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IJSTE - International Journal of Science Technology & Engineering | Volume 1 | Issue 12 | June 2015

ISSN (online): 2349-784X

Industrial Safety Auditing in BHEL

Ashutosh Shandilya
Department of Industrial Safety Engineering

Vineet Banodha
Department of Industrial Safety Engineering

Aim in this project is to perform safety auditing in different departments of BHEL plant to identify the hazards and to minimize
the hazard in order to make the working environment safe. BHEL Jhansi is place where manufacturing the power transformer &
locomotive and its Maintenance carried out. During the manufacturing of transformer & locomotive there is a high Probability of
accident on every working day.
Keywords: Safety Auditing, Job Safety Analysis

BHEL is the largest engineering and manufacturing enterprise in INDIA. BHEL deals in the manufacturing of power transformer
and locomotives. This plant of BHEL is equipped with the most modern manufacturing processing and testing facilities for the
manufacture of power, special transformer and instrument transformers, Diesel shunting locomotives and AC / DC locomotives.
It has two manufacturing unit, transformer unit and locomotive unit.

A. Audit:
Audit is a systematic and, wherever possible, independent examination to determine whether activities and related results
conform to planned arrangements and whether these arrangements are implemented effectively and are suitable to achieve the
organization's policy and objectives.
1) Types of Audit:
1) Health and safety audits
2) Health and safety management audit
3) "Walk around audit"
4) Project Health, Safety & Environmental (HSE) auditing
5) Process safety audit
6) Product safety audit
7) Safety Management
B. Job Safety Analysis:
Job safety analysis is accident prevention technique that is used to identify the potential hazard associated to the job and gives
control measure to minimize the hazard.
2) Analysis Includes Five Steps:
1) Select a job
2) Break the jobs down into steps
3) Identify potential hazards.
4) Apply the controls to the hazard.
5) Evaluate the controls.
Job Safety Analysis worksheet
For civil work in the plant
Company name: ..
Site name:
Permit to work:
Activity .
Approved by:



Table 1


Fall from height, exposure to live wire, falling objects impact,

Use of safety harness, use of ears

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Industrial Safety Auditing in BHEL

(IJSTE/ Volume 1 / Issue 12 / 003)

Concret ing and
Glass work



Piling operations
Roof slabs fixing
Masonary work

Storage in open yard /
closed shed
Material handling
By crane

Storage / handling of gas

Storage of lubricantoil

Handling of mineral wool

Material handling


Exposure to noise.

Use of ear plugs / muffs.

Safety / belts helmets in use,
Use of ear plugs / muffs.
Use of safety gloues.

Fall from height, exposure to noise.

Handling of sharp objects
Exposure to dust and suspended material.
Flying object impact.
Handling of sharp objects.
Falling objects impact.
Falling objects impact.

Company name: ..
Site name:
Activity .

exposure to noise.

Use of nose pads .

Use of goggles / helmets.
Use of safety gloues.
Safety / belts helmets in use.
Use of helmets.

Job Safety Analysis worksheet

For civil work in the plant
Permit to work:
Approved by:
Table - 2

Fire due to broken inflammable packing scraps, fire

due to dry weeds and bushes.
Falling object impact, moving object impact

Fire in leaked oil
Exposure to dust of mineral wool
Cut due to handling of sharp objects

Packing scraps are transferred to the identified
scrap yard
No smoking are
Fitness testing of cranes and slings done half
yearly, escorted with rigger.
Hand gloves are in use
Valve checking to be carried out, hand trolley to
be used, fire drill required.
Fire extinguisher is provided, no smoking area
Respiratory mask and hand gloves to be provided
Hand gloves in use

The use of job safety analysis methodologies contributes to the prevention of accidents and helps to make the system a safe place
to work in the plant. Thus in this job safety analysis has been performed in every section of work place in the plant. Potential
hazard associated to maintenance work under different section have bee identified and power control measure have been
recommended by preparing job safety analysis worksheet.


Design Manual for BHEL (DMBHEL) (2003) Volume 5 Section 2, Part 2, HD19/03: [Department for Transport]
Previous studies such as by Mitchison and Papadakis (1999) have demonstrated that effective safety management improves level of safety in organization
and thus can be seen to decrease damages and harm from incidents (cited from Bottani, Monica & Vignali, 2009).
[3] Mayors Transport Strategy (May 2010)
[4] C. S. Ramani gopal,G. Palaniappan (June 2013) Safe Work in BHEL Plant , The BHEL Safety Action
[5] Construction (Design and Management Regulations) (2007) [Health and Safety Executive]
[6] Manual for Plant (2007) [Department for Transport]
[7] Abdullah, Spickett, Rumchev & Dhaliwal 56 Hsu, Lee, Wu, and Takano (2007) study on organizational factors on safety Levels of Collision Risk in BHEL
Plant (2008)
[8] Alli, B. O. 2001. Fundamental principles of occupational health and safety
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vol. 47, pp. 155 162.
[10] Carder, B. & Ragan, P.W. 2003. A survey-based system for safety measurement and improvement, Journal of Safety Research, vol. 34, no. 2, pp. 157
[11] Cheyne, A., Oliver, A., Tomas, J.M., & Cox, S. 2002. The architecture of employee attitudes to safety in the manufacturing sector, Personnel Review,
vol. 31, pp. 649 670
[12] Fleming, M. & Lardner, R. 1999. Safety culture the way forward, The Chemical Engineer, 16 - 18. Retrieved: 15 January 2007
[13] G. Salvendy (Ed.), Handbook of Human Factors and Ergonomics. New Workplace health, safety and welfare. Workplace(Health, Safety and Welfare)
Regulations 1992. Management of health and safety at work. Management of Health and Safety at Work Regulations 1999. Approved Code of Practice
and guidance L21 (Second edition) HSE Books 2000.

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