Professional Documents
Culture Documents
FOR RESTRICTED
CIRCULATION ONLY
GUIDELINES
ON
INTERNAL SAFETY AUDITS
(PROCEDURE AND CHECKLISTS)
Prepared by:
COMMITTEE ON “ INTERNAL SAFETY AUDITS”
2
NOTES
3
FOREWORD
Safety Audits have been conducted in the oil/gas
industry in one form or other. Generally, Safety Audits are of two
types viz. Internal Safety Audits and External Safety Audits. While
methodology to be adopted for carrying out the External Safety
Audits is separately dealt with, this document contains guidelines
for conducting Internal Safety Audits in a professional
manner and is expected to assist the industry further in
maintaining and improving the Safety.
The Co-ordinator
Committee on Internal Safety Audits
OIL INDUSTRY SAFETY DIRECTORATE
th
7 Floor, ‘New Delhi House’
27, Barakhamba Road
New Delhi – 110 001
.
4
INTRODUCTION
5
SCOPE
6
COMMITTEE ON
`INTERNAL SAFETY AUDITS'
REVISION-I
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NAME ORGANISATION
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LEADER
MEMBERS
MEMBER CO-ORDINATOR
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In addition to the above, several other experts from Industry contributed on the preparation, review and
finalisation of this document.
7
OISD - GDN - 145
REVISION-I
GUIDELINES
ON
INTERNAL SAFETY AUDITS
8
SECTION - 1
9
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SECTION DESCRIPTION PAGE NO.
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1.0 INTRODUCTION
5.6 Briefing
5.8 Discussions
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10
INTERNAL SAFETY AUDITS
PROCEDURES
1.0 INTRODUCTION
Identification of vulnerable areas and specific potential hazards, is one of the prime function
of loss prevention in oil industry. Safety audit is an important tool in undertaking this function.
While the basic aim of safety audits is to identify the areas of weaknesses and strengths,
safety audits are undertaken to meet different specific objectives viz.-
1. To identify any design deficiencies and also any weaknesses which might
have cropped up during modifications / additions of facilities.
2. To ensure that fire protection facilities and safety systems are well maintained.
11
Audit conducted by Internal Audit teams of the organisation is categorized as Internal Safety
Audit.The methodology for carrying out such Internal Safety Audit is described in greater detail
under paras 5.0 to 8.0. Internal Safety Audits will be coordinated by local management under
the overall direction from the Corporate Office.
External Safety Audits will be carried out by outside teams consisting of technical experts from other
organizations in oil industry, professional bodies and statutory authorities under the overall
coordination of OISD.
All the facilities in a particular Refinery/Installation should be covered minimum once every year.
In case of LPG bottling plants the internal safety audit should be conducted minimum once
a year as per OISD-STD-144. However, facilities' design can be audited every 3 years or after
any major modification or additions. For this purpose, the individual organisation/ installation should
draw up a calendar in advance for carrying such audits for every calendar year which should
be made known to all the Departments and concerned Area Managers. The areas to be audited
should be clearly identified and logically grouped. The suggestive groupings in case of a Refinery
Installation are given below. Similar groupings can be done for other types of Installations.
However, this could be modified depending upon layout and complexity of the individual
installation.
Group – II All dispatch facilities like Tank-Wagon loading Tank - lorry loading, Bitumen
filling and dispatch facilities.
Sub Groups -
IV - C Secondary Processing Unit like FPU / FCCU/HCU & H2 along with Treating
Units.
IV - E N2 & Others.
Group - V Power House, Electrical Sub-stations, Water Block, Utilities, Effluent Treatment.
Group - VII General Audit, Fire Fighting and Safety, Layouts etc.
9
5.2 FORMATION OF MULTI-DISCIPLINARY AUDIT TEAMS:
The Internal Audits should be carried out through multidisciplinary audits teams. The composition of
the Internal Safety Audit may vary depending on the Group and areas to be audited, however,
person(s) concerned should have necessary experience and background to undertake in-depth audit in
a particular discipline. A team of 4 to 5 experienced officers from various disciplines viz. Process /
Production, Maintenance / Inspection, Electrical, Instrumentation, Fire & Safety and with the
activity involvement of concerned Plant / Area Manager is suggested. One of the team members should be
nominated as the leader of the audit team. In multi-unit organizations, the team members could also
be drawn from the Head Office / Corporate Office and other operating Units under its control.
Depending on the nature of audit and type / complexity of the installations in the selected group, the
duration of internal safety Audit can be fixed. This may vary from 2 to 7 working days for facilities under each
group.
Check lists are the most useful tool for undertaking systematic Safety Audit. Even for a skilled and
well qualified engineer a good check list would be necessary as a guide. Like a code of practice, a
Check List is a means of pooling the knowledge and hard won experience and ensures that no
important aspect is overlooked or forgotten. Such check lists help maintaining uniformity and speeding up
the audits.
In Section-II of this document, detailed model Checklist covering important areas are given. It is
suggested that oil industry members should adopt these model check lists for carrying out
Internal Safety Audits.
Before the safety Audit team visits any particular facility for carrying out Safety Audit, it would be essential
to study all relevant documents as below to get complete picture :
- Layouts
- P & IDs
- Operating Manuals
- Maint. / Inspection Manuals
- Fire and Safety Manuals, etc.
Depending upon the nature of audit more emphasis can be given to study specific documents. All the
audit team members should study these documents in advance to know the details of the installation.
5.6 BRIEFING:
Before beginning of each audit, all concerned persons of the area/installation be briefed by the team leader
about the purpose of the audit. No impression should be left that audit will throw bad light on them.
Most of the information could be gathered through site inspection using ready-made check lists. The
auditors should enter their observations under the remarks column and not simply state "yes" / "no".
Wherever necessary, observations should be recorded in separate sheet. Inspection should be carried out
accompanied by Installation / Plant Manager or the assigned officials.
10
5.8 DISCUSSIONS:
Further information can also be gathered through discussions (formal & informal), with site personnel and
Installation / Plant Manager, who is in-charge of the area or other site officers. The audit team should
interact with persons from various disciplines such as Production, Maintenance, Electrical,
Instrumentation, etc.. Formal discussions could be in the form of brief periodical sessions while informal
discussions could be over a cup of tea with personnel working in the area.
In addition to the documents which are already studied before inspection of the facilities, other
documents, such as Operating Instructions, Standing Orders, Log Books, Log sheets, Accident Records,
Minutes of Safety Committee Meetings etc. may also be studied as required.
The work of the Internal Safety Audit item should be presented in the form of a Safety Audit Report for
each group which should contain observations & recommendations and also in brief the
modalities adopted in conducting audit and the names of the audit team members.
Before finalizing the report, the Safety Audit Team can give a presentation as feedback to the Operating /
Management personnel of the Area / Installation. Additions or deletions could be made in the draft
report based on the discussions and comments received during the presentation. This approach is always
constructive and does not undermine the technical competence of the audit team.
Generally, the Internal Safety Audit Reports are submitted to the concerned authority who appoints the audit
team for undertaking needful follow up actions. Only the appointing authority should exercise judgement
in rejecting any of the recommendations. The appointing authority shall be of senior management level (
General Manager and above ).
The crux of the safety audits lie in removing the weakness identified during the audit. Sometimes audit
reports identify only the problem / weakness, but not the solution.
In such cases, it would be necessary to undertake a detailed study of the specific area and to identify the
rectification measures. Wherever the necessary in-house expertise is not available for detailed studies,
help of consultants / professional bodies should be sought for.
The final and most important phase is the implementation of recommendations. A senior person should
be nominated for coordinating implementation of all accepted recommendation under a time bound
program. Senior management should review the progress of implementation of recommendations
periodically through Management Safety Committee meetings and other review meetings.
11
SECTION : 2
CHECKLISTS
12
SECTION : 2
CONTENTS
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Sr. CHAPTER SAFETY AUDIT PAGE NOS.
CHECK LIST NO.
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1. GENERAL SAFETY AUDITS OISD-GDN-145-01 6 - 11
3. LAYOUTS OISD-GDN-145-03 19 - 23
ANNEXURE 88
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13
OISD-GDN - 145-01
REVISION I
14
OISD-GDN-145-01
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ITEM AUDITOR REMARKS
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1.2 PROCEDURES
- Operation
- Inspection and maintenance
- Electrical
- Mechanical
- Instruments
- Civil
- Fire fighting & Safety
- Emergency and disaster management plans
15
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ITEM AUDITOR’S REMARK
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-
1.5 SAFETY CONSCIOUSNESS & PROPAGATION
- Safety posters/slogans.
- Safety precautions at strategic points
through sign boards.
- Type
- Frequency
- Participants
Any other Motivation scheme exists ?
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16
ITEM AUDITOR’S REMARK
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1.8 PLANT SECURITY
*Ratings:(Notation Followed)
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18
ITEM AUDITOR’S REMARK
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e) Is there display of Do's and Dont's for handling of
toxic chemicals?
- syllabi
- course materials
- class room/field on job training
- on job
- fire and safety
19
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ITEM AUDITOR’S REMARK
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4.3.1 Implementation
4.3.2 Dissemination
20
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ITEM AUDITOR’S REMARK
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-
b) Whether any review is under taken at top
management/ corporate level periodically, to
review the safety performance and new goals
are set up?
21
OISD-GDN-145-02
REVISION I
FIRE PROTECTION
CONTENTS
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SECTION DESCRIPTION PAGE NO.
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1.0 PHILOSOPHY AND STANDARDS 13
2.0 FACILITIES 13
3.0 PROCEDURES 16
3.1 Organisations 16
3.2 Disaster Management Plan 17
3.3 Inspection and Testing facilities 17
3.4 Training 17
3.5 Checklist for DMP 18
22
OISD-GDN-145-02
2. FIRE PROTECTION
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ITEM AUDITOR'S REMARKS
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2.0 FACILITIES
2.2.2 Mains
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ITEM AUDITOR’S REMARK
24
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26
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ITEM AUDITOR’S REMARK
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d. Are the hoses periodically tested/ checked
and replaced?
Note 3
e. Are the hose boxes painted fire red as
per OISD Standard.?
f. Are adequate sand drums / buckets
available ?
g. Are all various types of nozzles/foam branch
pipes etc. provided as per OISD STD.?
Note 3
h. Are the hoses BIS Approved ?
2.8 OTHERS
- Evacuation, etc.
- First Aid training to personnel on shift.
3.0 PROCEDURES
3.1 ORGANIZATION
- Organogram
- Fire hydrants layouts and P & ID
diagrams
- Fire fighting procedures / manual
28
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ITEM AUDITOR’S REMARK
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a. Pumps
b. Hydrants
h. Foam concentrate
3.4 TRAINING
29
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ITEM AUDITOR’S REMARK
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3.5 CHECKLIST FOR DMP
30
OISD-GDN-145-03
REVISION I
LAYOUTS
CONTENTS
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SECTION DESCRIPTION PAGE NO.
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4.0 TANKFARMS 20
5.1 Location 21
5.2 Control room 21
5.3 Field 21
OISD-GDN-145-03
31
SAFETY AUDIT CHECKLIST
LAYOUTS
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ITEM AUDITOR'S REMARKS
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3.0 INTER-DISTANCES
- Block/facility to block/facility
4.0 TANKFARMS
4.2 DYKES
32
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ITEM AUDITOR’S REMARK
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5.1 LOCATION
- Consolidated / Scattered
5.3 FIELD
6.3 ROADS
- Peripheral locations
- Separation from hazardous areas
- Upwind from sources of flammable / toxics
35
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ITEM AUDITOR’S REMARK
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6.6 GANTRIES
- Peripheral location
- Peripheral locations
6.10 PIPING
36
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ITEM AUDITOR’S REMARK
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6.13 COMPRESSORS
6.14 MISCELLANEOUS
- Greenscaping area
37
OISD-GDN-145-04
REVISION I
PROCESS PLANTS
CONTENTS
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SECTION DESCRIPTION PAGE NO.
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1.0 GENERAL 25
1.3 Housekeeping 26
1.4 Training 26
1.6 Electrical 27
1.7 Instrumentation 27
38
SAFETY AUDIT CHECKLIST
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ITEM AUDITORS REMARKS
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1.0 GENERAL
40
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ITEM AUDITOR’S REMARK
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1.3. HOUSEKEEPING :
1.4 TRAINING
41
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ITEM AUDITOR’S REMARK
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1.6. ELECTRICAL
1.7 INSTRUMENTATION:
42
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ITEM AUDITOR’S REMARK
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c) Whether any schedule exists for checking
up of various interlocks, shutdown
systems ? Are such schedules followed
and recorded ?
43
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ITEM AUDITOR’S REMARK
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f) Whether the hot pumps are provided with
warm up lines ?
45
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ITEM AUDITOR’S REMARK
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g) Do all columns have two sets of level
indicators ?
46
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ITEM AUDITOR’S REMARK
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n) Whether the location and height of FD fan
air intake can be considered safe ?
48
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ITEM AUDITOR’S REMARK
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o) Whether vapor depressurising system has
been provided for emergency situations
such as runaway reaction, exposure to
fire etc.?
49
SAFETY AUDIT CHECKLIST No.OISD-GDN-145-05
CONTENTS
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SECTION DESCRIPTION PAGE NO.
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1.0 TANK FARM 35
2.0 TANKS 35
3.0 PIPING 36
50
SAFETY AUDIT CHECKLIST
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ITEM AUDITOR'S REMARKS
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1.1 GENERAL :
51
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ITEM AUDITOR’S REMARK
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1.2 SEWERS :
2.0 TANKS :
3.0 PIPING :
47
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ITEM AUDITOR’S REMARK
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b) Whether pipe supports, anchors,
guides are in order ?
48
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ITEM AUDITOR’S REMARK
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49
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ITEM AUDITOR’S REMARK
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For detailed checklist on individual areas refer other OISD checklists as follows :
Layouts OISD-GDN-145-03
52
SAFETY AUDIT CHECKLIST No.OISD-GDN-145-06
A. TANK WAGONS
CONTENTS
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SECTION DESCRIPTION PAGE NO.
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1.1.1 General 40
1.1.2 Drainage 40
1.1.3 Miscellaneous 40
1.1.4 Electrical 40
53
OISD-GDN-145-06
A. TANK WAGONS
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AUDITOR'S REMARKS
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1.0 FACILITIES AND SYSTEMS
1.1.1 General
1.1.2 Drainage
1.1.3 Miscellaneous
1.1.4 Electrical
-diesel
-steam
-electric
54
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ITEM AUDITOR’S REMARK
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55
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ITEM AUDITOR’S REMARK
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56
SAFETY AUDIT CHECKLIST No. OISD GDN-145-06
B. TANK TRUCKS
CONTENTS
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SECTION DESCRIPTION PAGE NO.
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1.0 FACILITIES & SYSTEMS 43
57
SAFETY AUDIT CHECKLIST
B. TANK TRUCKS
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ITEM AUDITOR'S REMARKS
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1.0 FACILITIES AND SYSTEM
58
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ITEM AUDITOR’S REMARK
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59
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ITEM AUDITOR’S REMARK
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p Whether approved quality spark
arrestors provided on the engine
exhaust and Muffler / Silencer is
not cut off from the exhaust ?
60
OISD-GDN-145-06 REVISION I
CONTENTS
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SECTION DESCRIPTION PAGE NO.
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1.0 FACILITIES & SYSTEMS
1.4 Drainage
1.5 Miscellaneous
1.6 Electrical
2.4 Training
2.5 Miscellaneous
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SAFETY AUDIT CHECKLIST
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ITEM AUDITOR'S REMARKS
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1.0 FACILITIES AND SYSTEMS
1.4 DRAINAGE
1.5 MISCELLANEOUS
1.6 ELECTRICAL
64
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ITEM AUDITOR’S REMARK
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d) Whether the loading arms/hoses are having
proper electrical continuity provision and
earthing connection ?
65
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ITEM AUDITOR’S REMARK
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good ?
satisfactory ?
needs improvement ?
2.5 MISCELLANEOUS
68
SAFETY AUDIT CHECKLIST No.OISD-145-07
CONTENTS
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SECTION DESCRIPTION PAGE NO.
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1.0 BULK STORAGE AREA 53
5.0 TRAINING 59
69
SAFETY AUDIT CHECKLIST
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ITEM AUDITOR'S REMARKS
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1.1 GENERAL:
1.4 INSTRUMENTATION:
proofed?
1.6 ELECTRICAL:
2.1 FACILITIES:
2.2 ELECTRICAL:
3.1 FACILITIES:
74
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ITEM AUDITOR’S REMARK
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3.4 OPERATING PROCEDURE AND PRACTICES :
4.1 FACILITIES
- Valid licenses
- fittings as per CCE such as flame arrestor,
fire screen etc.
- safety instruction booklet
4.2 OPERATION
76
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ITEM AUDITOR’S REMARK
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5.0 TRAINING
Layouts OISD-GDN-145-03
Electrical OISD-GDN-145-09
BULK TT CHECKING :
77
SAFETY AUDIT CHECKLIST No.OISD GDN-145-08
CONTENTS
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SECTION DESCRIPTION PAGE NO.
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1.0 GENERAL ORGANISATION AND ADMINISTRATION 61
78
SAFETY AUDIT CHECKLIST
LPG BOTTLING AND DISPATCH
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AUDITOR'S REMARKS
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1.0 GENERAL ORGANISATION AND ADMINISTRATION
80
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ITEM AUDITOR’S REMARK
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b) Whether filling/loading/unloading/storage
areas are adequately covered with mastic
coating on floors and pillars to avoid
accidental sparks?
- Cylinders filled
- Valve leak
- Bung leak
- Body leak
- "O" ring defect
- Spurious cylinders
84
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ITEM AUDITOR’S REMARK
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b) Whether fire organisation chart is
prepared upto date and displayed?
General (Organisation
Admn. Training etc) OISD-GDN-145-01
Layouts OISD-GDN-145-03
Electrical OISD-GDN-145-09
86
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ITEMS AUDITORS REMARKS
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f) Calibrations/Adjustments of devices
indicated in above.
e) Greasing/lubrication of :
- Central column
- Carousel Driving unit.
87
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ITEM AUDITOR’S REMARK
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9.3 QUARTERLY MAINTENANCE
88
SAFETY AUDIT CHECKLIST NO. OISD GDN-145-09
ELECTRICAL SYSTEM
CONTENTS
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SECTION DESCRIPTION PAGE NO.
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1.0 SPECIAL REQUIREMENTS 70
89
SAFETY AUDIT CHECKLIST
ELECTRICAL SYSTEM
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ITEM AUDITOR'S REMARKS
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1.0 SPECIAL REQUIREMENTS
91
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ITEM AUDITOR’S REMARK
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92
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ITEM AUDITOR’S REMARK
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r) Are all the power (H.T. & L.T) and
control cables in trenches properly
segregated?
ff) Whether shock restoration chart & First Aid Box provided?
93
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ITEM AUDITOR’S REMARK
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- Metal Frameworks
- A.B. Switches and circuit breakers
- D/O and H/G Fuses
- Poles/switches/insulator pins/stay
clamps
- Operating handle of the A.B. switch
94
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ITEM AUDITOR’S REMARK
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b) Whether the underground cables in
excavated trenches are laid at designed
depth with sand filling, brick
protection? (check at on Random trial
pit basis) Is u/g cable exposed at any
location?
95
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ITEM AUDITOR’S REMARK
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- 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
96
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ITEM AUDITOR’S REMARK
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97
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ITEM AUDITOR’S REMARK
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98
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ITEM AUDITOR’S REMARK
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99
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ITEM AUDITOR’S REMARK
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100
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ITEM AUDITOR’S REMARK
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101
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ITEM AUDITOR’S REMARK
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102
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ITEM AUDITOR’S REMARK
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103
SAFETY AUDIT CHECKLIST
CONTENTS
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SECTION DESCRIPTION PAGE NO.
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1) COATING CONDITION 81
2) CATHODIC PROTECTION 81
5) INTERNAL CORROSION 82
6) PIGGING 82
7) INHIBITOR INJECTION 83
8) CPL/EWP SURVEY 83
9) SOIL TESTING 84
16) DOCUMENTATION 87
104
SAFETY AUDIT CHECKLIST
ELECTRICAL SYSTEM
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ITEM AUDITOR'S REMARKS
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1.0 COATING CONDITIONS:
2.6 No. of test lead points for PSP Survey ..... Nos.
6.0 PIGGING
6.1.0 Descaling
107
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ITEM AUDITOR’S REMARK
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- Installations Yes/No
- Mainlines Yes/No
- Off-shore facilities Yes/No
16.0 DOCUMENTATION
112
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