external safety audit checkilist of cross … .pdfexternal safety audit checkilist of cross country...

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Prepared By Approved By

EXTERNAL SAFETY AUDIT CHECKILIST OF CROSS

COUNTRY PIPELINE SYSTEM

Oil Industry Safety DirectorateGovernment of India

Ministry of Petroleum & Natural Gas8th Floor, OIDB Bhavan, Plot No. 2, Sector – 73, Noida – 201301 (U.P.)

Website: www.oisd.gov.in

Tele: 0120-2593800, Fax: 0120-2593802

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SCOPE

This checklist covers the minimum safety audit requirements for onshore cross- country pipelines (including pipeline interconnecting various industrial units), pump and compressor station equipment used in connection with transportation of crude petroleum, petroleum products and natural gas.

However, Jetty lines, if any, adjoining the terminal under ESA will also be covered and the audit of the same will be carried out w.r.t. OISD-140.

The general information of pipeline system to be provided as per format enclosed as Annexure-I.

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CHECKLIST FOR EXTERNAL SAFETY AUDIT OF CROSS COUNTRY

PIPELINE SYSTEM

FOR

______________________ PIPELINE

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S.No CHECKLIST POINT ORGANISATION COMMENT

AUDITORS COMMENT

A. SAFETY MANAGEMENT SYSTEM

1.0 SAFETY POLICY

1.01 Whether Safety Policy approved by Management is available?

1.02 Whether the Policy is displayed in prominent location in Regional Language, Hindi and English?

1.03 Whether declared/approved Safety Policy is available in written form, in Regional language, Hindi and English?

1.04 Whether safety Policy document has been made available and disseminated to :

a) Officersb) Non-Management staff

2 SAFETY ORGANIZATION

2.01 Whether there is a statutory requirement, as per Factory Act / Rules, of a full time designated “Safety Officer” and his appointment has accordingly been made?

2.02 Whether the Safety Officer has other staff members at his disposal, as identified to be necessary, for performing his duties?

2.03 Whether any safety committee is in existence in the location, in line with the requirements of Factory Act / Rules?

2.04 Whether sufficient representation from non management cadre exists, in the committee, as per Factory Rules?

2.05 Whether Safety Committee meetings are conducted at regular intervals in line with

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Factory Act / Rules?

2.06 Whether Safety Committee meetings are chaired by the location in-charge and participated by all its members?

2.07 Whether Safety Committee reviews the decisions and action points of the previous meetings as recorded earlier?

2.08 Whether only safety related issues are discussed in the meetings? (Previous records of meetings to be checked and interaction with safety committee members to be made to ascertain their participation)

2.09 What is the safety organogram for the pipeline system?

2.10 Whether Safety Deptt. empowered to stop all hazardous practices?

3 SAFETY REGULATIONS, STANDARDS & STATUTORY APPROVALS

3.01 Whether following documents are available at site (i.e main pipeline / compressor / pumping stations)

a) Petroleum Act & Rulesb) The Petroleum Pipelines (Acquisition of

Right of users in land) Act 1962, Amended in 1972.

c) Regional & Central Pollution Control Acts & Rules

d) Factory Act / Rulese) Indian Electricity Act / Rulesf) Operation Manualsg) Fire Safety and Environment Protection

Manualh) Maintenance Manual giving procedures

for various equipmenti) Manufacturer’s manual for operation of

special equipmentj) OISD standards / other documentation

as specified in clause 21.0 of OISD-141k) Codes to which the pipeline has been

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designed, constructed and maintained.

3.02 Whether following licenses / approvals are available?a) Explosives Licensesb) Factory Licenses / DGMS Approvalc) Pollution Board Consent for discharge

of effluents to: (i) Air (ii) Waterd) H.F/VHF licensee) Govt. notification for “Protected Area”

declarationf) Any other applicable statutory license /

approval4 EMERGENCY PREPAREDNESS & DISASTER MANAGEMENT PLANS

(DMP)

4.01 Whether well defined updated Disaster Management Plan (DMP) for “onsite / offsite” emergencies is available for the location, duly approved by Factories Inspectorate?

4.02 Whether the updated DMP is based on risk analysis?

4.03 Whether resource requirements, roles of different personnel / agencies are clearly identified in DMP?

4.04 Whether all concerned have been provided with individual copies?

4.05 Whether mock drills for Disaster Management are organized and actions taken on observations during drilling for improvement?

4.06 Whether Emergency handling tools and tackles are readily available and maintained?

4.07 Whether Mutual Aid Scheme is available? If yes, whether the same is discussed periodically with members and records maintained?

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4.08 Whether organogram of Disaster Management team is displayed at prominent locations in Regional Language, Hindi and English?

4.09 Whether DMP is updated at regular intervals based on feed backs and changed scenarios?

4.10 Whether copies of updated DMP are available at Disaster Control Centre for emergency use?

4.11 Whether alternate emergency control centre is identified and established at remote location?

5 SECURITY SYSTEMS & PROCEDURE FOR INSTALLATIONS

5.01 Whether an effective security system exists at Installation and suspended crossings?

5.02 Whether a system exists at the location to monitor movement of visitors / vehicles and record thereto maintained and available?

5.03 Whether identity badges / cards / passes are issued and are worn by employees, visitors and contractors personnel before admission to restricted areas?

5.04 Whether metal detectors and mirror trolleys are available at installations and regularly used?

5.05 Whether the boundary wall / compound wall is as per Ministry of Home Affairs / Bureau of Public Enterprises guidelines and maintained properly?

5.06 Whether random frisking of persons passing through gate is done and records maintained?

5.07 Whether well illuminated periphery road and watch tower are provided?

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6 COMMUNICATION SYSTEM

6.01 Whether effective means exists for communication:a) within plantb) with outside agenciesc) with other stations enroute pipelined) for pipeline patrolling teame) with unit headquarterf) with pipeline headquarters

6.02 Whether communication system has reliable and alternate means of power supply?

6.03 Whether alternate mode of communication system exists to meet the emergency requirement?

6.04 Whether the upkeep of communication system is as per clause 7.00 of OISD-141and records maintained?

B.INTERNAL SAFEYT AUDITS AND FOLLOW UP

1.01 Whether Internal Safety Audit is carried out as per OISD-145?

1.02 Whether Internal Safety Auditors are conducted at regular intervals?

1.03 Whether the composition of Internal Audit Team is adequate to cover all aspects of the audit?

1.04 Whether the reports are submitted to the chief executives?

1.05 Whether safety audit recommendations are reviewed and implemented with a time bound schedule?

1.06 Whether quality control assurance plan of location / company is being followed and records properly maintained?

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C. INDUSTRIAL HAZARD CONTROL

1 LAYOUT OF TERMINALS / INTERMEDIATE STATIONS

1.01 Whether the plant layout has statutory approval (CCE / DGMS etc.) and is maintained accordingly?

1.02 Whether segregation of battery area have been considered in the layout?

1.03 Whether the inter distances at Intermediate stations and terminals are as per OISD-118? (Ref. Annexure-II)

1.04 Whether dyke / fire walls meet OISD-118 / CCE Regulation. Dyke wall design calculations to be enclosed.

1.05 Whether the location of halipad is safe and conforming to DGCA norms?

1.06 Whether fire station is located at a safe place?

1.07 Whether motorable roads are available around the tank farm for movement of fire tenders?

1.08 Whether the adequate provisions for maintenance of equipment is available?

1.09 Whether storm water and oily water drains are segregated in the tank farm and kept clean?

1.10 Whether the plant surface drainage system is adequately sized and properly maintained?

1.11 Whether drainage from tank farm is routed through oil – water separator and isolation valve is provided at tank farm floor drain outlet?

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1.12 Whether tank data and painting / cleaning schedule is painted on tanks?

1.13 Whether there is a provision of double valve segregation on inlet / outlet nozzles of the tank?

1.14 Whether surge relief system is provided in the delivery line and is properly connected?

1.15 Whether TRVs are provided on pipelines between valves at tank inlet / outlet and are discharging to tanks?

1.16 Whether the pipeline and associated equipment are numbered and painted as per colour code?

1.17 Whether delivery to suction bypass / recirculation line to storage tank has been provided?

1.18 Whether adequate ventilation exists (in case of covered pump / compressor house)?

1.19 Whether the location of effluent treatment plant / system is safe?

1.20 Whether all drains, wherever hydrocarbons, are being handled, are routed through Oil water separator (OWS)?

1.21 Whether effluent treatment plant / OWS discharge water meets prescribed standards and analysis of discharge is carried out periodically and records maintained?

2 HOUSEKEEPTING2.01 Whether housekeeping in the following

areas is satisfactory and it is free of dry vegetation / waste / rubbish and other unwanted materials?

a) Tank farmb) Pump house (Product / Compressor

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house)c) Electrical Control Roomd) Cable Trenchese) Telecommunication Roomf) Battery charger roomg) Utility blockh) Effluent treatment facilitiesi) Fire water pump housej) Workshopk) Roads and walkwaysl) Storm water channelsm) Stores / warehouse

2.02 Whether area cleaning is done and the waste disposed off on regular basis in a safe manner?

2.03 Whether housekeeping methods are part of written safety instructions?

2.04 Whether any rodent control measures have been taken and records maintained?

2.05 Whether electrical cable trenches are free of oil / water and maintained properly?

2.06 Whether sump is provided at pump / compressor house to collect spills and is kept clean?

3 EQUIPMENT SAFETY, INSTRUMENTATION

3.01 Whether minimum safety instrumentation has been provided at tanks, pressure vessels, compressors, pumps piping etc. are well maintained?

3.02 Whether all electrical fittings, motors are as per electrical area classification and installed accordingly?

3.03 Whether coupling guards are provided for pumps / motors?

3.04 Whether pump / compressor safety interlocks are regularly checked / calibrated

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and records maintained?

3.05 Whether pressure relief devices are calibrated and records maintained in line with statutory requirements and also as per OISD-132 (as stipulated in clause 8.8 of OISD-141).

3.06 Whether instrumentation actuated by electrical signals are provided as per electrical area classification?

3.07 Whether cross checking of auto level gauges is done through manual gauge while the tanks are in operation?

3.08 Whether process interlocks / safe shut down systems are maintained and checked for their effectiveness at regular intervals for effective functioning?

3.09 What is the system of bypassing process safety interlocks during running of plant? Whether such actions are recorded in shift log book and repeated in safety register?

3.10 Whether smoke / heat / gas, hydrocarbon detectors are provided as per area requirement , are functional and records maintained?

3.11 Whether instrumentation system are being maintained as per OISD-153 (as stipulated in clause 14.4.21 of OISD-141).

3.12 Whether SCADA, telemetry and leak detection system are provided and maintained in accordance with clause 5.4, 14.4.20 and 14.4.18 of OISD-141?

4 WORKING AREA PROTECTION IN TERMINALS / INTERMEDIATE STATIONS

4.01 The general safety features, to be assessed in the areas, such as:a) condition of floors

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b) unprotected floors openingc) effectiveness of lightning arrestorsd) effectiveness of earthing / pipeline

continuity systeme) integrity of pipeline insulating jointsf) adequate illumination / ventilationg) crossovers over pipe racks / trestlesh) platforms / handrailsi) walkways in tank farm areasj) human body static charge dissipationk) effectiveness and adequacy of air and

water pollution measures

4.02 Whether noise level in the pump house / gas turbine shed / compressor house and other such areas is within acceptable limits of Factory Rules?

5 PERSONAL PROTECTIVE EQUIPMENT (PPE)

5.01 Whether PPE requirements / specific to jobs are identified adequately and the same are available?

5.02 Whether these are easily available at the time of need?

5.03 Whether these are periodically inspected for continued use / replenishment and records maintained?

5.04 Whether personnel are trained for effective use of PPE?

5.05 Whether antistatic working uniform and footwear are used by personnel working / visiting areas prone to Fire and explosion?

5.06 What is the system of crosschecking for ensuring the use of PPE at the time of work and records of observation maintained?

5.07 Whether there is a system of enforcing use of PPE by contractors workmen?

5.08 What actions are taken in case plant

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personnel / contractor workmen are not using PPE while working?

6 ELECTRICAL AND LIGHTNING PROTECTION SYSTEM

6.1 ELECTRICAL

6.1.01 Whether inspection of electrical equipment is carried out in accordance with OISD-137 (as stipulated in clause 14.4.14 of OISD-141)?

6.1.02 Whether all electrical fittings, lightning provisions etc. are as per electrical area classification?

6.1.03 Whether all earthing connections / pits are provided as per IS:3043?

6.1.04 Whether suitable lightning arrestor is provided on double pole (DP) structure?

6.1.05 Whether separate earthing grid is provided for lightning arrestors?

6.1.06 Whether thermometer and other safety devices provided on the transformer are in working condition?

6.1.07 Whether the transformer oil is tested and maintained in accordance with Indian Electricity Act / Rules?

6.1.08 Whether suitable circuit breakers are provided at the incoming supply and is easily accessible and operable to isolate all incoming supply (ies)?

6.1.09 Whether suitable breaker system is provided on secondary side to break the supply in full load condition?

6.1.10 Whether all protective relays are functional?

6.1.11 Whether clear spacing is provided in front and rear of the main panels for

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maintenance?

6.1.12 Whether rubber mats of adequate rating with ISI marking are provided, in front and rear of the electrical panels?

6.1.13 Whether proper ventilation is provided in the room for battery room?

6.1.14 Whether the cable termination in switch boards bus bars, motors and other equipment are provided with lugs and properly secured?

6.1.15 Whether identification of TR units, ground beds and TLPs location for CP system is displayed?

6.1.16 Whether emergency lights are provided in DG set room and control room?

6.1.17 Whether proper identification for cables and switches is provided?

6.1.18 Whether foolproof interlocking between two different electrical supply sources has been provided?

6.1.19 Whether there is a provision of adequate ventilation for transformer, (if installed indoor)?

6.1.20 Whether fire and security personnel are trained for isolating the supply in an emergency?

6.1.21 Whether the fire siren circuit is energised even when LT side is isolated from the rest of the load in emergency?

6.1.22 Whether First Aid instruction chart for electric shock in regional language, Hindi and English is displayed?

6.1.23 Whether all damper / caution / work in progress boards are displayed at appropriate

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places?

6.1.24 Whether air conditioning system for control room etc. is properly maintained and records of the same kept?

6.2 EARTHING

6.2.01 Whether earth grid drawing is available?

6.2.02 Whether physical condition of earthing strips and pits for fixed roof tanks is checked and recorded at regular intervals?

6.2.03 Whether continuity of earth strips between ladder, roof and shell for floating roof tanks is checked and recorded at regular intervals?

6.2.04 Whether all structures are properly earthed?

6.2.05 Whether double earthings are provided for all motors and other equipment?

6.2.06 Whether records of pre and post monsoon for all earth resistance maintained?

7 GENERAL CHEMICAL HAZARDS

7.01 Whether authentic safety data sheets of all materials used in the location are available?

7.02 Whether there are any toxic / hazardous substances used in the location?

7.03 Whether the storage of toxic, flammable and oxidising materials is done separately in a safe place?

7.04 Whether containers of toxic materials are disposed off by authorised person in a manner as prescribed in safety manual?

7.05 Whether monitoring of work environment for detection of toxic chemicals / gases etc. being done and records kept?

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8 HEALTH AND MEDICAL FACILITIES

8.01 Whether adequate First Aid facilities are available at location and for mobile maintenance / patrolling team and sufficient no. of employees are trained at a recognised institution to handle the emergencies?

8.02 Whether transport facilities are available for shifting an injured / sick person for medicare?

9 WORK PERMIT SYSTEM

9.01 Whether safety work permit system (SWP) is in practice as per OISD-105 for all types of maintenance jobs?

9.02 Whether SWP format is in accordance with OISD-105?

9.03 Whether all SWPs are serially numbered and printed, in accordance with OISD-105?

9.04 Whether all the checklist items are ticked by the initiator of SWP before authorising issuing the permit?

9.05 Whether on completion of jobs, work permits are returned to issuing department, reviewed and preserved?

10 MAINTENANCE

10.01 Whether the updated Asset Register is maintained?

10.02 Whether history cards for machines equipment are maintained and updated?

10.03 Whether there is a schedule for inspection of equipment / tanks / piping, safety valves etc. and whether inspections are carried out as per schedule and records maintained?

10.04 Whether all plant modification jobs are

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undertaken only after HAZOP study followed by approved engineering drawings?

10.05 Whether a pre start up safety audit is carried out before commissioning of plant / facilities after modifications, major repairs etc. ?

10.06 Whether the spillages of oil or process liquids during maintenance are being promptly attended to and work area kept clean and dry as per requirement?

10.07 Whether records for preventive and break down maintenance are available?

10.08 Whether maintenance staff is aware about the safe working practices to be followed in the area of work?

10.09 Whether the proper type of tools are being used as mentioned in the SWP issued for the job?

10.10 Whether cathodic protection for underground plant / piping, tank bottoms and underground tanks provided and maintained (if reqd.)?

10.11 Whether goose neck type vent outlets to atmosphere are provided with protective wire mesh?

10.12 Whether foam / neoprene seals are checked regularly for perfect sealing and records maintained?

10.13 Whether the ladders, stairways / catwalks are checked and are in good condition?

10.14 Whether pipeline maintenance equipment is being maintained as per clause 14.4.6 of OISD-141.?

10.15 Whether inspection of storage tank / vessel

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is carried out as per OISD-128 and OISD-129 (as stipulated in clause 14.4.17 of OISD-141)?

10.16 Whether cross country pipelines are hydrotested as per clause 12.0 of OISD-141after repairs?

10.17 Whether valves in the cross country pipelines are maintained as per clause 14.4.16 of OISD-141?

10.18 Whether line filters / strainers are checked, maintained at regular intervals and records kept?

10.19 Whether the rotating equipment are maintained as per clause 14.4.17 of OISD-141?

10.20 Whether all weld repairs are carried out in line with clause 11.10.2 of OISD-141?

10.21 Whether jetty lines are inspected and maintained in accordance with OISD-140?

10.22 Whether cathodic protection system is properly operated and maintained and records kept and corrective actions taken?

10.23 Whether cathodic protection system provided with continuous power supply suitably backed by UPS, if reqd.?

11 FIRE PREVENTION / PROTECTION SYSTEM

11.01 Whether the fire water network provided is well designed and covers all fire hazard prone areas of the location?

11.02 Whether fire hydrants / water monitors are provided in all sides of the plant and are they located minimum 15 M away from nearest hazard?

11.03 Whether all the hydrants /monitors / hose

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boxes are easily accessible and are periodically serviced?

11.04 Whether fire hydrant network is maintained in accordance with OISD-142 (as stipulated in clause 13.5.6 of OISD-141)?

11.05 Whether adequate nos. and types of portable fire extinguishers have been provided in all plant buildings / operation areas?

11.06 Whether system for fire alarms and PA system are in working order?

11.07 Whether fire drills are conducted at regular intervals and records of observations made during drill maintained?

11.08 Whether a refresher course / training on fire fighting is being given to employees in this regard?

11.09 Whether fire water storage capacity is as per OISD-117 (Ref. Annexure – III).

11.10 Whether the sources of water supplying the fire water storage tanks are adequate?

11.11 Whether fire water pumps are installed as per OISD-117?

11.12 Whether main hydrant line is always kept under pressure?

11.13 Whether the fire water pumps are kept in “Auto start or Manual” mode?

11.14 Whether log book is available for operation and maintenance of FW pump?

11.15 Whether fire fighting pumping units are inspected and maintained and records kept in line with OISD-117?

11.16 What are the types and quantity of foam compound that are available? (Ref.

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Annexure-III)

11.17 What are the storage arrangements for foam compound and its accessibility?

11.18 Whether foam compound is tested for shelf life and test results are available?

11.19 Whether provisions for corrosion protection of fire hydrants system exists, regular monitoring done and records maintained?

11.20 Whether fire hydrant pressure at farthest point is maintained min 7 kg/cm2 with fire hydrants points open?

11.21 Whether fire hydrant network is connected with adjoining installations network, wherever possible?

11.22 Whether the portable extinguishers provided meet OISD requirements? Are they ISI approved (Ref.Annexure-IV)

11.23 Whether wheeled equipment are placed and maintained as per OISD standards?

11.24 Whether hoses, nozzles and accessories are available and maintained as per OISD standards?

11.25 Whether adequate no. of cartridges and DCP are available in the store? (50% of the total extinguishers)

11.26 Whether hand operated / electric siren (3 km range) are provided at strategic locations?

11.27 Whether the installation has foam pourer system and is maintained properly?

11.28 Whether the storage tanks / vessels are provided with sprinkler system and is maintained properly?

12 CONDITION MONITORING OF CROSS COUNTRY PIPELINES

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12.01 Whether a comprehensive integrated condition monitoring system comprising of the following exists:a) Checking of coating & wrapping of

underground pipelinesb) Cathodic protection systemc) Common inhibitor injection systemd) Internal corrosion monitoring systeme) Pig launching and receiving systemsf) Inspection of main line valvesg) Pressure limiting & regulating devicesh) Telemetry and leak detection system

12.02 Whether inspection of pipeline is carried out as per OISD-140 and 141?

12.03 Whether close monitoring of the individual system has been carried out and records properly maintained?

12.04 Whether the findings of such implementations are evaluated and corrective measures taken in time bound schedules?

12.05 Whether such inspections are carried out at regular / predetermined intervals?

12.06 Whether exterior condition of pipeline is regularly monitored in accordance with clause 10.2 of OISD 141 and records maintained?

12.07 Whether internal condition of pipeline is monitored in accordance with clause 14.4.15of OISD-141 and records maintained?

12.08 Whether soil resistivity survey has been carried out after the commissioning of pipeline in accordance with clause 11.2.3 of OISD 141 and records maintained?

12.09 Whether pipeline cleaning by pigs are done in accordance with clause 12.1 OISD-141?

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12.10 Whether any intelligent pig survey (IPS) has been undertaken for quantified assessment of the internal / external metal loss in accordance with clause 14.4.4 of OISD-141and records maintained?

12.11 Whether any corrective actions have been taken consequent to IPS?

12.12 Whether capacity test for liquid hydrocarbon transporting pipeline are done?

12.13 Whether the leak detection system is checked and maintained as per clause 14.4.18 of OISD-141?

12.14 Whether new techniques eg. ON/OFF pipe to soil potential, close order potential, direct current voltage gradient survey adopted for condition monitoring of pipelines?

12.15 Whether safety appliances provided for pipeline against lightning, stray current inter reference from foreign objects at pipeline crossings etc. is maintained and updated records kept?

13 MONITORING OF PIPELINE RIGHT OF WAY (ROW)

13.01 Whether regular patrolling system exists for ROW condition monitoring in accordance with clause 14.4.2 of OISD-141?

13.02 Is the present system of ROW inspection is in accordance with clause 14.4.1 of OISD-141?

13.03 Whether a check is kept on unauthorized construction in ROW?

13.04 Whether competent authority has been engaged in accordance with Pipeline Act?

13.05 Whether the pipeline route markers are maintained and inspected at regular intervals?

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13.06 Whether rail / road bridge and suspended crossings are regularly inspected as per clause 14.4.1 of OISD-141 and records maintained with reference to exposed bends?

13.07 Whether rail / road crossings are regularly inspected as per clause 14.4.1 of OISD-141 and records maintained with reference to exposed bends?

13.08 Whether a regular inspection of submerged (river / canal) crossings is carried out as per clause 11.7.3 of OISD –141 and records maintained?

13.09 Whether the inspection reports are reviewed by pipeline incharge and corrective actions taken?

13.10 Whether caution boards are displayed at all strategic locations and public suitably informed?

D.STATISTICS REPORTING & ACCIDENT INVESTIGATIONS

1 REPORTING FORMATS

1.01 Whether printed and serially numbered reporting formats are available as per OISD-FRM 107, fora) Explosionsb) Firesc) Accidents causing injuries to personnel

and damage to equipment and products (other than the explosion / fire)

d) Near misses

1.02 Whether coverage of all items in the format are adequate?

2 REPORTING PROCEDURES

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2.01 Whether the responsibilities are clearly defined as regards to preparation of the reports?

2.02 Whether the above standard formats are always used?

2.03 Whether the reporting procedures is in compliance with CCE regulations / Factory Act (Rules) / DGMS?

2.04 Whether the system has adequate provision to ensure that minor incidents and near misses also get reported to appropriate authorities?

3 ACCIDENT INVESTIGATION AND FOLLOW UP OF RECOMMENDATIONS

3.1 INVESTIGATIONS

3.01 Whether a system of investigation of all accidents exists and records kept?

3.2 IMPLEMENTATION

3.2.01 Whether responsibilities are assigned for implementing the recommendations?

3.2.02 Whether recommendations are implemented with time bound schedules?

3.3 DISSEMINATION

3.3.01 Whether the procedure / systems are established and streamlined for dissemination of information?

3.3.02 Whether responsibility is identified for disseminating the lessons learnt?

3.3.03 Whether the lessons learnt from accidents are disseminated adequately?

4 MAINTENANCE OF RECORDS AND DATE

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4.01 Whether accident statistics for previous year is maintained and easily available.?

5 REVIEW OF ACCIDENT DATA

5.01 Whether periodical review of the trends of accidents is carried out and corrective actions taken to prevent them?

5.02 Whether any review is undertaken at top management / corporate level periodically to review the safety performance and set up new goals for enhanced safety?

E. SAFETY TRAINING AND PROMOTION

1 Whether regular training courses are conducted for all employees including contractors workmen on safety and fire fighting and records maintained?

2 Whether contractors workman are appraised on safety aspects before and during the tenure of work?

3 Whether course modules are framed as per OISD-154 in relevance of location requirement?

4 Whether first aid training imparted to staff by authorised agencies in line with Factories Act (minimum 20% of total Employees)

5 Details of training to officers on various statutory regulations such as Petroleum Act, Explosives Act, IE, Pollution control, Factories Act, Weights & Measure, Manufacture storage and import of hazardous chemicals?

6 Observation on assimilation of safety training / awareness in respect of:a) officersb) Non management staffc) Contractor’s workmen

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7 Whether refresher courses on fire and safety are organized periodically for improvements?

8 Whether the assessment of training of employees on fire and safety is done and records maintained?

9 Whether membership of National / International safety organizations have been taken to promote and update safety awareness by access to more information?

10 Whether any National / International awards have been given to the location?

11 Whether safety bulletins, posters etc. are issued and replaced at appropriate intervals?

12 Whether display of “Cumulative Accident Free Hours” “ No Smoking” signs etc. in prohibited zones have been done and updated?

13 Whether other safety posters are displayed in the location and changed at appropriate intervals?

14 Whether employees participation is ascertained in the identification of various safety requirements?

15 Whether safety suggestions are considered appropriately and follow up action taken?

16 Whether inhouse safety competitions are held at regular intervals for the promotion of safe practices?

17 Whether a proper safety orientation programme for new entrants conducted and records maintained?

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ANNEXURE - IEXTERNAL SAFETY AUDIT OF _________________________

GENERAL INFORMATION

1. The information for 1.00 to be provided for complete Pipeline

2. All other information from 2.0 to 9.0 be given for all intermediate locations and separate sheets may be used.

S.NO NAME OF THE PIPELINE DATE

1.0 Name of the Pipeline :1.1 Date of Commissioning :1.2 Length of the Pipeline :

(Size/Sizes of Pipeline) :1.3 No.of intermediate stations and :

Its chainage1.4 No. of repeater stations :1.5 No. of CP stations :1.6 No. & location of isolation V/vs :1.7 No. of River crossings :1.8 No. of cased crossings Railway/Road: .1.9 No. of suspended crossings :

Name of location for which information is being provided

2.0 LAND : 2.1 Total land area :2.2 Licensed Area :2.3 Delicensed Area :

3.0 ADJOINING PROPERTIES

3.1 North side :3.2 East side :3.3 West side :3.4 South side :

4.0 NEAREST FACILITIES

4.1 Fire station : 4.2 Police Station :4.3 Hospital : 4.4 Railway Station :

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/ 2 /

5.0 PLANT FACILITIES

5.1 Tankagea) MS :b) HSD : c) SKO : d) CRUDE : e) LPG : lf) GAS :

5.2 Back up Power-Generators capacity : 5.3 Communication system:

a) Telephones : b) PA/Paging : c) VHF : d) Walkie/Talkie :

6.0 YEARLY THRUPUT

Product wise:a) MS :b) HSD :c) SKO :d) CRUDE :e) LPG :f) GAS :

7.0 MANPOWER

7.1 Management : 7.2 Non-Management (Clerical staff) : 7.3 Non-Management ( Labor staff ) : 7.4 Casual labors (Avg/day) : 7.5 Contract workmen (Avg./day) : 7.6 Security guards (Company) : 7.7 Security guards (Contractors) :

8.0 No. of operating shifts :

9.0 ANY OTHER INFORMATION

9.1 Awards/Achievements :

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ANNEXURE -II

INTERDISTANCE & SAFETY DISTANCE BETWEEN FACILITIES :

Recommended Actual (Mtrs ) .

1. Between tank farm & pumphouse : 8

2. Between tank farm & Fire water : 30Pump house

3. Between pump house & sub.stn. : 15

4. Between storage tanks & : Dia of Tankcompound wall

5. Between storage tanks & : Half the height Dyke wall of the tank

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ANNEXURE - III

FIRE WATER CALCULATION

ASSUMPTION : TANK:

NO. ON FIRE

A.

1. Water required for cooling the tank : .on fire…

.

2. Water required for cooling the tanks :within (R+30) M radius from from centre of tank on fire.

3. Water required for cooling the outside :R+30 M radius from centre of tank on Fire

4. Water required for applying foam on :large fixed roof/floating roof tank.

A = 1+2+3+4 = .

B.

i) Water requirement for 4 hydrants : 4*36 = 144 M3/Hr

ii) Water requirement for 1 motor : 1*144 = 144M3/Hr

Total B = 288 M3/Hr

A or B whichever is higher

Water storage for 4hours OR

Water storage for 3 hours if make upWater is 50%

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Total water requirement in KL =Present water storage in KL =Additional tankage requirement in KL =

Fire water pumps =Main Pumps =

Standby =Existing Pumps =

FOAM CALCULATION :

1. Foam requirement for largest = .Fixed roof tankOR

2. Foam requirement for largest =floating roof tank

ORFoam monitor - 4320 LTSHoses - 4104 LTS

Foam storage for 30 minutes in KL =

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ANNEXURE – IV

A:

Area 10 Kg.DCP Actual 75 Kg Actual

1. Petroleum 2 per 200M2 areaProductWarehouse, Package

2. Pump house 1 per 2 pumpsClass A&B max. 4 nos.Class C 1 per 4 pumps

3. T/T loading 1 per 2 bays 1 no. .& unloadinggantry

4. T/W loading 1 per 30 meter 1 no.unloadinggantry

5. Office 2 nos. each canteen/storage

4. Electric 1 no. 4.5 Kg CO2 MCC Room per 25 M2 area

B WHEELED EQUIPMENT

Required Actual

1. Wheeled portably water/foamMonitor 2400 Lit/Min.

2. Foam compound trolley 200/210 litres

3. 250 Kg.DCP trolley

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C. HOSES/NOZZLES.

1. Fire hose 4 .(30 % of hydrant points or min. 10 nos.)

2. Jet nozzles with branch 4 .pipe (IS:903)

3. Fog nozzles (IS:952) 44. Universal nozzles (IS:2171) 45. Foam branch pipes(IS:2097) 4

D. ACCESSORIES

1. DC Powder (50% of the fire existinguishers) - .

2. CO2 Cartridges (50% of the fire extinguishers)3. Sand scoops 4 -4. Safety Helmets 8 - .5. Water curtain nozzles 2 - .6. Stretcher 1 - .5. First aid box with anti 1 -

Snake serum8.` Rubber hand gloves for 3 -

electrical jobs9. Explosivitimeter 1 - .10. Fire entry suit w/o 2 - .

Breathing apparatus11. Resuscitator 2 - .12 Electrical siren 1 Km range 2 -13 Hand operated siren 1 -14 Water jel blankets As reqd. -13 Red/Green flag for fire 1 each -

Drills13. Position pressure type self 1 -

Contained breathing appa-Ratus with spare cylinder(30 minutes)

external safety audit checkilist of cross … .pdfexternal safety audit checkilist of cross country...

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