether Safety awareness competitions are held periodically ? .Participants Any other Motivation scheme exists ? 1.Type . .

ITEM AUDITOR’S REMARK ------------------------------------------------------------------------------------------------------------------------------------------------1.8 PLANT SECURITY a) Whether installation has wall/fence as per prescribed norms? b) Whether gates are manned? c) Whether identity badges/cards are issued and worn by employees, visitors and contractors personnel for admission to restricted areas? d)How it is ensured that visitors/contractor personnel do not trespass into non permitted areas? e)Whether frisking is done for contractor personnel / visitors / employees; if so, how much percentage is covered under each category? f) Whether Crisis Management Scheme for BOMB Threat exists? g) Whether watch towers exist? 2.0 INDUSTRIAL HAZARD CONTROL 2.1 HOUSE KEEPING Ratings * 1 2 boundary

-

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

-

-

2.2 MACHINE GUARDING

- Rotary equipment in operating areas - Workshops - Others -

-

2.3 GENERAL SAFETY FEATURES Check For: - unprotected Floor openings protected - Slippery defective floors - Stairway surfaces --------------------------------------------------------------------------------------------------------------------------------------------------

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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 ? --------------------------------------------------------------------------------------------------------------------------------------------------

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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

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3.3.t specific case .2 a) Dissemination Whether the procedures /systems are established & streamlined for dissemination of information? What is the MIS upto Chief Executives level w.1 a) Implementation for Whether responsibility is assigned implementing the recommendations? b) Whether the recommendations are implemented with time bound schedules? c) How far the recommendations arising out of previous accidents are implemented? 4.-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK ------------------------------------------------------------------------------------------------------------------------------------------------4.r.5 REVIEW OF ACCIDENTS DATA a) Is there any system to periodically review the trends of accidents for taking necessary actions ? 20 . accidents and near misses? b) 4. how fast any case history could be located? .r.3 FOLLOW UP OF RECOMMENDATIONS 4.based on particular area/type 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.t information on fires.w.4 MAINTENANCE OF RECORDS & DATA a) Accident statistics of last how many years are available ? b) If required.

-------------------------------------------------------------------------------------------------------------------------------------------------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 .

1 2.6 2.OISD-GDN-145-02 REVISION I SAFETY AUDIT CHECKLIST FIRE PROTECTION CONTENTS --------------------------------------------------------------------------------------------------------------------------SECTION DESCRIPTION PAGE NO.2 2.4 3. -----------------------------------------------------------------------------------------------------------------------1.0 2.0 2.0 3.1 3.3 3.7 2.3 2.8 3.2 3.5 PHILOSOPHY AND STANDARDS FACILITIES Fire water Fire Hydrant System Foam System Fire Station Fire Extinguishers Fire Hoses and Accessories Protective/ Safety Equipment Others PROCEDURES Organisations Disaster Management Plan Inspection and Testing facilities Training Checklist for DMP 13 13 13 14 14 15 15 15 15 15 16 16 17 17 17 18 22 .4 2.5 2.

1 FIRE WATER Fire water storage a.Is manpower available and effectively trained to handle the fire fighting equipment.What are replenishment source ? adequate ? Are they d. these are divided into a number of simpler items/ questions which could be evaluated/answered with reasonable clarity.Are emergency control procedures adequately established. Are the facilities adequate for anticipated fires ? and reliable 2.1.What's the internal replenishment rate ? -------------------------------------------------------------------------------------------------------------------------------------------------- 23 .What is the capacity & how was it determined b. 1. FIRE PROTECTION -------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR'S REMARKS --------------------------------------------------------------------------------------------------------------------------------------In order to evaluate the adequacy of fire fighting facilities and procedures. 2.0 FACILITIES Whether following facilities are provided adequately and have the necessary efficacy. 3. Since the scope under each query is too broad and it is difficult to give simple answers.OISD 117(for Marketing-POL) and OISD 144 (LPG bottling plants) as necessary ? 2. answers should be obtained for the following four basic queries: 1.Is it sufficient ? Is the storage AG/UG or other wise ? c.0 PHILOSOPHY AND STANDARDS Does basic philosophy for designing the fire fighting facilities follow OISD 116 (for Refinery).1 2.OISD-GDN-145-02 SAFETY AUDIT CHECKLIST 2.

What's the capacity of each pump and at what head ? e. g. d. What's the power source ? How many are diesel & elect driven ? c. Please comment on the system as per the following.2 a. What's the priming system? f. Network . -------------------------------------------------------------------------------------------------------------------------------------------------- 24 . e.ITEM 2.Grid type/Closed type/Any other Mains What's the material of construction of pipes ? How corrosion protection is ensured ? How is the sectionalising of hydrants system ? How are the spacings between hydrants Are monitors / hydrants properly distributed in critical areas and all facilities covered ? Are these hydrants/monitors easily accessible and operable ? Is the layout vulnerable at any points from fire hazard FOAM SYSTEM What are the types of foam available? What are the dilution potential and the quantities ? What are the storage arrangements and its accessibility 2.1 2. f.1. Is location away (from hazardous area) ? b. condition of pipeline etc. What's the stand by philosophy ? d. 116/ 117/144.2 FIRE HYDRANT SYSTEM Check and comment on the hydrant system layout design position of hydrants/monitors.2 Fire Water Pump : AUDITOR’S REMARK a. What's the diesel fuel tank capacity (hrs) ? k How frequently does jockey pump start ? How long it runs ? l. flow rate pressure at the farthest point. Is there any jockey pump ? g. Are the fire water pumps/engines started & observations logged as per OISD Std. 2. b. What's fire water pump starting system manual/auto ? I.2.3 a. c.2. What's the capacity ? What's set pressure? h. b. 2. c. What's the condition of battery of diesel engine ? j.

f. 25 .4 a. c. maintenance and testing of fire extinguisher are promptly carried out and proper records maintained in line with OISD Std. b. e. Do the coverage and application rate for floating roof/fixed roof tanks meet OISD norms ? Are foam branch pipes. ? What is the monthly cartridge and product ? consumption of e. 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 Fire Extinguishers attached to TTs should also bear the TT number Note 3 .suitability proper pick up FIRE STATION Is the location away from hazardous areas ? Are the no. 2. of hydrants in the system ? g. f.? FIRE EXTINGUISHERS Are portable extinguishers meeting OISD requirements ? Are they BIS approved ? Whether periodical inspection. no. flow proportioning system etc. c.5 a. FIRE HOSES AND ACCESSORIES Are no of hoses sufficient w.r. nozzles. 2.? Are replacement of extinguishers on shell failure or hydrotest ensured and necessary records available ? Are quantity of cartridge and powder sufficient at work site and spares available in store in line with OISD Std.ITEM AUDITOR’S REMARK ------------------------------------------------------------------------------------------------------------------------------------------------d. b.t. and variety of fire vehicles sufficient ? Facilities on fire vehicles capacity. Daily starting of vehicles and other check logs.6 a. 2. pressure. wheeled equipments available and adequate as per OISD Stnadard ? Proportioning equipment . d.

Are the hose boxes strategically placed ? Are the hoses easily removable during an emergency ? 26 . c.b.

Inspection and maintenance schedule . .Condition of radio communication equipment. Are all various types of nozzles/foam branch pipes etc. Are the hose boxes painted fire red Note 3 as per OISD Standard.7 Are the hoses BIS Approved Note 3 ? 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.? Check the locn./range and report .156 ? 2.Within and to outside. 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.-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK ----------------------------------------------------------------------------------------------------------------------------------------------d.8.Normal and emergency. Differentiation between different types fires / emergencies. Are adequate sand drums / buckets available ? g. Are the hoses periodically tested/ checked and replaced? e.? f.Availability of alternate power supply during normal supply failure .8. provided as per OISD STD. 2. .1 Fire siren and fire alarm network (Electrical/ mechanical/ hand operated) Satisfactory working.2 Ambulance/Other means of transport and First-Aid services with complete kit Note 3.? h. Contingency Plan for medical emergency.Training of the users. . of 27 .

-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK ------------------------------------------------------------------------------------------------------------------------------------------------- Evacuation, etc. - First Aid training to personnel on shift. 2.8.4 Availability of critical areas. emergency, lights in

2.8.5

Availability of special fire fighting components aprons / suits / emergency flood lights, power megaphones, etc. PROCEDURES ORGANIZATION Whether the organogram of fire fighting and other supporting services well defined ? Is periodic fire drill conducted, shortcomings observed and necessary action initiated ? Does location have well defined fire order ? Whether organogram has provision to meet emergency situation during idle shift / sundays and holidays.

3.0 3.1 a.

b.

c.

d.

Whether relevant fire order is displayed at various work stations indicating station employees role during fire / emergency ? Whether following documents are updated and displayed as reqd. - Organogram - Fire hydrants layouts and P & ID diagrams - Fire fighting procedures / manual

e.

f.

Whether layouts and organogram displayed ? DISASTER MANAGEMENT PLAN (Ref.to new checklist for DMP) Whether mutual aid schemes are made with neighboring industries, local fire brigades, etc. Whether resource requirements are worked out

3.2

a.

b.

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 ? Is foam proportioning equipment in working order ? Whether hydrotesting and regular inspection of fire gate mains undertaken and records maintained ? Whether various checks & records of periodical running of Diesel engines carried out? 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?

d.

e.

f.

g.

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. 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. Is emergency control centre planned properly furnished / fitted to meet requirement ? Whether DMP is based on MCA and analysis ? and the

f.

7.

8.

risk

30

1 Electrical power lines 21 6.0 TOPOGRAPHY OF INSTALLATION SURROUNDING OF THE INSTALLATION INTER .2 Electrical switchgear 21 6.1 4.3 5.8 Water cooling towers 22 6.DISTANCES TANKFARMS Grouping of tanks Dykes LPG storage PROCESS UNITS Location Control room Field OTHER FACILITIES AND EQUIPMENT 20 20 20 20 20 20 20 21 21 21 21 21 6.7 Waste water facilities 22 6.0 2. ------------------------------------------------------------------------------------------------------------------------------------------ 1.5 Boiler plants 22 6. OISD GDN-145-03 LAYOUTS CONTENTS -------------------------------------------------------------------------------------------------------------------------------------SECTION DESCRIPTION PAGE NO.0 5.2 5.13 Compressors 23 6.2 4.10 Piping 22 6.9 Elevated platforms 22 6.3 Roads 22 6.0 3.11 Rail spurs 23 6.OISD-GDN-145-03 REVISION I SAFETY AUDIT CHECK LIST No.12 Fire hydrants/ monitors/ safety showers/ hose etc.6 Gantries 22 6. 23 6.14 Miscellaneous 23 ------------------------------------------------------------------------------------------------------------------------------------------------- OISD-GDN-145-03 31 .1 5.0 4.4 Administrative buildings/ workshops/canteen 22 6.3 6.0 4.

0 SURROUNDING OF THE INSTALLATION . 2.Susceptibility for flooding .0 TANKFARMS 4.Mixing of different class products in POL tank farm Accessibility of tanks for fire fighting.Routing / Cris.2 DYKES .0 INTER-DISTANCES Code / standard/ regulations followed /deviated (Ref.SAFETY AUDIT CHECKLIST LAYOUTS ------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR'S REMARKS ------------------------------------------------------------------------------------------------------------------------------------------------1.crossing of process / fire hydrant lines inside dyked tank farm . 32 .1 GROUPING OF TANKS .Equipment/block/facility to boundary walls .Location of process units and tank farms in undulating areas.Construction and dimensions of dyke wall .Provision of fire walls.Flammables / Toxics/ Ignition sources up/ down wind 3. 4.Aggregate capacity of tanks in each Dyke / enclosure .0 TOPOGRAPHY OF INSTALLATION .OISD-STD-118/144). .Block/facility to block/facility .Equipment to Equipment switch in a block / facility. 4.Capacity of Dykes with respect relevant group to .

t.Safety of control room from any blast situation .Consolidated / Scattered .Easy approach to entrance and to fire fighting facilities .r.Down wind from ignition sources 5. . Note 3 5.Vapour trap 5. .Packing and grinding of susceptible leaky areas 33 .General state of terrain without depression / large ditches .Upwind from sources of flammables / toxic materials .Orientation w.Design for minimum occupancy .Adequate provision of oily water sewers and catch pits.2 CONTROL ROOM . water and storm .3 LPG STORAGE .3 FIELD .Emergency Light during power failure at Process Control room.Over head clearances for passage of heavy equipment like cranes .1 LOCATION .Positioning of process equipment without stacking .Electrical area /equipment classification . wind direction .0 PROCESS UNITS 5.-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK ------------------------------------------------------------------------------------------------------------------------------------------------4.Segregation of equipment handling hazardous / materials .Separation from tank farm/concentration of people .No of vessels in each group and the capacities aggregate -Provisions of slope and spill collection shallow pumps.Adequacy of accessways for the movement of equipment and people.Strategic location of fire fighting equipment .

34 .

Separation from elevated structures which may fall across power lines .3 ROADS .-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK ------------------------------------------------------------------------------------------------------------------------------------------------6.Accessibilities to each process unit/tank .1 ELECTRICAL POWER LINES .5 BOILER PLANTS Upwind and separation from flammable materials sources of 35 .Routes of overhead power cable and instrument cable trays and their fire protection/ fire proofing 6. Separate entry points product movement for employees and .Layout of the roads for minimum truck traffic in grass .Concreted / asphalted (condition) .Rooting below / above ground .Location of power receiving station & layout hazard 6.Upwind from flammable sources .Passing over critical facilities .2 ELECTRICAL SWITCHGEAR .0 OTHER FACILITIES AND EQUIPMENT 6. Note 3 6.Process Plants and facilities shall have access roads for fire tenders from at least two sides.4 ADMINISTRATIVE BUILDINGS /WORKSHOPS/ CANTEENS Peripheral locations Separation from hazardous areas Upwind from sources of flammable / toxics 6.Road widths and turning radii for movement of large fire fighting vehicles .Crossing of pipe alleys .High ground in flooding areas .

6.9 ELEVATED PLATFORMS .-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK ------------------------------------------------------------------------------------------------------------------------------------------------6.No facility opposite the end of the spur.6 GANTRIES . 6.Alternate routes for descent .Down wind from concentrations of people ignition sources / .Peripheral locations .Down wind from ignition sources/ concentration of people 6.11 RAIL SPURS .12 FIRE HYDRANTS / MONITORS / SAFETY SHOWERS / HOSE ETC.Any treatment facility to dischargeable water for pollution control 6.8 WATER COOLING TOWERS .Separation from main line of rail / road 6. .Fire proofing of pipe racks.Downwind from ignition sources .Head bumpers. shin splitters and tripping hazards .Landing at grade in safe locations 6.10 PIPING .7 WASTE WATER FACILITIES .Clearance for derailments .Personnel protection from hot lines .No obstruction for approach.Permanent platforms for all operating points .Peripheral location . Good path for retreat 36 .

Provision of Truck parking area 37 .Down wind from rest of unit 6.Storm water drains & easy drainage .-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -----------------------------------------------------------------------------------------------------------------------------------------------6.Display of Layout drawing and display of P & I DRAWING -Check piping layout for minimum piping .TTL gantry and easy exit through the product movement gate .Not in closed buildings .Grading of various block facilities .Location of fire station and fire pump .Flood light towers & security towers .14 MISCELLANEOUS .Height of flares is adequate .13 COMPRESSORS .Greenscaping area .Location of smoke booths .

OISD-GDN-145-04 REVISION I SAFETY AUDIT CHECKLIST No.7 2. ---------------------------------------------------------------------------------------------------------------1.3 1.0 2.1 2.9 GENERAL Layout and Drainage Fire Protection facilities Housekeeping Training Inspection & Maintenance Electrical Instrumentation PROCESS SUB-SYSTEMS Control room Pump House Compressor house Heat exchangers/ condensers/ coolers Process vessels and columns Process furnaces Process piping Relief and Disposal System First aid 33 25 25 25 26 26 26 27 27 27 27 28 29 29 30 30 31 32 38 .6 1.2 1.0 1.4 1.5 2.4 2.3 2.2 2.OISD GDN-145-04 PROCESS PLANTS CONTENTS --------------------------------------------------------------------------------------------------------------SECTION DESCRIPTION PAGE NO.1 1.7 2.8 2.6 2.5 1.

0 GENERAL 1. Whether the hydrants.1 LAYOUT AND DRAINAGE a) OIDF-STD-118 ? (deviations. platforms provided are as per standard engineering practices and can be considered adequate ? Whether oil water sewers are adequately sized and the manholes on these sewers covered properly ? Whether the plant surface drainage systems are adequately sized and properly maintained ? Whether a closed blow down been provided for draining of from the vessels / equipments pump out arrangement from tank ? FIRE PROTECTION FACILITIES Whether the fire water network provided is well designed (Ring type) and covers all sides of the plant ? refer OISD116. if any to be specified) Whether the location of the control room & furnace meets the OISD-STD-118 Whether proper approach roads to the plant have been provided ? Whether ladders. hose boxes are easily accessible ? Whether adequate number of portable fire extinguishers have been provided all over system has hydrocarbon with proper underground b) c) d) e) f) g) 1.0 PROCESS PLANTS ----------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITORS REMARKS -----------------------------------------------------------------------------------------------------------------------------------------1.2 a) b) c) d) e) 39 .SAFETY AUDIT CHECKLIST 4. water monitors are provided from all sides of the plant ?And are they located more than 15 meters away from nearest hazard ? Whether steam lancers have been provided and are adequate ? Whether all hydrants. monitors.

the plant as per the OISD-116 ? 40 .

-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------f) Whether communication systems. fire alarms and p. . a) b) c) 1. safety and fire fighting at the induction stage ? Whether subsequent refresher training programs are organized-periodically? Whether contractor employees are given basic training on hazards of petroleum products & safe practices ? Whether the workers are using proper personnel protective clothing such as hand gloves. face shield etc. heat exchanger areas are regularly washed to avoid Oil Accumulation ? Any visible Oil Accumulation on the floor. disaster control manual.3.4 a) b) c) d) e) 41 . fire & safety manual. safety shoes. drains found ? Are redundant pipes/valves/ pump foundations /insulation debris removed from process area ? Whether the general housekeeping in the area can be considered as . helmet.adequate .a.not adequate TRAINING Are copies of updated operating manual. system have been provided ? Are they working ? Whether a copy of fire fighting manual is available in the plant control room ? Whether safety committee meetings are conducted at plant level ? Is the frequency adequate? HOUSEKEEPING : Whether the plant floors particularly in pump house. ? g) h) 1. standing instructions available in the control room ? Are the working personnel in the area given thorough training on operations.

vessels.Energizing and de-energizing of electrical Equipment.7 a) Whether electronic instrumentation provided are as per area classification? Whether minimum safety instrumentation provided for furnace.Vessel Entry .Hot/Cold work . Refer OISD-105. ELECTRICAL a) Whether all motors.Excavation .5 a) INSPECTION & MAINTENANCE Whether inspection of equipments/ tanks /piping /safety valves etc.-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK ------------------------------------------------------------------------------------------------------------------------------------------------1. .6. Whether all the modification works are undertaken only with approved engineering drawings ? Whether a well designed work permit system exists for the following and is rigidly followed . and is well maintained ? b) 42 . are carried out as per schedules? Are history cards maintained ? Refer OISD129 / OISD-127. b) c) 1. compressors etc. .Entry of Vehicle into battery area. electrical fittings in the plant are as per area classification ? Is area classification drawing available ? Whether equipments properly earthed ? readings taken periodically ? Are records maintained ? Whether illumination can be considered adequate ? Whether emergency lighting system has been provided ? Whether any interlocks bypassed and recorded ? INSTRUMENTATION: b) c) d) e) 1.

t. if it is hazardous area ? Whether the cable entry in the control room is properly sealed ? Whether control room pressurization has been provided and working satisfactorily ? PUMP HOUSE : Whether the location of the pump house with respect to furnace is as per OISD 118 ? Whether hot pump have been segregated from pump handling lighter hydrocarbons ? Whether hot pumps are properly located so as to prevent fire due to spillage of hydrocarbon from over head ? Whether piping arrangement w.r.2 a) b) c) d) e) 43 .1 a) b) c) d) e) f) g) 2. shutdown systems ? Are such schedules followed and recorded ? d) Whether any process interlock bypassed and recorded ? Whether smoke / heat / gas / hydrocarbon detectors are provided and are working ? PROCESS SUB-SYSTEMS CONTROL ROOM Whether fire protection provided and considered adequate ? Whether updated P & I diagram available ? Whether emergency shutdown controls are available ? Whether requisite PPE & first aid kit available ? Whether control room is blast proof.-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK ------------------------------------------------------------------------------------------------------------------------------------------------c) Whether any schedule exists for checking up of various interlocks.0 2. personnel's movement satisfactory ? Whether hot pumps are properly insulated ? (including the associated piping) ? e) 2.

-------------------------------------------------------------------------------------------------------------------------------------------------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 ? Whether reciprocating pumps have proper safety release system. is it functional ? d) e) f) g) 44 .3 a) b) Whether various alarms and signaling systems are in working condition ? Are the safety valves on the discharge side of the compressor checked as per schedule ? Whether suction strainer is periodically cleaned ? Whether the compressor has a proper depressurising system ? Is venting system proper ? Whether there is a condensate collection system at suction / discharge of the compressor ? if so. if discharge is blocked ? Are the threaded joints on the pump vents / drain lines found corroded? Whether all pump drains are connected to CBD and OWS ? Any of the drains found congealed ? Does the pump house floor drain have a proper water seal to prevent propagation of fire from OWS to pump house ? Are the auto start / stop of the pumps (where applicable) checked as per schedule and recorded ? Check at random ? COMPRESSOR HOUSE Whether the location is well ventilated ? Whether the following are in working condition ? c) Vibration monitoring system Anti surge device Speed control system Shut down system Lubrication system h) i) j) k) l) 2.

5 a) b) c) d) e) f) 45 .-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK ------------------------------------------------------------------------------------------------------------------------------------------------h) Whether the compressor has nitrogen inerting system ? if so. of high vents / low points drains with proper isolation provided ? Whether provision for thermal relief/ thermal expansion has been provided ? Are TSVs on line ? Whether the insulation / cladding is fully covering the exchanger ? Is earthing proper ? Are supports fire proofed ? Does sacrificial anode exist for coolers / condensers where different metals are in contact ? Whether the operating parameters and test pressures have been tagged on the equipment and is being operated within that? 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 ? PROCESS VESSELS AND COLUMNS: (REFER OISD STD-152) Whether relief valves are periodically tested and records maintained ? Whether all the utility connections are in working condition ? Whether the vessel has been provided with adequate safety instrumentation ? Are the nozzles.is it functional ? i) Do compressor safety valve atmospheric vents have nitrogen / steam purging especially for hydrogen rich gases ? HEAT EXCHANGERS/CONDENSERS/COOLERS Are adequate nos.4. a) b) c) d) e) f) 2. nipples on idle drains and vents capped / blinded ? Whether vessel supports are fire proofed and it is in proper condition ? Whether insulation / painting is proper ? 2.

face shield etc.6 a) PROCESS FURNACES.-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK ------------------------------------------------------------------------------------------------------------------------------------------------g) Do all columns have two sets of level indicators ? 2. are used by operators regularly while adjusting / viewing burners ? Whether the location of the explosion door can be considered safe ? 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 ? Whether the damper control system is satisfactory ? Is position of damper readable from ground level ? Whether the control system for drop out doors opening can be tested on line ? b) c) d) e) f) g) h) i) j) k) l) m) 46 . (REFER OISD-STD-111) Whether the pass flows are provided with recorder and controller and are properly working ? Whether skin temperature and bridge temperatures are recorded ? Whether each main burner has a pilot burner ? Whether electric igniters are provided for each burner and are they well maintained? Whether fuel oil supply header is properly steam traced and insulated ? Whether both oil and gas lines have proper blinding facilities at the battery limit ? Whether the furnace has a trip system / flame out protection system ? Whether on line testing of the same is done ? Whether furnace has step ladder & monkey ladders to reach each platform ? Is alternative escape ladder available from burner-valves platform ? Whether safety wears such as safety goggles.

(Refer OISD-STD-106 ). OWS line connection & manhole location for the furnace be considered safe ? Whether the support structures are properly fire proofed ? PROCESS PIPING Whether expansion loops / expansion joints in working order ? Whether TSVs provided are periodically tested. whether the set pressure is within design pressure ? p) q) r) 2. records maintained ? Whether pipe supports (sliding / spring supports ) guides and anchors are in order ? Does the piping slope towards drain points / knockout pots ? Whether all piping above 60 deg.0 kg / sq.7 a) b) c) d) e) f) 2. ATF etc.8 a) b) c) d) 47 . RELIEF AND DISPOSAL SYSTEM Whether the relief valves have been set at 10% over normal operating pressure ? Whether difference between set pressure and the normal operating pressure is maintained minimum 2.cmg ? Whether safety valve has been installed directly on the protecting equipment / on the connected piping without any isolation valve ? Whether multiple safety valves have been used ? if so.-------------------------------------------------------------------------------------------------------------------------------------------------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 ? Whether noise level near the furnace is within permissible limit ? Is it monitored atleast once a year ? Can the condensate draining. naphtha. C surface temperature have safety insulation ? Whether continuity jumpers provided between flange joints for LPG.

0 m/second.minimum exit velocity of 15.-------------------------------------------------------------------------------------------------------------------------------------------------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 : .10 minutes from a single contingency ? Whether pumps with auto start / stop at high / low level have been provided to pump out the contents ? Whether high / low level alarms for the knock out pots have been provided in the control room ? h) i) j) k) l) m) n) 48 . are disposed through closed system ? 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 ? Whether unit knock out drums have been provided ? if so . . chlorine etc.discharge vertically upward through individual stack .snuffing steam provided ? g) Whether use of common atmosphere vent stack for several relief valves is observed ? Whether any vent stack is observed discharging at an elevation of less than 3m above the tallest structure. phenol. can it hold liquid discharge for 5 . within 15m radius Whether acoustic insulation has been provided on vents producing excessive noise ? Whether toxic vapors like SO2.

9 a) FIRST AID What is the percentage of shift employees trained in first aid ? how many can provide artificial resuscitation ? Does every control room including pump houses possess a first aid box. Note 3 b) c) d) 49 .? 2. exposure to fire etc. water gel blanket and explosive meter ? What is the accident record of the last two years ? All incidents requiring first aid should be recorded.-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK ------------------------------------------------------------------------------------------------------------------------------------------------o) Whether vapor depressurising system has been provided for emergency situations such as runaway reaction.

SAFETY AUDIT CHECKLIST No.0 5. -------------------------------------------------------------------------------------------------------------------------------------1.OISD-GDN-145-05 OIL STORAGE AND MOVEMENT CONTENTS -------------------------------------------------------------------------------------------------------------------------------------SECTION DESCRIPTION PAGE NO.0 TANK FARM 35 2.0 6.0 TANKS PIPING OPERATING PROCEDURES INSPECTION & MAINTENANCE ADDITIONAL CHECK LIST ITEMS 35 36 37 38 38 50 .0 4.0 3.

1 a) GENERAL : Whether the location.SAFETY AUDIT CHECKLIST 5.0 TANK FARM : 1. layouts interspacing in the tank farm meet OISD-STD-118/statutory requirements? Whether Dyke / fire walls meet OISD-118 / statutory requirements ? Whether the roads are available around the tank farm for movement for fire tenders ? Whether piping in the dyke farm is kept minimum ? Whether any piping not connected with the tanks to any individual dyke is passing through it ? Whether any hydrocarbon detection system has been provided ? If so. Whether illumination in the area is adequate / inadequate What is the procedure adopted for recovery and disposal of the tank bottom sludges ? b) c) d) e) f) g) h) i) j) 51 . Whether communication system is available in the tank farm areas.0 OIL STORAGE AND MOVEMENT ----------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR'S REMARKS ----------------------------------------------------------------------------------------------------------------------------------------1. is it working satisfactorily ? Whether house keeping in the area is satisfactory and it is free of any dry vegetation.

2 a) Whether the tank farm closed drains. high pressure indicator and alarms ? Whether any product is stored above its flash point ? If yes what are the additional safety consideration? Whether the breather valves provided matches the pumping in / pumping out requirements of the tank ? Whether any depression due to tank settlement observed on the tank pad along the circumference ? b) 2.0 a) b) c) d) e) f) g) h) i) 46 . drains are clear ? Whether provision exists to divert tank farm drainage either to storm water or to oily water sewer ? TANKS : Whether tanks properly painted and important specifications.-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------- k) Whether leaded gasoline sludge if any. are marked on the tank ? Whether all nozzles of 2" and above sizes have been provided with reinforcing pads with tell .. buried into the tank farm with clear demarcation ? SEWERS : 1.tale holes ? Whether all tanks are provided with circumferential railings ? Whether the roof drain of floating roof tanks is provided with a check valve ? Whether any alternative arrangement to read / record level in the tanks have been provided ? Whether the tanks with steam heating / blanketing are provided with high temp.

If so.0 a) 47 . Naphtha. whether periodically the Halon system is checked and records maintained ? Whether the tanks are properly painted and numbered ? Whether flame arrestors are provided on fixed roof storage tanks which are likely to have explosive mixture in the vapor space ? Whether goose neck type vent connections are provided with suitable wire mesh to avoid birds entry /formation of nests ? Whether oil of proper viscosity is used in oil breather valves ? PIPING : Whether pipe alleys properly graded to ensure that no oil/water gets accumulated below ? l) m) n) o) p) q) r) 3. chemicals services are internally coated ? 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) ? Whether sprinkler systems are provided on all fixed roof tanks as per OISD norms ? Whether Halon system is provided on any tank.-------------------------------------------------------------------------------------------------------------------------------------------------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.

have curb walls and drains connected to OWS ? Whether steam traps of tracer lines are functioning properly ? Whether any bolt is found missing on flanges of hydrocarbon lines. Whether there is any possibility of product contamination during tank line up/changeover.0 a) b) 48 .------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -----------------------------------------------------------------------------------------------------------------------------------------------b) Whether pipe supports. are available to all concerned and a copy available in the C/R. d) e) f) g) h) i) j) k) 4. Naphtha etc. Whether the redundant lines are kept positively isolated with all the ends plugged/blinded and actions are taken to get them removed ? OPERATING PROCEDURES : Whether a copy of updated operating manual with operating instructions. guides are in order ? c) Whether pipes carrying heavy products have been properly heat traced and insulated ? Whether proper color codings. blending etc. MS. products identification marks have been provided ? Whether low point drains and high point vents have been provided with proper caps ? Whether the tanks are having proper manifolds and are located outside the dyke ? Whether Hammer blinds are provided on the tank manifolds and are operable ? Whether the floor under the manifold are paved. particularly of LPG. anchors.

while the tanks are under operation. Whether any blending of DP product and NDP product is resorted to ? If so. Whether pre.monsoon checks are carried out. and recorded for rectification. piping etc. Whether it is ensured during initial filling a flow velocity of maximum 1 m/sec is maintained for products like SKO. floating roof valves. what are the procedures & safety precautions taken. ATF ? Whether use of nylon rope for sampling was observed ? d) e) f) g) h) i) j) 49 . Whether cross checking of auto level gauge is done through manual gauge. lines are segregated from other lines with positive isolation during blending operation ? Whether periodical checks are made for locating any leakage on tank. Whether the roof drain valves of floating roof tanks are normally kept open .------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------c) Whether the blending pumps.

breather valves.-------------------------------------------------------------------------------------------------------------------------------------------------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. flame arrestors ? Whether records are maintained in line with OISD STD-129. stairways are in good condition ? Whether the pipeline relief valves are kept relieving to tanks or to outside ? 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. What is the frequency of inspection of PV vents. relief valves.0 a) INSPECTION & MAINTENANCE : What are the schedules of inspection of tanks (floating / fixed) and whether records maintained in-line with OISD STD-129. Note 3 What are the schedules for painting of tanks ? e) f) g) h) i) j) 50 . b) c) d) Whether the pontoon covers are in place and are in good condition ? Whether foam/neoprene seals are checked regularly for perfect sealing and record maintained. Whether any provision exists for static electricity discharge ? What is the frequency of inspection of earthing connections and whether records maintained. Whether any documented procedure exists for tank cleaning ? What is the methodology to ensure strict adherence ? Whether the ladders.

51 .

what is the frequency of inspection & whether records maintained ? 6.-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------k) Whether Nitrogen blanketing system provided on any tank. & Organization Fire Fighting Layouts Electrical systems OISD-GDN-145-01 OISD-GDN-145-02 OISD-GDN-145-03 OISD-GDN-145-09 52 .0 ADDITIONAL CHECKLIST ITEMS : For detailed checklist on individual areas refer other OISD checklists as follows : General Admn. If so.

1.3 1.1.2 2.OISD-GDN-145-06 POL LOADING & UNLOADING A.1 2.1 1.0 1. TANK WAGONS CONTENTS -------------------------------------------------------------------------------------------------------------------------------------------------SECTION DESCRIPTION PAGE NO.SAFETY AUDIT CHECKLIST No.1 1.2 1.4 FACILITIES AND SYSTEMS Tank Wagon Gantry General Drainage Miscellaneous Electrical 40 40 40 40 40 40 2.3 OPERATING PROCEDURES AND PRACTICES Placement of rakes and loading Sick wagons House keeping 40 40 41 41 53 .1.0 2. -------------------------------------------------------------------------------------------------------------------------------------------------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. PLACEMENT OF RAKES AND LOADING Whether the type used are : -diesel -steam -electric of loco 54 . Whether proper facilities have been provided for handling sick wagons ? Whether the rail sleepers are of concrete / metallic construction ? WAGONS b.0 POL LOADING & UNLOADING-TANK A.4 Electrical a.0 OPERATING PROCEDURES AND PRACTICES 2.2 Drainage Whether concrete flooring has been provided below rail track and with proper slope ? 1.1 a. 1.1.0 FACILITIES AND SYSTEMS 1.1. TANK WAGONS -------------------------------------------------------------------------------------------------------------------------------------------------AUDITOR'S REMARKS -------------------------------------------------------------------------------------------------------------------------------------------------1. Whether the diesel shunter used is equipped with spark arrestors and proper cooling of engine exhaust ? 2.1.OISD-GDN-145-06 SAFETY AUDIT CHECKLIST 6.1 TANK WAGON GANTRY 1.1 General a. Whether the rail tracks are provided bonding strips and connected to maintained earthing system ? with well b.

e. Whether replacement check is carried out to ensure that platform . loading arms/hoses do not hit the incoming rake ? Whether the wagons are placed with master valve closed and bottom sluice valve and cover plate normally in opened position ? Whether checks are made for any left over materials.pre-fabricated fill pipes are available for use ? Whether the following are ensured after completion of loading : .-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------b. g.Top covers are properly closed and sealed Bottom sluice valves fully closed Bottom cover plates are boxed up with proper gaskets d. j. l m Whether any loose shunting is done ? Whether the shunting speed of 10 kmph (Max.fill pipes (if exists) are properly capped . f.) is maintained ? Whether necessary caution boards are displayed while loading / unloading in progress ? n 55 . h. k. in case of open type wagons. 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. previous product & fitness of wagons by operating staff on placement ? Whether the TXR staff check / inspect each wagon and issue a formal certificate prior to loading ? Whether wagons declared defective are shown on tally sheets and also marked on the wagons ? Whether Railways are informed in writing about wagons found defective during loading ? Whether the tightness of Master valve is checked by TXR staff during this initial filling and in case of leak declared as SICK WAGON ? Whether. i.

W.-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------2. 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.3 House keeping a Whether the gantry floor.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. ? c Whether Rly. railway tracks etc. tracks / sliding is free from unused T. fittings ? 56 .

SAFETY AUDIT CHECKLIST No.0 4. -------------------------------------------------------------------------------------------------------------------------------------------------1.0 FACILITIES & SYSTEMS 43 1. TANK TRUCKS CONTENTS -------------------------------------------------------------------------------------------------------------------------------------------------SECTION DESCRIPTION PAGE NO.0 Headers & loading hoses OPERATING PROCEDURES AND PRACTICES Placement of trucks Loading operations VEHICLE CREW AND CHECK ADDITIONAL CHECKLIST ITEMS 43 43 43 43 43 51 57 .0 2.1 2.1 2. OISD GDN-145-06 POL LOADING & UNLOADING B.2 3.

1 PLACEMENT OF TRUCK a Whether any system exists to regulate number of trucks coming at a time to loading area ? Whether any parking / place has been provided for the trucks near the loading area ? Whether the placement of trucks in the gantry is allowed only on production of filling advice ? Whether any safety checks are carried out on the trucks before issuing loading advice ? b c d 2.0 POL LOADING & UNLOADING .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.SAFETY AUDIT CHECKLIST 6.0 FACILITIES AND SYSTEM 1.0 OPERATING PROCEDURES AND PRACTICES 2. loading hoses are properly connected to earthing system before commencing loading ? Whether decantation of any over filled truck done to closed system (for DP) and with close supervision ? Whether the following are ensured after completion of loading : Fill pipes properly capped Top covers are properly closed and sealed b c - 58 .2 LOADING OPERATIONS a Whether it is ensured that the trucks. TANK TRUCKS -------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR'S REMARKS -------------------------------------------------------------------------------------------------------------------------------------------------1.TANK TRUCKS B.

emergency communication etc ? Whether the driver has a copy of standing instruction and TREM Card ? Whether the exhaust is wholly in front of tank truck and has ample clearance from Fuel oil system and combustible material ? b c d e f g h i j k l m n o 59 .-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------3. emergency procedures.0 VEHICLE AND CREW CHECK a Whether the vehicles design has been approved by CCE ? Whether license and explosives certificates are available in the vehicle ? Whether the vehicle is in good condition and the RTO has issued a fitness certificate? Whether the vehicle has non-sparking electrical fitting and external wiring through conduits ? Whether the vehicle has a cut off master switch for electrical system ? Whether there is facility to shut off the drain valves in case of emergency ? Whether the vehicle has two fire extinguishers ? Whether the gross and tare weight painted on the vehicle tally with the permit Whether the vehicle has First Aid Box. etc in the vehicles ? Whether the vehicle has atleast a driver and a cleaner as its crew member ? Whether the driver has a valid driving license ? Whether the crew is trained for hazardous nature of petroleum products. Tool Box and Emergency Lighting ? Whether there are any sources of ignition like candles.

in bold letters at least 7 cm high and on a back ground of sharp contrasting color. to cut off the battery in emergency ? Whether battery terminals have protective rubber covers ? Whether vehicle's cabin is checked for presence of any flammable/explosive substance being carried by the crew ? r s t u v w x y z aa) 60 . have been provided ? Whether all junction boxes are sealed properly ? Whether electrical equipments like generator switches. fuses and circuit breakers are located inside the cabin or engine compartment ? Whether battery is in easily accessible position with a heavy duty switch close by.-------------------------------------------------------------------------------------------------------------------------------------------------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. ? Whether vent openings are covered with two layers of wire-mesh of size not less than 11 mesh per centimeter ? Whether Tank Truck is conspicuously marked on each side and rear. Whether effective spark arrestors fitted on air intake system of the engine ? Whether electric wiring is of heavily insulated quality and adequate carry maximum loads ? Whether suitable over current protection in the form of fuses / automatic circuit breakers etc. cms. (The word "flammable " and name of product are required to be marked ) as per UN code.

2 2. COMMON CHECKLIST FOR LOADING AND UNLOADING OF TWs & TTs CONTENTS -------------------------------------------------------------------------------------------------------------------------------------------------SECTION DESCRIPTION PAGE NO.5 1.4 2.0 Pump house Structure & platforms Headers and loading arms Drainage Miscellaneous Electrical OPERATING PROCEDURES AND PRACTICES Inspection & maintenance Work Permit Systems House keeping Training Miscellaneous FIRE PROTECTION FACILITIES ADDITIONAL CHECKLIST 61 .0 4.4 1.0 2.OISD-GDN-145-06 REVISION I SAFETY AUDIT CHECKLIST OISD GDN-145-06 POL LOADING AND UNLOADING C.3 1. -------------------------------------------------------------------------------------------------------------------------------------------------1.0 FACILITIES & SYSTEMS 1.5 3.6 2.2 1.3 2.1 1.1 2.

have been blinded off? Whether P.2 a) b) 62 . gantry and control room during normal operation/emergency ? Whether all the drains are routed to OWS and the system has water seal to act as fire barrier ? Whether the idle loading headers. meters (if provided) have proper electrical fittings as per area classification ? STRUCTURE & PLATFORMS Whether easy access available to the platform from both sides of the gantry ? Whether escape ladders provided along the platforms are adequate ? b) c) d) e) f) g) h) i) j) 1. not in use for long time.0 FACILITIES AND SYSTEMS 1.SAFETY AUDIT CHECKLIST 6.D.0 POL LOADING AND UNLOADING C.1 PUMP HOUSE a) Whether the pumps are numbered/name of product handled written ? Whether white oil and black oil pumps are segregated ? In case of common service pumps whether these are properly grouped keeping product quality (flash point) in view ? Whether the hot pumps and the associated piping are heat traced and properly lagged ? Whether delivery to suction bypass line / recirculation line to storage tank has been provided ? Whether adequate ventilation exists (in case of covered pump house) ? What is the system of communication between pump house. COMMON CHECKLIST FOR LOADING AND UNLOADING OF TWs & TTs -------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR'S REMARKS ------------------------------------------------------------------------------------------------------------------------------------------------1.

3 a) b) c) d) e) f) g) h) i) 63 . rubber pads and other safety features to avoid frictional spark ? Whether handrails are provided on the platform ? HEADERS & LOADING ARMS Comment as to how the loading velocities are maintained within safe limits ? Whether shock eliminators are provided on each header ? Whether quick isolation valves/MOV provided for emergency shut off of loading headers ? Are they operable during emergencies ? Whether color coding has been provided for loading headers and individual loading points? Whether heavy oil headers are heat traced and properly insulated up to loading valve ? Whether product compatibility has been considered in case of common loading arm ? Whether any of the loading arms swivel joints/valves are leaking. 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 ? Whether the gantry shed is covered with asbestos sheet and has side protection ? Whether the ladders from platform to the top of the vehicles are provided with railings/security chain.-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------c) Whether the swing ladders are provided with counter weight. if so how many ? 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 ? e) f) g) 1.

quality and condition & meets BIS norms? Whether the idle loading headers/ loading arms not in use for long time are blinded off ? DRAINAGE Whether oily water drains from the area are connected to effluent treatment/disposal facility (OWS)? Whether a well designed system exists for draining and transfer of heavy oils like LSHS to avoid congealing of OWS system ? Whether the heavy oily drain collection system is steam traced ? Whether concrete flooring has been provided with slope towards drains to avoid spillage accumulation ? MISCELLANEOUS Whether road barriers have been provided in the gantry area to restrict entry of unauthorized persons/vehicles ? Whether smoking booths with CODE approval have been provided for the area at safe locations ? Whether the electric lighters. welding apparatus receptacles. lighting provisions.4 a) b) c) d) 1.5 a) b) c) 1. are as per hazard area classification ? Whether illumination in the gantry & pump house is adequate ? Whether ground level illumination is provided and found adequate ? in k) 1.6 a) b) c) 64 . etc. installed the smoking booths.-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------j) Whether the rubber hose are of proper diameter. are well maintained ? ELECTRICAL Whether all electrical fittings. length.

of earthing pits are adequate and they are inter connected ? Whether condition of FLP fittings are periodically checked and records maintained ? Whether the motors are provided with proper earthing. and earth test done every year and records maintained. Whether initial filling is done at a slow rate for safeguard against hazard off static charges ? Whether established communication system exists between gantry & pump house to control loading rates / pumping rate ? Whether the loading operation is done under the close supervision ? Whether operator's constant attention is there while the loading points have been opened ? Whether it is ensured that "no vehicle entry" in the gantry area is permitted during loading and unloading operations ? b) c) d) f) g) 65 . Is the catwalk antiskid ? Whether earthing bosses with flexible cable and robust clamping device have been provided adjacent to loading points ? f) g) h) i) j) k) 2. Whether structure is earthed as per std.0 OPERATING PROCEDURES AND PRACTICES a) Check and comment on earthing and bonding practices during loading / unloading.-------------------------------------------------------------------------------------------------------------------------------------------------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 ? How frequently are the tests of bonding / earthing carried out ? Any records maintained ? Whether the No.

3 a) c) 66 . ? Whether records are maintained ? Whether adequate inventories are maintained for prompt replacement of passing valves and damaged hoses ? Whether all modification jobs are undertaken only with approved engineering standards ? WORK PERMIT SYSTEM Whether as per OISD 105 (for Hot/Cold works and OISD 137 for Electrical Equipment being followed.2 a) b) c) 2. Whether display boards have been provided at strategic locations covering key safety instructions ? Whether Emergency and Disaster Control Plans for the area is available with written procedures ? 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 ? Whether the gantry floor are regularly washed to avoid oil accumulation ? Any visible oil accumulation in the area ? 2. arms/hoses. till the filling pipe is completely submerged and thereafter at the rate not exceeding 6 M/Sec ? INSPECTION & MAINTENANCE Whether any schedules exist for lubrication for loading valves/swivel joints and records are maintained ? Whether schedules exist for inspection the loading headers. etc.1 a) b) c) c) 2.-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------h) Whether initial loading is done at a rate not exceeding 1 M/Sec.

long range water/foam monitors are provided on both sides of gantry and are they safely located ? Whether all hydrants.0 a) b) c) d) e) f) g) h) i) 67 .4 a) TRAINING (REFER OISD 154 STD. PA system provided and are working ? Whether the communication system. monitors are easily accessible ? Whether proper approach roads exist for Fire Tenders and Fire Fighting Equipment ? Whether communication system like Fire Alarms.5 a) 3.) Whether subsequent refreshed training programs are also organized periodically ? Whether contract employees (if any) are given basic training on hazards of petroleum products and safe practices ? Whether the workers are using required personal protective wears ? MISCELLANEOUS Whether Operating Manuals/Standing Instructions are available at site ? FIRE PROTECTION FACILITIES Whether the fire water network Provided is well designed (Ring type) Whether isolation valves exist for isolation of each section maintenance Whether hydrants.-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------d) Whether the drain channels are cleaned & well maintained ? 2. sprinklers are periodically checked and records maintained ? Whether any mock drills are conducted for fire fighting ? Whether adequate number of portable extinguishers have been provided all along the gantry ? b) c) 2.

-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------j) Whether a copy of Fire Fighting manual is available in the gantry control room ? 4. organization Fire fighting Layouts Electrical Systems OISD-GDN-145-01 OISD-GDN-144-02 OISD-GDN-145-03 OISD-GDN-145-09 68 .0 a) ADDITIONAL CHECK LIST ITEMS For comprehensive check lists on individual areas also refer OISD check lists as indicated below: b) General admn.

SAFETY AUDIT CHECKLIST No.0 3.0 6.0 4.0 PUMPS/ COMPRESSORS AREA TANK WAGON GANTRY AREA TANK TRUCK GANTRY AREA TRAINING ADDITIONAL CHECKLIST ITEMS 55 56 58 59 59 69 .0 5. -------------------------------------------------------------------------------------------------------------------------------------------------1.OISD-145-07 LPG BULK LOADING & UNLOADING CONTENTS -------------------------------------------------------------------------------------------------------------------------------------------------SECTION DESCRIPTION PAGE NO.0 BULK STORAGE AREA 53 2.

Whether five year hydraulic test records are available ? Whether any signs of corrosion observed on pipelines? Whether paintings are done as per schedule ? Whether all bolts of proper sizes are put on the flanges or some are found missing or of smaller sizes Whether any portion of pipe length found buried with soil or undergrowth? b) c) d) e) f) g) i) 1. area classification drawings have been duly approved by CCE ? Whether any new facilities (permanent or temporary natural) have been installed Area they considered to be safe.SAFETY AUDIT CHECKLIST 7. what is the condition of insulation. Whether general house keeping in the area is satisfactory ? Whether storage vessels are insulated.1 GENERAL: a) Whether the layout.0 BULK STORAGE AREA: 1.2 RELIEF SYSTEM: a) b) Whether relief system is adequately designed ? Whether minimum two relief valves are provided in each vessel? Whether the relief valves are opened to flare / atmosphere? Any steam connection given? Is system opened to atmosphere? Whether the relief valves are provided with isolation valves?If so what is the system/ method to avoid inadvertent closing of isolation valves ? Whether the safety valves are periodically tested and records maintained ? c) d) e) 70 .0 LPG BULK LOADING & UNLOADING -------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR'S REMARKS -------------------------------------------------------------------------------------------------------------------------------------------------1. If so.

4 a) b) c) d) 1.3 DRAINING a) Whether water drain chamber has been provided away from shadow of sphere ? Whether the area under the sphere is having concrete pavement with proper slope ? Whether antifreeze valve provided on the drain line Whether double block valves have been provided on water draining line (quick shut off type near the chamber and the other a globe valve) ? Whether safety instructions for draining operations have been prominently displayed? Whether draining is done under constant supervision ? Whether sampling points are provided with duplicate valves? INSTRUMENTATION: Whether level gauge of two types have been provided for direct level measurement and counter checking? Whether monitoring of levels of all the vessels are done ? Whether High Level alarms have been provided in storage vessels and are in working conditions ? Whether remote operated valves (ROVs) have been provided on liquid outlets/inlets and are checked for proper operations ? FIRE AND SAFETY: Whether gas detection system is provided in the area and is working satisfactorily? Whether capacity of fire water pumps and header are adequately designed? Whether sprinkler/Deluge system are provided on all the vessels and are periodically tested for satisfactory operation ? Whether the sprinkler/Deluge Valve are remote operated and are located 15M away from storage vessels? Whether the supports of the vessels are fire b) c) d) e) f) g) 1.-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------1.5 a) b) c) d) e) 71 .

-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------proofed? f) Whether periodical checks are done with explosive meters to detect any gas leaks? ELECTRICAL: Whether bonding strips have been used across the flanges for electrical continuity ? Whether all the electrical fittings in the area meet area classification requirement? Whether earthing connections are provided and are properly maintained? Whether illumination in the area is adequate? PUMPS/COMPRESSORS AREA: FACILITIES: Whether the layout of the area meets statutory requirements in terms of safety distance from storage vessels, roads and other facilities? Whether the pumps have double mechanical seals to minimize leakage? Are the seals in good condition? Whether recirculation line to storage vessels have been provided? Whether the venting is done through high rise vents? Whether steam connections are provided for atmospheric vents ? Whether the drains/vents/sample points have double isolation valves and are provided with caps? Whether Gas Detection system has been provided in the area and working satisfactorily? ELECTRICAL: 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? Whether the motors are provided with proper earthing? Whether illumination is adequate in the area ?

1.6 a)

b)

c)

d) 2.0 2.1 a)

b)

c)

d)

e)

f)

2.2 a)

b)

c)

72

-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------2.3 GENERAL: a) Whether all the equipments in the area are properly painted? Whether an established communication system exists between the loading area and the pump area during normal operation/emergency? Whether safety instructions have been displayed? (e.g. `NO SMOKING', `MEN AT WORK' etc.) Whether all maintenance tools used in the area are non sparking type? FIRE PROTECTION: Whether long range monitors/sprinkler system have been installed to cover the area and are in good working condition? Whether adequate nos. of fire extinguishers have been provided? TANK WAGON GANTRY AREAS: FACILITIES: Whether the layout of the gantry meets statutory requirements? 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. Whether loading arm swivel joint gas seals are periodically greased and maintained properly? Whether high vent flame arrestors are cleaned periodically? Whether facilities have been provided to handle leaky wagons in situ (Evacuation of T/Wagons)? Whether emergency stop push button for loading pumps exists in the gantry? LOADING HEADERS AND ARMS: 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)

c)

d)

2.4 a)

b)

3.0 3.1 a)

b)

c)

d)

e)

f)

3.2 a) b)

73

-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------c) Whether loading velocities are maintained within safe limits by providing restriction orifice on each loading point ? Whether loading headers are provided with proper earthing/bonding connections? Whether loading hoses not in use are stored properly and open end is kept blinded? Whether loading hoses are having any sign of kinks/wears etc.? Whether the following facilities are available on each loading point ? Excess flow check valve on the filling line h) vapor return line with check valve back to storage vessel flexible hoses on filling vapor return line Whether depressurising system has been provided on the gantry header discharging to high vents/flare? Whether temperature and pressure gauges have been provided at convenient points ? Whether the loading header is provided with ISV relieving to high point vent ? Whether proper capacity weigh bridge has been provided on each spur of the gantry Any risk of gas accumulation observed in the pit ? Whether bonding strips as provided for continuity of rail tracks ? Whether bonding connectors (copper strips/wires are provided for piping ?) FIRE PROTECTION AND SAFETY : Whether water sprinkler system has been provided and working satisfactorily ? Whether adequate nos. fire hydrants, long range water monitors have been provided ? Whether gas detector system have been provided with alarm in the control room ?

d)

e)

f)

g)

i)

j)

k)

l)

m)

3.3 a)

b)

c)

74

-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------3. refer to OISD-STD-144? TANK TRUCK GANTRY AREAS FACILITIES Whether the truck loading facilities have been installed as per CCE approved drawings? Whether separate entry/exit gates exist for the tank trucks? Whether weigh bridge is available within the Installation and is calibrated periodically and maintained? Whether the no.All engines nearby are switched off . any corrosion on tanker. "O" rings.All wagons are secured by hand brake e) Whether it is ensured that non sparking tools are used for connecting/disconnecting the hoses? Whether used of any synthetic fiber material was observed? Whether loading hoses are periodically hydraulic tested. before commencement of loading operation? Whether the following are ensured before loading ? .All hot jobs in the area are stopped . thermometer etc. safety valve. physical damage.0 4.4 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 ? Whether the TXR staff check and issue fitness certificates in writing for fitness of tank wagons ? Whether checks are done for gaskets.1 a) b) c) d) 75 .Proper earthing connection are made . of trucks parked at the gantry area is restricted? b) c) d) f) g) h) i) j) 4. discarded/replaced and records maintained? Whether all hoses carry test code & date? Whether constant supervision is ensured during loading/unloading operation? For detailed checklist for loading T/W pl.

fire hydrants.safety instruction booklet g) Elimination of ignition sources like loose wires.Valid licenses . . long range water monitors have been provided? Whether gas detector system has been provided with alarm in the control room? Whether provision to start water sprinklers from loading gantry/Control Room / Weigh Bridge exists? Whether water sprinkler system adequately covers T/T bullet ? Provision to stop pump from loading gantry / WB Cabin ? 4. Whether gas detection system has been provided in the area & working satisfactory OPERATION Whether the vehicle engine is always shut off during loading operations? Whether it is ensured that earthing connection is properly checked before connecting hoses to tank truck? Whether blank flanges are fitted on the truck inlet flange and to the end of hoses when not in use? Whether loading arm open and is blinded when not in use? FIRE PROTECTION AND SAFETY Whether water sprinkler system has been provided and working satisfactorily? Whether adequate nos.2 a) b) c) g) 4.fittings as per CCE such as flame arrestor.-------------------------------------------------------------------------------------------------------------------------------------------------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? . fire screen etc.3 a) b) c) d) e) f) 76 . uncovered battery terminals etc.

t. oxygen content etc.to OISD-STD-144.r. are always done by plant operators rather than tank truck crew ? Whether operating procedures have been displayed in vicinity of the tank loading bays ? Whether protective gloves are being used by the operating crew ? Whether the vehicle crew has been trained on hazardous nature of LPG and to handle emergency situation ? ADDITIONAL CHECKLIST ITEMS For detailed checklist on specific areas refer other OISD check lists as follows : General (Organization Admn.) For detailed checklist for loading TT pl .0 a) TRAINING Whether pocket size instruction booklets/manuals in widely understood languages. Training etc ) Fire fighting Layouts Gantry Operations Electrical BULK TT CHECKING : How it is made sure that only TT fit for loading are taken up for filling?(w.0 OISD-GDN-145-01 OISD-GDN-145-02 OISD-GDN-145-03 OISD-GDN-145-06 OISD-GDN-145-09 77 . b) c) d) e) 6.-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------5.ref. have been issued to all concerned employees ? How it is ensured that loading operations such as hose connection etc.

-------------------------------------------------------------------------------------------------------------------------------------------------1.SAFETY AUDIT CHECKLIST No.0 GENERAL ORGANISATION AND ADMINISTRATION 61 2.0 4.0 8.0 5.0 MANPOWER AND TRAINING CYLINDER STORAGE AREA BOTTLING SHED NEW AND DEFECTIVE CYCLINDERS CYLINDER LOADING SAFETY AND FIRE PROTECTION ADDITIONAL CHECKLIST ITEMS SUGGESTED INSPECTIONS MAINTENANCE CHECKS 61 62 63 64 65 66 67 67 78 .0 6.0 7.0 9.OISD GDN-145-08 LPG BOTTLING AND DISPATCH CONTENTS -------------------------------------------------------------------------------------------------------------------------------------------------SECTION DESCRIPTION PAGE NO.0 3.

Whether adequate no. contractor. smoking booths etc. personnel and visitors ensured? Whether work permit/clearance (for hot & cold jobs) procedures followed as per approval? Whether following manual/documents are available and updated. Whether plant approach/access roads are well maintained & at least one emergency exit is provided. . Whether frisking of employees.Storage of LPG . . offices. of escape routes/staircases available around each of the facilities viz. k) l) 79 .. filling shed. LPG Operations Manual S&EP Manual Emergency/Disaster Control Plan Operation/Inspection/Repair Manual of epuipment supplied by vendor. check & change rooms.Storage of LPG cylinders .OISD Standards. are meeting safety requirement.SAFETY AUDIT CHECKLIST LPG BOTTLING AND DISPATCH -------------------------------------------------------------------------------------------------------------------------------------------------AUDITOR'S REMARKS -------------------------------------------------------------------------------------------------------------------------------------------------1. maintenance offices. b) c) d) e) f) g) h) i) j) 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.0 GENERAL ORGANISATION AND ADMINISTRATION a) Check for valid licenses of CCE pertaining to the locations. cylinder storage area? Whether fencing/boundary wall around the Plant is in proper condition? Whether truck parking area has been provided as per OISD-STD-144.Filling of LPG cylinders Whether inter distances from/to admn.

(English/Hindi/local language)? Whether important Do's and Dont's displayed prominently in operating areas? CYLINDER STORAGE AREA Whether Transfer of cylinders from/to truck is done through .Telescopic Conveyer/ Trolleys /Conveyers? Any dropping. rolling. mishandling noticed? Whether Inspection/visual checks are done to detect leaky/defective cylinders to segregate spurious leaky/defective cylinder? Whether storage is segregated and marked for? .-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------2. Does he possess fire/safety engineering qualifications and his duty list drawn clearly? Whether Training Programs are organized periodically in LPG Operations fire fighting/emergency handling etc.Other defective cylinders Whether cylinders stacked in vertical position in tiers as per the norms? b) c) d) e) f) 3. Whether operating manuals and standing instructions are provided to working personnel? Whether safety booklets distributed to all including contractor employees. Disaster Control/ Emergency handling? Whether Safety Officer is available and duly designated as safety officer.Contractor Workmen .Security Staff.0 MANPOWER & PLANNING a) Whether supervisory/managerial cadre staff fully trained in all aspects of LPG Plant operations.5 year testing due cylinders .Regular Staff .Spurious cylinders .Tank Truck Operators/drivers . for: .0 a) b) c) d) 80 .

d. Evacuation units.-------------------------------------------------------------------------------------------------------------------------------------------------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. filed and gas free cylinders? Whether the daily stocks of cylinders (empty/filled/defective) are displayed? BOTTLING SHED Whether cylinder washing facility provided? Whether filling/loading/unloading/storage areas are adequately covered with mastic coating on floors and pillars to avoid accidental sparks? Check for condition of mastic flooring. Unit filling Machines. Whether tare weight of the body is marked distinctly on the body of the cylinder? Whether empty cylinders are checked for 'o' ring presence? Whether filling is done based on gross weight? Whether AUTO CUT OFF facility exists on filling machines? Whether filling head gun hoses are of approved quality and periodically tested? Whether proper earthing provided to? a.0 a) b) c) d) e) f) g) h) i) j) Check for accumulation of vapors in 81 . Conveyers b. f) g) i) j) 4. Carousel units (bonding of filling guns). c. Whether cylinders stacking areas are periodically inspected for leakage with explosimeter or probable leak detector? Whether cylinder offload bay platform provided with proper buffers? Whether stacks of cylinder are identified by markers to show empties.

-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------recess/pits in the area with the explosimeter k) Whether vapor extraction system with suction points at carousel. valve change shed is provided and in working condition? .To check defective cylinders . Kg. Whether persons working on carousel wear hand gloves & safety shoes? Whether Statistical Quality Control checks (SQC) carried out & records maintained? (See foot notes) m) n) o) p) q) r) s) t) u) v) w) x) 82 . evacuation unit.To check weight correction. Whether bung leak/body leak checks are done through in-line water bath for both 14.To check for conveyors .Whether carousel unit is interlocked with vapor extraction system? l) Whether accuracy of check scales being checked daily and records maintained? Whether filling machine check scales are calibrated periodically and records maintained? Whether facilities are provided for 100% cross checking of weight of filled cylinders? Are they in use? Whether check weigh scales are calibrated periodically? Whether CVT checks done after filling for`O' ring and valve defects? Check for facilities: . and 19 Kg.Al foil/PVC seal? Check for neck labels plastic/paper.2. cylinders? Whether capping/sealing facilities are provided .Whether standby blower is available? . Whether tagging of overfilled/underfilled cylinders done? Check for leakage from carousel filling guns.To check 'O' Ring .

are they at appropriate location? Whether wire mesh provided on cold flare line? Whether degassing facility provided in cold repair shed? Is it 15 M away? Whether cylinder repairs/valve change etc are supervised? Whether stock of leaky cylinders is below the stipulated limits? Whether Torque wrenches with proper settings are used for valve removal replacement (20 +/.)? b) c) d) e) f) g) h) i) 83 .Weight variation (Over filling) . of cyls.Bung leak ."O" Ring missing .Cyls. found defective.'Pressure Control valve' Filling procedure . Mt. of cylinders checked at random.Remarks if any. . .Total No. found defective.Valve leak . 5.No.2 meter above the roof edge? Whether Cold Repair facilities are available? If so.% of cyls.2 kg.-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------y) Whether Movement of cylinders is done through floor conveyers/trolleys? statistical checks include .Total No.Defective "O" Ring (by CVT Test) .Weight variation (under filling) . of cylinders filled. . in last month .Other minor defects . due for retesting .0 a) NEW/DEFECTIVE/LEAKY CYLINDERS Whether Purging facilities are available for new/retested cylinders? Whether Facilities provided for evacuation of leaky/partially filled cylinder are working satisfactorily? Whether venting/cold flaring of LPG is done at safe height .

0 a) 84 .-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------j) Whether PTFE tape/paste used while fixing valves? Whether cylinders are checked for denting are declared defective? Whether records of defective cylinders maintained supplierwise? Whether records of leaky /defective cylinders (company wise) detected during filling/are maintained on daily basis with following particulars: n) Cylinders filled Valve leak Bung leak Body leak "O" ring defect Spurious cylinders k) l) m) Whether record of defective cylinders returned by distributors is maintained on daily basis? Whether spurious cylinders and cylinders declared as scrapes are destroyed by crushing properly and records maintained? CYLINDERS LOADING INTO TRUCK 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? Whether cylinders are loaded into trucks through conveyers? Whether cylinders stacked without protrusions? vertically o) 6.0 a) b) c) d) Whether explosimeter checks are done before releasing the truck? Whether Loading/unloading of cylinders is done in safe manner? SAFETY & FIRE PROTECTION Whether Contingency Plans are available and updated for tackling major emergencies? e) 7.

/ Hospitals / other offices etc. Also whether in critical areas like carousel evacuation unit. are provided and periodically inspected and records maintained? Whether MV Spray Sprinkler System having remote / local operated deluge valves provided in the storage shed and in working condition. Whether gas monitoring system having sensors to monitor gas leak near carousel. of hydrants. Meters area.-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------b) Whether fire organisation chart is prepared upto date and displayed? c) Whether important telephone nos. risers/monitors -yellow.Blue) Whether hydrants/monitors are provided at a minimum distance of 15 meters from the sheds and provided for every 30 meters distance? Whether adequate No. automatic detection of heat / flame for automatic operation of sprinkler system provided? 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. 100/70 Kg. DCP FE per 200 Sq. long range monitors etc. . of state Fire Services/Police/Dist. DCP Mobile unit per shed. meters)? Whether portable DCP Fire Extinguishers are provided at appropriate location? -2 Nos. are displayed? Whether Fire/Emergency mock drills conducted periodically? Whether Fire Water Network provided around the facilities is as per prescribed norms and adequate? Whether Pressure and flow are adequate at farthest end? Is system painted as per standard norms (Hydrant pipelines . valve d) e) f) g) h) i) j) k) l) m) 85 .1 No. valve change shed.Red. Admn. & sprinkler system. evacuation unit. 10 Kg.

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? Whether 'No smoking' and other cautions sign in Hindi/English/local language displayed at prominent places? Whether Emergency lighting system provided in strategic locations and is working satisfactorily? Whether Flame proof torches available? o) p) q) 8.0 ADDITIONAL CHECK LIST ITEMS For detailed checklist on specific areas refer other OISD check lists as follows: General (Organisation Admn. Training etc) Fire Fighting Layouts Gantry Operations Electrical OISD-GDN-145-01 OISD-GDN-145-02 OISD-GDN-145-03 OISD-GDN-145-06 OISD-GDN-145-09 86 .-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------change shed provided? if so: .

CVT etc. filling guns. ejction device. Calibrations/Adjustments of devices indicated in above. introduction/ejection devices. Checking the sensitivity of check scales Conducting test run/test filling to see the performance of filling-gun. Air Service Units. Oil topping in dampers of in-line check scales and calibration with standard weights. Water draining from filters of check scales & filling gun. Zero checking of Introduction Device/Ejection Device.Carousel Driving unit. WEEKLY MAINTENANCE Oil topping in Air service unit/cleaning of Air Filters. air service units. Air leak control from check scale.2. CVT etc. CVT etc. Checking/control of oil level in check scale & filling gun. a) b) c) d) e) 87 . Greasing/lubrication of : . check scales.----------------------------------------------------------------------------------------------------------------------ITEMS AUDITORS REMARKS ------------------------------------------------------------------------------------------------------------------------------------------- SUGGESTED INSPECTION & MAINTENANCE CHECKS 9. b) c) d) e) f) g) h) 9.1 a) DAILY MAINTENANCE Cleaning the cover plate of introduction device.Central column . Cleaning of the bearings and suspensions of Filling machines Greasing & leakage control of Introduction system & Ejection System.

Inspection of ejection system for wear & tear. check scales.4 a) b) c) d) e) 88 .-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------9. Calibration of filling machines with standard weights.3 QUARTERLY MAINTENANCE a) Earthing strip tightness of equipment like in-line control Check Scale & Filling Machine. central column & driving units. Inspection of Gun hanger. Inspection of wear & tear for knife edges & bearing. b) c) d) e) f) 9. if necessary. Inspection of rails of conveyer system for setting &tightening of fish plate. ropes & pulley inspections. Inspection of power cylinder of introduction system & cleaning. Checking the filling hoses for stiffness and replacement. ANNUAL MAINTENANCE Overhauling of machines & replacement of defective parts of filling machines. Inspection & adjustment for proper functioning of Differential Pressure valve. Checking the level of Introduction system & Ejection system. introduction/ejection system.

0 CABLE NETWORK TERMINATIONS & JOINTS 5. OISD GDN-145-09 ELECTRICAL SYSTEM CONTENTS -------------------------------------------------------------------------------------------------------------------------------------------------SECTION DESCRIPTION PAGE NO.0 MOTORS CONTROL STATIONS 6.0 BATTERY CHARGER/ UPS 10.SAFETY AUDIT CHECKLIST NO.0 SWITCHYARD AND OUTDOOR EQUIPMENT 4.0 PORTABLE APPARATUS/ MOBILE EQUIPMENT (ELECTRICAL /BATTERY OPERATED) 71 73 73 74 75 75 77 78 78 78 89 .0 ELECTRICAL HEAT TRACING 11.0 EARTHING & BONDING 8.0 CAPTIVE GENERATION 9.0 LIGHTING INSTALLATIONS 7.0 SUBSTATION (EQUIPMENT & BUILDING) 3. -----------------------------------------------------------------------------------------------------------------------------------------------1.0 SPECIAL REQUIREMENTS 70 2.

) and the electrical equipment was accordingly replaced to conform to revised classification? Whether the suggested remedial measures given in the Accident Investigation Reports.SAFETY AUDIT CHECKLIST ELECTRICAL SYSTEM -------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR'S REMARKS -------------------------------------------------------------------------------------------------------------------------------------------------1. Rule No. as per approved schedule (Review the inspection records)? b) c) d) e) f) g) h) i) j) 90 .E.E.0 SPECIAL REQUIREMENTS a) Whether main single line diagrams of Electrical Power Distribution "updated" and "As-built"? Whether the Installations are duly approved by the Chief Electrical Inspectorate to Govt.) As per I. if any. have been implemented? (Review the Accident Report of the last 5 years)? Whether the list of electrical "authorized persons" is being maintained (I. 3) and displayed? Whether inspection of electrical equipment is carried out. for energisation? (DGMS for Oil Field Installations) Is there any unauthorized installation in operation including temporary construction power installations? Whether action taken on IE inspector visit report? 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. 45)? Are the electrical equipment installed conforming to the Area Classification (IS:5572) approved by CCE? Whether there has been revision in the hazardous area classification from the original (due to modifications/expansions etc. Rule No.

carried out? Whether CO2 fire electric fires? extinguishers provided for m) n) o) p) q) r) s) t) 2.oil drums.E. Relays. Inspection and Maintenance? Are the minimum clearances around the equipment maintained as per I.-------------------------------------------------------------------------------------------------------------------------------------------------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) Whether the substations / power plant rooms/control room /MCC rooms etc. are vermin proof? Whether preventive Maintenance Schedules as per OISD-STD-137 etc. are used as storage area for scraps. clothes. Transformers & Busducts etc. Rule 51? Are all the substation equipment provided with double earthing connections? b) c) 91 .) and junction / terminal boxes etc. spares and such other foreign materials Are the flameproof features maintained intact for flameproof equipment? (Any damages or missing bolts /nut in the junction boxes/panel covers /terminal boxes etc. Motors. convert the equipment to non-flameproof) Whether flameproof telephones are used in the classified hazardous areas? Whether the Transformer & Switchyards are free of vegetation/dry grass? Whether all the electrical equipment( switchboards.0 a) Whether sand-buckets provided? SUBSTATION (EQUIPMENT & BUILDINGS) Is the substation equipment freely accessible for Operation.

Blue and Black)? Whether the conduits used for cable entry are sealed and earthed? Are the energized electrical equipment provided with caution notices? Is the substation building made water tight and all the openings in walls ( such as cable trench entry/ bus duct entry) sealed? Whether any water stagnation is there inside the cable trenches? e) f) g) h) i) j) k) l) m) n) o) p) q) 92 . Yellow.-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------d) Are the live parts of equipment made inaccessible from inadvertent contacts? (by barriers/shrouds)? Whether the rubber glove and mats with voltage test seals are provided in front of the switchboards and are in good condition? Whether the switchboards are dust / verminproof? Is pest control treatment given for substations? Are any unused cable entries left open? Have the protective relays been set at the recommended values (as per the design)? Whether the fuses used are of HRC Type and of ratings specified in the single line diagrams ? Whether each outgoing distinct circuit from the switchboard is separately controlled by a suitable linked switch fuse or circuit breaker of required capacity? Whether circuit identification marks/ tags are provided or not? Are the relays and meters tested for proper functioning/calibration as per approved schedule? Whether the bus bars are provided with distinct color identification ( Red.

are these provided with flameproof equipment)? Whether all panel doors are kept closed? Whether all the indicating lamps in the Panel are in operating condition (i. not fused)? Are the oil immersed starters filled with oil to the required level and of required dielectric strength? Whether shock restoration chart & First Aid Box provided? t) u) v) w) x) y) z) aa) bb) cc) dd) ee) ff) 93 .free of tripping hazards? Whether the switchgear rooms located in the hazardous area are pressurized? (if not.T) and control cables in trenches properly segregated? s) Are the cables near the terminations clamped? Is there any combustible material used for construction of substation building? Whether the cable trenches are provided with concrete slabs / chequered plates? Are the earth electrodes periodically tested and maintained properly? Are the earth resistance of the grid measured. checked and recorded periodically? Is the substation provided with Emergency Lighting? Is the substation provided with telephone? Is the trench sump pump ( for dewatering ) in working condition ( wherever provided ) ? Are floors kept clean.-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------r) Are all the power (H.e.T. & L.

-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------3.H.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 .E. a) Are the following components individually earthed with two separate earthleads ( No.B.Operating handle of the A. shielding for lightning protection and whether it is properly maintained? Whether there is locking arrangement for the Transformer bay to prevent entry to the yard by unauthorized persons? If so. is it being followed? Whether the doors of the gate are rusted and need to be painted? c) the d) e) f) g) h) 4. conductors are maintained as per I.switch. switch b) Whether the vertical and horizontal clearances from O. for the protection of transformer/circuit breaker? Whether a separate earth electrode of proper size is provided properly for the lightning arrestors? Is there O.0 SWITCHYARD AND OUTDOOR EQUIPMENT.H.B.B. 8 SWG copper or equivalent)? Metal Frameworks A. Rule (79)? Are the earth electrodes provided in sufficient number? Whether earth pits are properly maintained and tests carried out as per schedule? Whether the lightning arrestors are connected after the A. Switches and circuit breakers D/O and H/G Fuses Poles/switches/insulator pins/stay clamps .

-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------b) Whether the underground cables in excavated trenches are laid at designed depth with sand filling. what is the arrangement? Whether one run of earthing strip fixed through the entire length of cable Tray (wherever cable tray is used) ? d) e) f) g) h) i) j) k) l) 95 . 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) Whether all the cables throughout their route protected mechanically from any external damages? Are the flameproof type terminations for cables carried out in the classified (Zone 1) areas? Are the cable joints staggered and having identification marks (when 2 or more cables laid in the same trench)? Is the oil seepage from process units getting drained through or collected in the cable trench/manholes? Whether the armour of cables exposed at the termination? Are the cables directly taken to the terminals without suitable cable glands/clamps/armour earthing? Are the cables above ground supported with proper clamps? Whether the cables : (telephone/ power / lighting cables) are taken through overhead system? (inside Refinery / Process / Areas)? If so.

I. and conduits earthed? Are all conduit ends for cables sealed at both ends? MOTORS CONTROL STATIONS 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? Is the approved inspection schedule followed ? Records maintained? Whether Terminal / junction Box properly sealed / covered? Is there any unauthorized modification carried out ( by way of local fabrication etc. pipes (conduits) used for cable entries (sleeves) sealed at both ends.-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------m) Whether proper mechanical protection and water sealing arrangement provided to cables especially at the following locations: n) 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 What are the fire protection arrangements adopted for cables laid above ground? Are the G.) on the flameproof motors/control stations / terminal boxes? ( to accommodate XLPE cable termination etc.) 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) Whether Emergency Isolating device for the motor is installed near the motor? o) p) 5.0 a) b) c) d) e) f) 96 .

through subdistribution/ fuse distribution & lighting panel final circuit boards? Whether lighting provided is sufficient? ( compare with IES chart for required levels of illumination at selected locations)? Is there auto changeover system provided for normal to emergency system and if so. Whether painting of motor body control station and supporting structure are in good condition? Whether there are motor guards provided to prevent inadvertent contact over the moving shaft? Are the nameplates of Motors worn out? Whether the inscriptions are visible? Whether the drive belts are antistatic fire resistant type? LIGHTING INSTALLATIONS Whether separate distribution for lighting system adopted from main switchboard. is it functioning satisfactorily? (test this) Whether the body of lighting fixtures are separately earthed in addition to cable armor earthing? EARTHING & BONDING Is the earthing carried out as per IS:3043? Is the earth leakage protection wherever provided functioning satisfactorily? h) i) j) k) l) 6. a) b) 97 .0 a) b) c) d) 7.-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------g) Whether the double earthing provided are from two separate distinct earth connections of the grid? Are the motors (75KW) provided with spaceheater and local ammeters.

earthed? Are the hardware used free from rust or corrosion? Are the Rail Tracks within the gantry premises earthed and bonded? Are the earthing connections to lighting protection and electrical system protection ( Neutral earthing and body earthing) provided separately? Whether there is any discontinuity of earthing connections? Whether the flexible wire used for tanker body earthing ( TTL Gantry ) is soldered to crocodile clips? Whether crocodile clips have lost the spring action causing improper grip with the surface? Whether earth jumpers across the pipe flanges (of gantry piping) are provided? Is the buried underground earth conductors getting exposed at any location? d) e) f) g) h) I) j) k) l) m) n) o) p) 98 . vessels. metallic structures / sheds and buildings and fencing etc. process piping.-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------c) Are the earth electrodes being tested periodically? (Check the test records) What is the grid resistance (in ohms)? Is this periodically measured and recorded? Whether all 3 phase equipments double earthed and single phase equipment single earthed? Are all the loading arms earthed? Is there earth continuity between the flexible hoses and loading arms ? Are the tanks. steel columns.

-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------q) Whether the earth pits with chambers are exposed and visible or is embedded inside the loose earth? Whether the earth strip connections on the earth electrode are loose / sheared off / tight? Are the weigh bridge (truck) platforms earthed? Whether the earth strip joints are having an overlapping equivalent to the width of the strip (minimum) and all the four sides are welded? 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? Whether the earth strip runs continuously through conveyers and are the supporting structures also earthed? Whether all electronic equipments which stores electrical energy are properly earthed? CAPTIVE GENERATION Is the neutral of the generator provided with an isolator? 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? 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? Whether the exposed wires near the Generator/Generator to switch board is in metallic conduit and the conduit earthed? r) s) t) u) v) w) 8.0 a) b) c) d) 99 .

-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------e) Whether the control panel for the generator is earthed with two separate and distinct connections with earth? Whether the generator panels are made vermin proof? Whether more than one generator is provided. BATTERY / CHARGER/UPS What is the type of battery used? Whether the Battery room is clean and well ventilated? Are the floors acid proof? Whether exhaust fans provided ? f) g) h) i) j) k) l) m) n) 9. and earthfault)? If synchronized with grid.0 a) b) c) 100 . whether provision of individual breakers are kept for paralleling arrangement? Whether danger notice is provided for the generator enclosure? Whether location (where generator is installed ) is dry and dust free and nearer to the loads? Whether provided with fire and weather proof enclosure with ventilation? Whether the exhaust provision provided is away from the enclosure? Whether control panel is available near to the generator. LSHS are used additional safety precautions should be taken. overcurrent. whether effective measures are available to prevent backfeeding? For Prime Mover where fuels like Naphtha. equipped with all protections ( short circuit.

0 a) b) c) d) 101 .-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------d) Are the cell voltage. and level of the electrolyte being checked and recorded as per approved schedules? Is there any corrosion on terminals / connectors? Whether all the safety equipment (Rubber apron. Are there damages to insulation / traces? Is the system water tight? e) f) g) h) 10.) are available? Is the operation of UPS satisfactory? (Test for critical services) Whether trickle charger working and checked properly. acid proof hand gloves etc. goggles. 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. specific gravity of cell. ELECTRIC HEAT TRACING Whether all indication lamps are functioning properly in the panel to ensure healthiness of tracer circuits.

-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------11. generators. and test instruments and tools inspected regularly? a) b) c) d) e) f) g) h) 102 . provided with 'armoring' and `gland' type terminations? Is the armoring bonded to earth? Are the portable tools/equipment being checked every time before use that there is no earth leakage? Is it ensured safe to use. switchboards etc.)? 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? Are the power cables used for portable equipment such as welding machines. (used for inspection / testing) especially in classified areas? 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. including the electrical system in the mobile equipment / vehicles (Battery Operated). by a "competent" person before issuing.0 PORTABLE APPARATUS/MOBILE EQUIPMENT (ELECTRICAL BATTERY OPERATED) 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) Are safe voltage (24 volts) being maintained for use of portable appliances such as hand lamps. torches.. Whether ELCB provided for portable equipment? Are the portable equipment. etc.

verify the accident investigation reports and compliance of recommendations) Whether connecting a welding machine the return path of the welding machine is directly connected to the work piece with proper insulation? n) o) p) 103 . of Portable tools/Mobile equipment (Electrically operated) in the last 2 years? (if so. so constructed and enclosed as to protect from mechanical damages? Whether any uninsulated current carrying part is exposed especially on the outer surface of the truck? Whether all the components are accessible for maintenance/repairs? Whether the battery has the protection means of a non combustible enclosure? by j) k) l) m) Are the Battery terminals provided with protective rubber gloves? Whether the battery enclosure is provided with sufficient ventilation to minimize the possibility of accumulation of explosive hydrogen air mixtures above the battery? Are there reported accidents due to improper maintenance / the wrong use/wrong selection etc.-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK --------------------------------------------------------------------------------------------------------------------------------------------i) Whether all wiring and current carrying parts of an industrial electric truck.

SAFETY AUDIT CHECKLIST 10.0 CROSS-COUNTRY PIPELINE CONTENTS -------------------------------------------------------------------------------------------------------------------------------------------------SECTION DESCRIPTION PAGE NO. -------------------------------------------------------------------------------------------------------------------------------------------------1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) 13) 14) 15) 16) COATING CONDITION CATHODIC PROTECTION POWER SUPPLY TO CP STATION ULTRASONIC THICKNESS SURVEY INTERNAL CORROSION PIGGING INHIBITOR INJECTION CPL/EWP SURVEY SOIL TESTING MAINLINE VALVE HYDROSTATIC TESTING PIPELINE PATROLLING TELECOMMUNICATION & TELEMETRY SINGLE BUOY MOORING SYSTEM CONTINGENCY PLANS DOCUMENTATION 81 81 82 82 82 82 83 83 84 84 84 84 84 86 87 87 104 .

Yes/No Yes/No . any action plan drawn for correcting the deficiencies on short term and long term basis? 2.) 2.3 Coating Condition (Survey report to be checked 1...5 Is schedule made for inspection of insulation joints/couplings (yearly) 2....Nos.. of test lead points for PSP Survey 2.4 Dielectric strength of Insulation Joints 2.11 (a) Effectiveness of C. Nos.8 Is schedule made for PSP survey (PSP readings at feeding points) (PSP readings at Test lead points quarterly) 2..SAFETY AUDIT CHECKLIST ELECTRICAL SYSTEM -------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR'S REMARKS -------------------------------------------------------------------------------------------------------------------------------------------------1.0 CATHODIC PROTECTION: (No. of C.9 If 'yes' the findings 2...P.2 Periodic calibration of AC & DC volt meter/Ammeter and PSP Meter of CP Units 2....1 Is rolling plan for pearson.4 Type of coating and its application method 2. Stations ..7 Condition of test led points 2.3 Number of insulating joints 2. Yes/No Satisfactory / Not Satisfactory Not Satisfactory Yes/No 105 . Satisfactory/ Not satisfactory Yes/No .P.2 If 'yes' is the schedule maintained 1. coating conductance and current drainage surveys made? 1..0 COATING CONDITIONS: 1. (To check PSP profile graphs in conjunction with CP station reports) (b) Is any stretch of pipeline left cathodically unprotected for a period more than one year Good/Bad Yes/No Satisfactory/ Not Satisfactory Yes/No Yes/No Satisfactory / not Satisfactory ..1 After revisioning of coating whether PSP readings are recorded and monitored to observe improvements 2..Nos.6 No.10 If 'not satisfactory.

.14 Is the C. earthing electrode taken & record maintained 2. if any..3 Condition of back up power supply.1 4.. unit connected with the earthing electrode ? 2.1 Inspection of source 3..1.2 Power availability of CP stations.13 If 'YES' any action taken/plan drawn for correcting the deficiencies 2. average 3.1 Is schedule made and followed for thickness survey of mainline at : Exposed section of Pipelines Sharp pipe bends/Riser bends If 'Yes".P. the findings Yes/No Yes/No Satisfactory/ Not satisfactory 4..hrs.2 4.0 C. . Is two yearly schedule made for thickness survey of unprotected pipeline section from I/F to scrapper launcher/receiver Yes/No Yes/No 106 ..2 4.1.20 Is the di-electric strength of oil checked ? 3.------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------2. transformer Yes/No Yes/No Yes/No Yes/No Yes/No Yes/No ------- Yes/No POWER SUPPLY TO CP STATION 3.0 ULTRASONIC THICKNESS SURVEY 4. .P.. any action plan for correcting the deficiencies drawn 4.P.P.15 Is the earthing resistance of C.16 Are all the C.18 Safety aspects for fault condition due to AC/DC power system 2... units provided with the lightening arrestors 2..19 Is the ground bed circuit resistance record maintained ? 2.4.3 If 'NOT SATISFACTORY'..17 Whether Lightening arrestor grid and Equipment Earthing grids are segregated 2./day Satisfactory/ Not Satisfactory 4.

2 If yes.3 Descaling Is schedule made for pigging ? And. If not satisfactory.1 Yes/No 6.. any schedule made for carrying out the survey (once in five years).2.1.. what is the value of a) Fe 0 % by mass b) Water....2.2 6..9 MPY/ > 4.2.2.0 6.. any action plan has been drawn to implement the recommendations Yes/No Yes/No Yes/No Yes/No .. ..1...0 PIGGING 6.1.1.2..1. findings of the survey..4 Yes/No 7. .1 Is inhibitor injection being done and records maintained Yes/No 107 .4 If yes.4 .-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------5.1 6.2 Yes/No 6.9 MPY 5.1 Whether coupons are installed 5.. Satisfactory/Not satisfactory 6.1.3 Satisfactory /Not satisfactory 6. corrosion rate ? 6.. Based on pig residue analysis internal condition of pipeline Intelligent Pigging Is any IPS survey carried out ? If no. Yes/No 6. % by mass c) pH value d) Acidity...3 Whether Electrical Resistance probes are installed 5.5 6. mg KOH/gm.is followed Is pig residue/dirty product analysis carried out? If yes. (To check the reports)..0 INHIBITOR INJECTION 7. If the survey has been carried out..0 INTERNAL CORROSION 5. corrosion rate < 1 MPY 1 to 4. ..0 6.

NOS.2 Is there any industrial affluent flowing over the ROW 9..4 Variations observed in soil resistivity 10..3 Supply to Motor Operated Valves (MOV) available 10.. 9.2 If No. 9. said sample tested to determine the efficacy of the existing coating of the pipe lines.4 MOV working 11.PPM/day 8.1 Is schedule made for maintenance of mainline valve 10. Yes/No Yes/No Yes/No Locally/Remotely 11...) 10. OF MAINLINE VALVES . pretested and kept at vulnerable locations for replacement if required Yes/No Yes/No 108 ..2.1 Is any CPL/EWP SURVEYS CARRIED OUT 8.0 SOIL TESTING 9.1 Soil samples within ROW being tested once in five years.3 If the survey has been carried out.-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------7. 9. any action plan has been drawn to implement the recommendations.2 If `yes'.3 If `yes'. 10. what are the findings (To check the report) 8.. Average dosing of corrosion inhibitor injection ..141&API 1110 11.1 Whether all repaired piping system are being tested in accordance with OISD . any schedule made for Carrying out the survey (once in five years) 8.2 Whether sufficient number of pipe lengths.0 MAINLINE VALVE (NO.0 CPL/EWP SURVEY 8.4 If not satisfactory.. schedule followed and valves operating freely.0 HYDROSTATIC TESTING Yes/No Yes/No Satisfactory/Not Satisfactory Yes/No Yes/No Yes/No Yes/No .

.1 Ground Patrolling by Patrolman each segment twice in a week by physical walking. 12.1.0 TELECOMMUNICATION & TELEMETRY (NO.OF REPEATER STN.2 Helicopter surveillance once in a month 12. 13..1 Is the schedule made for 12.2 If reply to the above is yes.1..1 13....1.-------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------12.5 13.4.6 109 .0 PIPELINE PATROLLING (Total length of Pipeline . whether various reports filled/ monitored regularly and proper checks on line patrolman exercised Yes/No Yes/No Yes/No Yes/No Yes/No Yes/No .c Submerged river crossing before and after monsoon 12. (other than load shedding) corrective action taken Whether all the lights and fans are working ? State Electricity Board Energy Meter working ? Energy Meter Readings being noted All the Radio Parameters as per Yes/No Yes/No 13.2 Availability of Power supply If no.NOS) 13.4 Inspection of Pipeline crossings at 12.1.b Road/Highway crossing quarterly 12.1..4..a Rail/Road Bridge and suspended crossing (exposed pipeline) quarterly 12.4.1.3 Right of way inspection and maintenance of above ground structures along ROW once in a year 12.3 Yes/No 13.1.4 Yes/No Yes/No 13.km) 12.

14 Yes/No 13. Auto change over working ? Is it free from leakages ? Whether Diesel Tank of DG set is full Whether all the alarms are in working order ? Whether no.------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------format are being checked Yes/No 13.13 Yes/No 13.O.12 13. Nos.23 Yes/No 13. number of faulty units Whether Engineering order wire (E.25 110 .19 Yes/No 13. are being identified and corrective action taken Whether specific Gravity of all the cells recorded in a register Sufficient reserve of distilled water available Check for the proper running of D.11 Yes/No 13.24 Yes/No 13.G. 13.8 13. Whether all the Battery voltages are (should be above 2 volts)being checked Yes/No Sick cells. if any.22 Yes/No 13. Whether Rooms are in dust free condition Whether all the parameters of charger are properly working.20 Yes/No 13.W) working. of fire buckets/ extinguishers adequate and in working order ? Whether aviation tower lights are in working condition ? Whether twilight switches are in working condition ? Whether the tower painting is done as per rolling plan ? Check the resistance of lightning Yes/No ..9 Yes/No 13.10 Yes/No 13.7 Whether all the Radio Units are in working condition ? If no..16 Yes/No Yes/No Yes/No 13.17 13.15 Yes/No 13.18 13.21 Yes/No 13. Set carried out.

Navigational aids 14. Whether Unauthorized Entry Alarm / Signal system is in working condition? SINGLE BUOY MOORING SYSTEM Whether the following items are being inspected daily and records kept ? Free floatation of buoys Draft Free movement of rotating assembly Yes/No 13.26 Whether Telecommunication link VHF/UHF/Microwave/Fiber optics is available ? Whether all the desired telesupervisory signals are passed on to master control station through remote terminal Unit (RTU) and data monitored? Functional test of telecommunication/ telemetry system are being carried out daily Telecommunication / Telemetry equipments are being inspected as per manufacturer's recommendations Pressure/Temperature/Flow recorder charts are in working order and are being checked for its safe limits Maintenance and inspection of safety instrumentation are being followed as per OISD-153.0 14.3 Whether visual inspection of buoys and equipments for external corrosion is carried out on monthly basis ? 14.29 Yes/No 13.Mooring ropes and ancillary equipments .30 Yes/No 13.2 Whether following items are being inspected weekly and records kept ? .1 Yes/No Yes/No Yes/No 14.31 Yes/No 13.4 Whether following item are being inspected on quarterly basis ? Anchor chains of buoys for wear tear and tension Fenders for damage Yes/No Yes/No Yes/No Yes/No Yes/No Yes/No 111 .28 Yes/No 13.Batteries .------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------arrestor (better than 2 ohms) 13.27 Yes/No 13.32 Yes/No 14.

are available in Pipeline installation ? 16.0 CONTINGENCY PLANS: 15.2 Is the contingency plans(s) displayed in conspicuous place ? 15.5 Whether following items are being inspected annually ? Expansion joints Oil swivel seals Yes/No Yes/No 14.2 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? 16.1 Whether the basic datas and parameters of the Pipelines/SBM system layout.4 Is the list of Mainline emergency equipments/tools available ? 15.------------------------------------------------------------------------------------------------------------------------------------------------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. length.3 Are all the employees familiar with it ? 15.0 DOCUMENTATION 16. diameter etc.6 Whether inspection of Hoses are being done as per the requirements of OISD-STD-135 15.5 Are the mainline emergency equipments/ tools stacked separately and marked for easy identification ? 16.3 Whether list of various codes to which Pipeline and SBM systems ? Yes/No Yes/No Yes/No Yes/No Yes/No Yes/No 112 .1 Is there updated contingency plans for emergencies at ? Installations Mainlines Off-shore facilities Yes/No Yes/No Yes/No Yes/No 15.

15. 6. Whether the height of the chimney in the fume chamber is sufficient. Is vacuum system adequate and working properly. 3. 113 . Are all Gas Cylinders kept outside buildings and kept properly secured. Whether the drainage system has been provided with a oil trap. 17. Whether ELCB/ECB installed in the main power switch board. Whether any emergency siren button provided in the Lab. Whether proper ventilation/exhaust system exists in the fume chamber area. Is the condition of the utility lines healthy. 5. Whether fittings in storehouse for returnable petroleum samples are of flameproof nature.ANNEXURE CHECKLIST FOR SAFETY IN LABORATORIES -------------------------------------------------------------------------------------------------------------------------------------------------ITEM AUDITOR’S REMARK -------------------------------------------------------------------------------------------------------------------------------------------------1. emergency procedures displayed. 18. 4. 14. Whether entry to the Laboratory area is restricted. 7. Whether important instructions. Check the condition of Test benches & cupboards.(Lab bench or near ground level) 8. 9. 2. Whether system exists for switching off all equipments at the end of the day. 16. Whether fire extinguishers are adequately positioned. Whether the switches/plug sockets for various equipments intrinsically safe. Whether emergency lighting available. 11. 12. 13. Whether the on-site emergency plan includes possibility of a fire in the Lab. 10. Whether samples of Class 'A' petroleum products in air tight containers.

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