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Disclosure to Promote the Right To Information

Whereas the Parliament of India has set out to provide a practical regime of right to

information for citizens to secure access to information under the control of public authorities,in order to promote transparency and accountability in the working of every public authority,and whereas the attached publication of the Bureau of Indian Standards is of particular interestto the public, particularly disadvantaged communities and those engaged in the pursuit ofeducation and knowledge, the attached public safety standard is made available to promote thetimely dissemination of this information in an accurate manner to the public.

!"#$% '(%)

!"# $ %& #' (")* &" +#,-. Satyanarayan Gangaram Pitroda

Invent a New India Using Knowledge

/0 )"1 &2 324 #' 5 *)6 Jawaharlal Nehru

Step Out From the Old to the New

7"#1 &" 8+9&") , 7:1 &" 8+9&") Mazdoor Kisan Shakti Sangathan

The Right to Information, The Right to Live

!"# %& ;

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IS 14489: 1998

Indian Standard

CODEOFPR CTICEONOCCUP TION L

S FETY NDHE LTH UDIT

ICS 13.100

0 BIS 1998

BUREAU OF INDIAN STANDARDSMANAK BHAVAN 9 BAHADUR SHAH ZAFAR MARG

NEW DELHI 110002

( Reaffirmed 2002 )

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Industrial Safety Sectional Committee, CHD 8

FOREWORD

This Indian Standard was adopted by the Bureau of Indian Standards, after the draft finalized by the IndustrialSafety Sectional Committee had been approved by the Chemical Division Council.

Due to the growing awareness of safety in the industrial sector and introduction of various Acts for implementingdirectives of the statutory bodies, the need has been felt to formulate this Indian Standard which will give aguideline to audit safety aspects in the industrial and other units of concern.

While formulating this standard, utmost care has been taken to cover all the possible elements relating to safety.A separate checklist giving questionnaires of safety audit has been included and given in Annex C for thebenefits of auditor and auditee. However, it may be reviewed from time to time for inclusion of newer elementswhich would be necessary due to the reasons intended for. A list of records to be maintained is also given inAnnex B of this standard as guideline.

This standard only gives a guideline for auditing industrial unit for safety parameters.

The composition of technical committee responsible for formulating this standard is given in Annex D.

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IS 14489 1998

Indian Standard

CODEOFPR CTICEONOCCUP TION L

S FETY NDHE LTH UDIT

1 SCOPE

This standard establishes audit objectives, criteria andpractices, and provides guidelines for establishing,planning, conducting and documenting of audits onoccupational safety and health systems at workplace.

It provides guidelines for verifying the existence andimplementation of elements of occupational safety andhealth system and for verifying the systems ability toachieve defined safety objectives. It is sufficientlygeneral in nature to permit it to be applicable oradaptable to different kinds of organizations. Eachorganization should develop its own specificprocedures for implementing this standard.

This standard does not cover audit of environmentalmanagement system for which a separate IndianStandard IS/IS0 14001 is available.

2 DEFINITIONS

For the purpose of this standard, the definitions givenbelow shall apply.

2.1 Auditee

An organization to be audited.

2.2 Audit Team

A team of persons designated as auditors who aresuitably qualified and have experience to performthese audits.

NOTE- The auditor designated to lead the audit team andmanage a safcety audit is called a Audit Team Leader (leadauditor).

2.3 Client

An organization which appoints auditing agency/teamto carry out third party audit on its behalf.

2.4 Management Representation

The official of the auditee organization authorized todeal with the audit team.

2.5 Nonconformity

The nonfulfilment of specified requirement.

2.6 Observation

A statement of fact made in the course of an audit andpreferably substantiated by objective evidence.

2.7 Objective Evidence

Qualitative or quantitative information, records orstatements of fact which is based on observation,measurement or test and which can be verified.

2.8 Occupational Safety and Health Audit

A systematic, objective and documented evaluation ofthe occupational safety and health systems and

procedures.NOTES

1 Henceforth in this document only the words OS&H shall beused in place of the words occupational safety and health andonly audit in place of safety and occupational health audit.

2 The audit typically applies to, but is not limited to. a snFeetysystem or elements thereof, and is applicable to process,products, or to services. Such audits are often called safetysystem audit, process safety audit, product safely audit,service safety audit.

3 There are two types of audits, external and internal. Externalaudits are those carried out by agrncies external to the auditeeorganizat ion. Internal audit . are those carried out by theemployees designated by the managerncnt For his purpose. Such

employees may be selected prcfcrably from amongst not havingdirect responsibility in ihe areas being audited no,- havingresponsibility for implcmcntation ofrccolnlncndationh.

4 One purpose of the OS&H audit is to identi fy the arcas fatimprovement or corrective action. An audit should not be COWfused with Periodic Safety Inspection activities performed byplant personnel for the purpose of checking effcctivcness ofimplementation of Safety System.

2.9 Occupational Safety and Health System

The organizational structure, responsibilities,procedures, processes and resources specified by topmanagement of an organization as required for

implementing occupational safety and healthobjectives.

NOTES

1 The area% o be covered under the OS&H system arc given inAnnex A.

2 The OS&H system should only be as comprehensive as isneeded to meet the objectives.

2.10 Organization

Company, corporation, firm, enterprise or institutionor part or combination thereof whether incorporated ornot, public or private, that has its own functions and

administration.NOTE - This definition is as per IS0 14001 Environmentalmanagement systems-Specification with guidance for use.

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IS 144x9 : 1998

2.11 Recommendation

Suggestion made by the audit team in the course ofaudit for improvement in the OS&H system.

NOTES

1 The defi nition covers the departure or absence of one or moreOS&H system elements from specified requirements.

2 For organization with more than one operating unit; a singleoperating unit may he defined as an organization.

3 AUDIT GOALS, OBJ ECTIVES ANDRESPONSIBILITIES

3.1 Audit Goals

Audits are normally designed to achieve one or moreof the following goals:

- to provide the auditee with an opportunity toassess its own OS&H system against a OS&Hsystem standard and identify areas for

improvement;- to determine the conformity of theimplemented OS&H system with specifiedrequirements and identify areas forimprovement; and

- to meet regulatory requirements.

NOTES

1 These audits may be periodic, or may bc: prompted by sig-nificant changes in the organizations OS&H system, process,product or service or by n nezd to follow up on corrective actionas specified in 4.1.2.

2 Audits are not aimed at, nor should result in a transfer of the

responsibility to achieve safety from auditce management to theauditing organization.

3 Audits are not acertification ofthe safety performance oftheauditee organization.

3.2 Audit Objectives

OS&H audits are conducted with the followingobjectives:

- To carry out a systematic, critical appraisal ofall potential hazards involving personnel,plant, services and operation method; and

- To ensure that OS&H system fully satisfy the

legal requirements and those of the companyswritten safety policies, objectives andprogress.

3.3 Roles and Responsibilities

3.3.1 Auditors

3.3.1.1 Audit team

It is desirable to have the OS&H audit team comprisingof two or more auditors; with different specializedbackgrounds which are complimentary. One of theauditors should be designated as the lead auditor andshould have overall charge and responsibility.

3.3.1.2 Lead auditors responsibilities

The lead auditor is ultimately responsible or all phasesof the OS&H audit. The lead auditor should havemanagement capabilities and experience and shouldbe given authority to make final decisions regardingthe conduct of the audit and any audit observations.

The lead auditors responsibilities also cover:-

-

-

-

-

-

communicating with client, auditee and otherauditors regarding audit requirements;

selection of other audit team members;

preparation of the audit plan;

interacting with the client and auditeesmanagement;

submitting the audit report; and

maintaining agreed time schedule.

3.3.1.3 Auditors responsibilities

Auditors are responsible for:-

-

-

-

-

-

-

complying with the applicable auditrequirements;

planning and carrying out assignedresponsibilities effectively and efficiently;

documenting the observations;

reporting the audit results;

verifying the effectiveness of correctiveactions taken as a result of the earlier audits (ifrequested by the client);

retaining and safeguarding documentspertaining to the audit ensuring suchdocuments remain confidential, a n dtreating . privileged information withdiscretion; and

Cooperating and supporting the leadauditor.

3.3.1.4 Independence of the auditor

Auditors should be free from bias and intluenceswhich could effect objectivity.

All persons and organizations involved with an auditshould respect and support the independence andintegrity of the auditors.

3.3.1.5 Auditors activities

The lead auditor should:

- define the requirements of each auditassignment, including selection of team;

- comply with applicable auditingrequirements and other appropriatedirectives;

- plan the audit, prepare working documents andbrief the audit team;

2

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- plan the field visit;- report critical nonconformities to the auditee

immediately;- report any major obstacles encountered in

performing the audit; and

- report on the audit results clearly, conclusivelyand without undue delay.

Auditors should:- remain within the audit scope;- exercise objectivity;- collect and analyse evidence that is relevant

and sufficient to permit the drawing ofconclusions regarding the audited OS&Hsafety system;

- remain alert to any indications of evidence thatcan intluence the audit results and possiblyrequire more extensive auditing;

- be able to answer such questions as presented;- ensure that the procedures, documents and

other information specifying requirementsdescribing or supporting the required elementsof the OS&H system are known, available,understood and used by the auditeespersonnel?

- ensure that all the documents and otherinformation used to describe the safety systemadequate to achieve the required OS&H

objectives? and- act in an ethical manner at all times.

3.3.2 Client

The client:

- determines the need for and the purpose of theOS&H audit and initiate the process;

- selects the auditing organization;- agrees in consultation with the lead auditors the

genera1 scope of the audit such as what OS&Hsystem standard or document is to be selectedas reference and the time schedule;

- receives the audit report; and

- determines what follow-up action is to betaken.

3.3.3 Auditee

The auditees management should:

- inform relevant officials and staff about theobjectives and scope of the audit;

- appoint one or two officials to coordinate/liasion with audit team and responsibleofficials to accompany members of the audit

tea-m during their visit to respectivedepartments;

3

-

-

-

-

IS 14489 : 1998

provide all resources needed for the audit teamin order to ensure an effective and efficientaudit process;

provide access to the facilities and evidentialmaterial as requested by the auditors;

co-operate with the auditors to facilitateachievements of audit objectives; and

determine and initiate corrective actions basedon the audit report.

4 AUDITING METHODOLOGY

1.1 Initiating the OS H Audit

4.1.1 AL&t Scope

The client in consultation with lead auditor makes thefinal decisions on which OS&H system elements,

physical locations and organizational activities are tobe audited within a specified time frame.

The scope and depth of the audit should be designedto meet the clients specific information needs.

The~standards or documents with which the auditeesOS&H system is required to comply should bespecified by the client. This may include the relevantlegal requirements; concerned and other relevantIndian Standard and the requirements specified by theauditee (see 4.1.3).

Suflicient objective evidence should be available todemonstrate the operation and effectiveness of theauditees safety system.

The resources committed to the audit should besufficient to meet its intended scope and depth. Theaudit will cover the objectives laid down and may alsocontact with individual workers to ascertain theirperceptions about the existing OS&H system, to gaintheir involvement, to encourage comments andsuggestion relating to safety and invite cooperation tobring the company to an approved OS&H standard.

4.1.2 Audit Frequent

The need to perform an audit is determined by theclient, taking into account of specified or regulatoryrequirements and any other pertinent factors.Significant changes in management, organization,policy, techniques or technologies that could affect theOS&H system, or changes to the system itself and theresults of recent previous audits, are typical of thecircumstances to be considered when deciding auditfrequency.

It is desirable that organizations have acombination of

external and internal OS&H audit system. While theexternal audit in respect of organizations may be

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IS 14489 : 1998

conducted once in two years, or as specified by anystatute, the frequency of internal audit may be set oncein every year. Records of accidents and dangerousoccurrences should be examined and used to identifyhigh risk areas and activities and consequently thefrequency of internal audit may be increased.

4.1.3 Preliminary review of auditees description andspecified requirement of OS&H system:

As a basis for planning the OS&H audit, the leadauditor should review for adequacy the auditeesspecified requirements and recorded description of themethods for meeting the OS&H system requirements(such as the safety manual or equivalent).

If this review reveals that the system described by theauditee is not adequate to meet the requirements,

further resources should not be expanded on the audituntil such concerns are resolved to the satisfaction ofthe client, the lead auditor and, where applicable, theauditee.

While it is desirable to have a well defined set ofspecified requirements and recorded description; intheir absence; audit may be conducted with referenceto legal requirements and concerned Indian Standards.

4.2 Preparing the OS H Audit

4.2.1 Audit Plun

The audit plan should be finalized after consultationwith lead auditor and the client and communicated tothe auditors and auditee.

The audit plan should be designed to be flexible inorder to permit changes in emphasis based oninformation gathered during the audit, and to permiteffective use of resources. The plan should include:

- the audit objectives and scope;- identification of reference documents (such as

the applicable OS&H system standard and theauditees description and specifiedrequirements of their safety system);

- size of the audit team as specified at 3.3.1.1;

- identification of the organizational units to beaudited;

- the schedule for audit activities;- the schedule of meetings to be held with

auditee management;- the list of documents to be pursued by the audit

team;

- audit report distribution and the expected dateof issue.

4.2.2 Audit Team Assignments

Each auditor should be assigned specific OS&Hsystem elements or functional departments to audit.Such assignments should be made in consultation withthe auditors concerned.

4.2.3 Working Documents of the Audit Team

The documents required to facilitate the auditorsinvestigations, and to document and report results,may include:

- check-lists used for evaluating OS&H systemelements (normally prepared by the auditorassigned to audit that specific element), and

- forms for documenting supporting evidencefor conclusions reached by the auditors.

Working documents should be designed so that theydo not restrict additio~nal audit activities orinvestigations which may become necessary as aresultof information gathered during the audit.

Working documents involving confidential orproprietary information shall be suitably safeguardedby the auditing organization.

4.2.4 Questionnaire of Preliminary Information

The audit team would send to the auditee managementa questionnaire seeking information about variouselements of OS&H system as given in Annex A. Thiswould be filled in by the auditee, plan and returned for

study by the audit team before the field visit.4.3 Executing the OS H Audit

This would include a field visit with the auditeeorganization by the audit team which would cover thefollowing activities. During this field visit, theconcerned officials of the auditee would accompanythe team during their visits around the plant.

4.3.1 Opening Meeting

The purpose of an opening meeting is to:

-

-

-

-

-

-

introduce the members of the audit team to theauditees senior management;

review the scope and the objectives of theaudit;

provide a short summary of the methods andprocedures to be used to conduct the audit;

establish the official communication linksbetween the audit team and the auditee;

confirm that the resources and facilities neededby the audit team are available;

fix a schedule of visits to individual plants/

departments;

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- discuss the auditees senior management; theareas of concerned and suggested areas offocus by the audit team;

- confirm the time and date for the closingmeeting and any interim meetings of the auditteam and the auditees senior management;

- clarify any unclear details of the audit plan.

4.3.2 Presentation by auditee management onorganization, manufacturing processes;organization structure and specified requirements ofthe~OS&H system.

4.3.3 Examination

4.3.3.1 Collecting evidence

Evidence should be collected through interviews,examination of documents, and observation ofactivities and conditions in the areas of concern. Clues

suggesting nonconformities should be noted if theyseem significant, even though not covered bycheck-lists, and should be investigated. Informationgathered through interviews should be tested byacquiring the same information from otherindependent sources such as physical observation,measurements and records (see Annex B).

NOTE - A questionnaire for performing safety audit has beengiven in Annex C for guidance only.

4.3.3.2 Audit observations

All audit observations should be documented. Afterall activities have been audited, the audit team shouldreview all of their observations to determine which areto be reported as nonconformities. The audit teamshould then ensure that these are documented in aclear, concise manner and are supported by evidence.Nonconformities should be identified in terms of thespecific requirements of the standard or other relateddocuments against which the audit has beenconducted. Observations should be reviewed by thelead auditor with the responsible auditee manager.All observations of nonconformities should beintimated to the auditee and acknowledged by it.

It should be remembered that purpose of audit is not tocomprehensively check implementation of each safetysystem element. The purpose is to sample/test checkthe implementation of each element of the OS&Hsystem. Therefore, the information is to be correctedfor a few cases of nonconformity in respect of eachelement; as a basis for evaluating implementation ofthat element. However, recommendations are not onlyto correct the observed nonconformities, but theimplementation of the element as a whole.

4.3.4 Audit Recommendations

The desired end result of a OS&H audit is theidentification of primarily unrecognized hazards, inthe light of experience and early recognition of short

IS 14489 : 1998

comings in the areas such as the maintenance andtesting of critical equipment. The auditor should makerecommendations to the auditee for the improvementsto the OS&H system.

In case of an organization whose OS&H systemspecified requirements/description are welldeveloped; it would be sufficient to point outnonconformities with the requirement. However,when these are not well laid down, it becomes ~a11 hemore important to make recommendations.

These recommendations are of two types:

- for improvement in the systems specifiedrequirements; and

- for more effective implementation of thespecified requirements of the system.

It is up to the auditee to determine the extent, the wayand means of actions to improve the OS&H system as

per recommendations of the audit team. However, therecommendations regarding compliance withstatutory and legal requirements are to be fullyimplemented.

4.3.5 Closing Meeting with Auditee

At the end of the OS&H audit, prior to preparing theaudit report, the audit team should hold a meeting withthe auditees senior management and those responsiblefor the functions concerned. The main purpose of thisineeting is to present audit observations andrecommendations to the senior management in such a

manner so as to ensure that they clearly understand theresults of the audit.

The lead auditor should present observations andrecommendations, taking into account their perceivedsignificance.

The lead auditor should present the audit teamsconclusions regarding the OS&H systemseffectiveness in ensuring that objectives will be met.

Records of the closing meeting should be kept.

4.4 OS H Audit Documents

4.4.1 Audit Report Preparation

The audit report is prepared under the direction of thelead auditor, who is responsible for its accuracy andcompleteness.

4.4.2 Report Content

The audit report should faithfully reflect both the toneand content of the audit. It should be dated and signedby the lead auditor. It should contain the followingitems, as applicable :

- An executive summary of the report presentingintroduction, objectives and methodology,overview of the site, plant description,managements OS&H system, workers

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I.2

3

4

5

6

7

8

9

IO

11.12

13

14

15

I

2

3

4

5

6

7

8

9

IO

11

f2

13

14

IS 1448931998

ANNEX A

(Clauses 2.1 and 4.2.4)ELEMENTS OF OCCUPATIONAL SAFETY AND HEALTH SYSTEM (OS&H)

Occupational safety & health policyOS&H organizational set-upEducation and trainingEmployees participation in OS&HManagementMotivational and promotional measures forOS&HSafety manual and rulesCompliance with statutory requirementsNew equipment review/inspectionAccident reporting analysis investigation andimplementation of recommendationsRisk assessment including hazardidentificationSafety inspectionsHealth and safety improvement plan/targetsFirs-t aid facilities - occupational healthcentrePersonal protective equipmentGood housekeeping

16.17.18.19.20.21.

22.23.24.

25.

26.27.28.29.30.31.

Machine and general area guardingMaterial handling equipmentElectrical and personal safeguardingVentilation, illumination and noiseWork environment monitoring systemPrevention of occupational diseasesincluding periodic medical examinationSafe operating proceduresWork permit systemsFire prevention, protection and fightingsystemsEmergency preparedness plans (on-site/off-site)Process/plant modification procedureTransportation of hazardous substancesHazardous waste treatment and disposalSafety in storage and warehousingContractor safety systemsSafety forcustomers (including material safetydata sheets)

ANNEX B

(Clause 4.3.3.1)TYPES OF RECORDS TO BE EXAMINED DURING THE SAFETY AUDIT

OS&H policySafety organization chartTraining records on safety fire and first-aidRecord of plant safety inspectionsAccident investigation reportsAccidents and dangerous occurrences -statistics and analysis

Record of tests and examinations of equipmentand structures as per statutesSafe operating procedures for variousoperations~Record of work permitsRecord of monitoring of flammable andexplosives substances at work placeMaintenance and testing records of firedetection and fire fighting equipmentMedical records of employeesRecords of industrial hygiene surveys (noise,ventilation and levels, illumination levels,

airborne and toxic substances, explosive gases)Material safety data sheets

15.

16.17.

18.19.20.

21.

22.23.24.25.

26.27.28.

29.

On-site emergency plans and record of MockDrillsRecords of waste disposalRecords of effluent discharges to theenvironmentHousekeeping inspection recordsMinutes of safety committee meetingsApproval of layouts; and other approval fromstatutory authoritiesRecords of any modifications carried out inplant or processMaintenance procedure recordsCalibration and testing recordsShut down maintenance proceduresIn service inspection manuals, recordsincluding that of material handlingSafety budgetInspection books and other statutory recordsRecords of previous audits

Safety in transportation of hazardoussubstances

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IS 14489 : 1998

ANNEX C

( CZause4.3.3.1SAFETY AUDIT QUESTIONNAIRE

I.

2.

3.

4.

5.

6.

7.8.

9.

IO.

HEALTH AND SAFETY POLICY 19.

Does the organization has a health and safetypolicy?(if yes, please attach one copy)Do you have any corporate safety policy ?(if yes, please attach one copy)Who has signed the health SafeEy policy ?(indicate his position)Whether it is prepared as per guidelines of thestatutory provisions ?When was the safety policy declared andadopted ?

How many times it has been updated tillnow ?

20.

21.

22.

23.

24.

25.

Whether the policy is made know to all ?Whether the safety policy was scrutinized byoutside expert agency ?What was the last date of updation ?Does it find a place in the annual report ?

26.

(C) Safety BudgetSAFETY HEALTH ORGANIZATION

(A) Safety Department

II.

12.i)

ii)

13.

14.

15.

16.

Does the factory has a safety department ?

If yes, furnish the following information :Head of the safety department:

a) Nameb) Designationc) Qualificationd) Experiencee) Status

Strength of the safety department includingsafety ofticers and staff.Does the head of safety department/ safetyofficer report to the chief executive ?

How often are the safety officers retrained inthe latest techniques of total safetymanagement ? What is the frequency ofretraining ?What additional duties the safety officer isrequired to do ?What is the power of safety officer vis-a-visunsafe condition or unsafe act?

(B) Safety Committee (s) 37.

17. Does the factory has a safety committee(s)?Give details of their types, structures and terms

of reference.18. Is the tenure of the safety committee(s) as per

the statute?

How are the members of safety committee (s)selected ? (elected/nominated)How often are the meetings of safetycommittee(s) held ?What are the subjects? Are the problemsdiscussed in the meetings ? (Attach a copy ofagenda and minutes of the last meeting)How are the recommendations of thecommittee(s) implemented ?Are the minutes of the safety committee(s)meetings circulated among the members ?Are the minutes forwarded to the trade union(s)

and chief executive and occupier?How the management and trade union playtheir active roles in supporting and acceptingthe committee(s) recommen- dations ?How are the safety committee(s) membersapprised of the latest developments in safety,health and environment ?

27.28.

29.30.31.32.

33.

34.

35.

36.

38.

39.

What is the annual safety budget?How much percentage is this budget of the totalturnover of the company.How much budget has utilized till date ?Is the safety budget adequate ?How is the safety budget arrived at ?What is the pattern of expenditure for the lastfive years ?What are the approved sanctions for theexpenditure in this budget ?Does this budget get reflected in the annualreport of the company ?

ACCIDENT REPORTING, INVESTIGA-

TION AND ANALYSIS

Whether the accident data for the last threeyears for reportable and non-reportableaccident available ?

Is there any system of classifying andanalyzing the near-miss incidents -andaccidents ? Give the details.

Are all near-miss incidents and accidentsreported and investigated ?

For how many years are the investigationreports retained?

By whom the accident statistics and data aremaintained ?

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40.

41.

42.

43.

44.

45.46.47.

48.

How is the top management apprised of thesedata ?Is the accident statistics effectively utilized ? Ifyes, how ?What nature of injuries occurred during the lastthree years ?How do you ensure implementation of therecommendations to avoid the recurrence ofthe incidents and accidents ?

SAFETY INSPECT-IONS

What type of safety inspections are carried outand what are their frequency ?Is there any system of internal inspection ?Who does the inspections ?Are the check-list prepared for theseinspections ? (Specify item-wise, for example,housekeeping, tire protection, etc).To whom the recommendations are submitted

SAFETY E-DUCATION AND TRAINING

(A) Training

49.50.51.

52.

53.

54.

55.

56.

Is there any training department ?Is there any programme of induction training ?Mention the duration of induction training foreach category of employees.Whether the assessment of the trainee workeris done or not ?

What infrastructural facilities withaudio-visual support are available for training?

Do the programmes cover the plant safetyrules, hazard communication and any otherspecial safety rules or procedures unique to theplant or specific departments ?Whether the training programmes areconducted in the local language ?Whether visits to safety institutions/organizations are arranged ?

(B) Periodic Training/Retraining

57.

58.

59.

60.

61.

Are all the employees trained and what is thefrequency of such training ?Do the training programmes cover safety andhealth aspects and if so how much (in terms ofnumber of sessions/hours) ?Do the trained supervisors train their ownemployees in safety and health aspects ?Is the retraining performed whenever newhazards/process changes are followed/introduced?How are the senior management personneltrained in safety and health ?

62.

63.

64.

65.

66.

IS 14489 : 1998

How many employees have been trained insafety and health in the last five years ? Givebreak up with details.How many man-days/hours are used intraining the employees?How do you ensure that the training is put touse by the employees trained in safety andhealth.What is the training plan for the next two years? Give details.What documentation system has beenestablished regarding safety and healthtraining ?

(C) Safety Communication/ Motivation IPromotion

67.

68.

69.

70.

71.

72.

73.

14.

75.

76.

77.78.

79.

80.

81.

82.

Does the factory has safety suggestionschemes ? Give details.Does your factory participate in National

Awards/Suggestion schemes ?Has your factory been awarded during last fiveyears?Are safety contests organized in the factory?Give details.What are the publications of yourorganization? Do they include information onsafety and health subjects?Is the literature on safety and health madeavailable to the employees?How is the safety and health publicized inyourfactory?

i) Bulletin boards?ii) Post serious accidents?

iii) New letter?iv) Others? Specify

Does the organization celebrate safetyday/week or organize safety exhibition?When was the last safety day/weekcelebrated?

FIRST AID

Are adequate number of first aid boxesprovided ? Give location details ?Is there any first aid/ambulance room ?Are qualified/trained first aids available ineach shift?How many qualified/trained first aides areavailable at each plant/department ?How many persons are trained/givenrefreshers training in first aid in a year?

OCCUPATIONAL HEALTH CENTRE

Whether occupational safety and health centeris provided or not ?Does it conform to the provisions of theexisting legislation ?

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IS 114x9 : 1YYS

83. Are the Medical Attendants/Doctors availablein each shift ?

84. Is ambulance van available in each shift ?85. Any liaison with the nearest hospital(s) ? Give

details.

GENERAL WORKING CONDITION

(A) Housekeeping

86.

87.

88.

89.

90.

91.

92.

93.

94.

95.

Are all the passages, floors and the stairwaysin good condition ?Do you have the system to deal with thespillage ?Do you have sufficient disposable bins clearlymarked and whether these are suitably located?Are drip trays positioned wherever necessary?Do you have adequate localized extraction andscrubbing facilities for dust, fumes and gases ?Please specify.Whether walkaways are clearly marked andfree from obstruction ?Do you have any inter-departmentalcompetition for good housekeeping ?Has your organization elaborated goodhousekeeping practices and standards andmade them known to the employees ?Are there any working conditions which make

the floors slippery ? If so, what measures aretaken to make them safe ?Does the company have adequate measures tosuppress polluting dust arising out from roadtransport?

(B) Noise

96.

97.98.

99.

100.

101.

102.

Are there any machines/processes generatingnoise ? Specify.Was any noise study conducted ?Which are the areas having high-levelnoise ?

Haveengineering and administrative controlsbeen implemented to reduce noise exposurebelow the permissible limits ?Is there a system of subjecting all thoseemployees to periodic audiometric test whowork in high level noise areas ?Whether the workers are made aware of theill-effects of high noise.Whether any personal protectiveequipment along with ear muffs/plugs areprovided and used.

(C) Ventilation103. Whether natural ventilation is adequate or

not?

104.

105.

106.

107.

108.

109.

110.

Whether dust/fumes/hot air is generated in theprocess ? Give details.

Isthere any exhaust dilution ventilation systemin any section of the plant ?

Whether any ventilation study has been carried

out in the section(s) to check the record ?Are periodic/preventive maintenance ofventilation system carried out and record ismaintained ?

Does any ventilation system recirculate theexhausted air in work areas ?

Is the work environment assessed andmonitored ?

Whether personal protective equipment aregiven to workers exposed to dust/fumes andgases ? Give details.

(D) I llumination

111.

112.

113.

114.

115.

116.

117.

118.

119.

120.

121.

122.

Was any study carried out for the assessmentof illumination level ?

Is there any system of periodical cleaning andreplacing the lighting fittings/lamps in order toensure that they give the intended illuminationlevels ?

Are the workers subject to periodic optometrytests and records maintained? Give details.

HAZARD IDENTIFICATION ANDCONTROL

Are all the hazardous areas identified ?

What are the types of hazards (physical- noise,heat, etc, and chemical-fire, explosion, toxicrelease, etc) ?

What steps have been taken to prevent thesehazards ? Give details.

Are there any safety inter-locks, alarms andtrip system ? Give details.

Are these tested periodically ? How often ?

Please specify.Are there any ambient monitoring devices withalarms for leakage of hazardous materials ?Give details.

Are safety audit or HAZOP or any otherstudies carried out and the recommendationsimplemented ? Give details.

What has been the major modification done inplant/process and has the approval of thecompetent authority concerned ?

What decision and monitoring equipment areavailable and used for checking theenvironmental conditions in and around theplant ? Give details.

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TECHNICAL ASPECT

123.

124.

125.

126.

Are written safe operating proceduresavailable for all operations ?Whether the written safe operating proceduresdisplayed or made available and explained inthe local language to the workers ?Whether the safe operating procedures areprepared jointly by the plant and safetydepartments ?What system is used to ensure that the existingsafe operating procedures are updated ? Givedetails.

127.

128.

129.

Have the workers been informed of theconsequences of failure to observe the safeoperating procedures ?Are contractor workers educated and trained to

observe safety at workplace ?Whether contractors workers are permitted onprocess/operations ? Give details.

WORK PERMIT SYSTEM

130.

131.132.

What necessary type of work permits exists inyour factory ? Give details.What are the hazardous chemicals handled?Are the keys kept for individual locks whichare used for electrical lock outs with thesupervisor concerned ?

WASTE DISPOSAL SYSTEM

133.

134.

135.136.

137.

Is identification done for various types ofwastes ? Give details.Are these quantities less than those specifiedby the hazardous wastes. (M anagementHarrdhg Rules, 1989) ?What are their disposal modes ?What are the systems/measures adopted forcontrolling air/water/land pollution?What is the system of effluent treatment plantand whether it is approved by the competentauthority?

138. How are the treated effluent used?

PERSONAL PROTECTIVE EQLJIP-MENT (PPE)

139.

140.

141.

142.

143.

Has a list of required PPE for each area/operation been developed and the requiredPPE is made available to the workers ?Are the safety department and the workersconsulted in the selection of PPE ?Have the workers been trained in proper~use ofPPE ?What is the system of replacement/issue ofPPE ?What are the arrangements for safe custody andstorage of PPE provided to the workers?

Safe Operating Procedures

144.

145.

146.

147.

148.

149.

150.

151.

152.

153.

154.

155.

156.

157.

158.

159.

160.

161.

162.

IS 14489 : 1998

Are the contractors workers provided with therequired PPE ? Who is responsible ? Givedetails.Are the PPE conform to any standard ? Givedetails.Give the details of PPE and also specify theresponsibility for their inspection andmaintenance ?

FIRE PROTECTION

Indicate on a plant layout the location. number(Quantiy) and types of portable fireextinguishers available.Are the fire fighting system and equipmentapproved, tested and maintained as perrelevant standard ?What is the inspection and maintenanceschedule of the above extinguishers ? Who

performs these functions ?Which areas of the plant are covered by firehydrants ? Indicate the locations of the hydrantpoints and how the required pressuremaintained in the system and ensured.What is the capacity of dedicated waterreservoir for supply to the hydrants ? What isthe source of water ?

i) How is the power supply to the firehydrant pump ensured ?

ii) What is the alternate source of supply incase of power failure ? Give details.

Are all personnel conversant with the fireprevention and protection measures ? Givedetails.What percentage of plant personnel and staffand officers, have been trained in the use ofportable fire extinguishers ? Give details.

Do you have fixed or automatic fire fightinginstallation(s) in any section of your plant?

Are the fire alarms adequate and free fromobstruction ?

Do you have fire department ? If yes, givedetails.

What is the system for conducting mock drills? Give details.

Do you have any mutual aid scheme with anyof your neighbouring industry or any localorganization(s) ?

Give details of the existing fire resistant wallsand doors.

Do you have any system of colour coding forall the pipelines for hazardous chemical ? Givedetails including marking of flow directions.

Are there any safe containers for the movementof small quantities of hazardous chemicals ?Give details.

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IS 14489 : 1998

163.

164.

165.

166.

167.

168.

169.

170.

171.

172.

173.

174.

175.

176.

177.

178.

179.

180.

181.

Are all self-dosing fire doors in good conditionand free from obstructions ?How many major and minor incidents/fireswere there in the factory during the last fiveyears ? Give department/plant-wise.

Have all the fires/incidents beeninvestigated and corrective actions taken ?Give break up.

EMERGENCY PREPAREDNESS

Is there an on- site emergency plan for yourfactory ? (attach a copy of the plan)What is the frequency of conducting mockdrills of on-site emergency plan?What are the number and location ofemergency control centre, assembly points?Whether emergency team or the key personnel

identified ?Are suitable and adequate protective andrescue equipment available ? How is theemergency rescue team trained to use theseequipment ?How is the emergency communication withlocal bodies and other organizations ensured?Give details.Is any alternate power source identified ? Givedetails.What is the medical emergency responsesystem ? Give details.Are you a member of any MUTUAL-AID-SCHEME of your area? If so give details.How many emergency alarm system(s) is/areavailable ? Give details.

PLANT LAYOUT AND AREACLASSIFICATION

What is the system of classification ofhazardous zones in the plant for electricalinstallations ? Please specify.Whether periodic inspection and preventive

maintenance of electrical installations is doneby a qualified person and record is maintained?

Whether plant layout with areaclassification has been displayed atappropriate place (s) ?

STATIC ELECTRICITY

Whether the process(s) and equipmentgenerate and accumulate static charge havebeen identified ? Give details.Whether all such equipment are properly

bonded and earthed?How is electrical resistance for earthingcircuits maintained ? Are periodicinspections done and recorded ?

182.

183.

184.

185.

186.

187.

188.

189.

190.

191.192.

193.

194.

19.5.

196.

197.

198.

199.

200.

Are adequate earthing arrangements made atthe terminal points where hazardous chemicalsare handled through pipes ?Are anti-static charge devices fittedwherever necessary ?

Whether these devices are periodicallychecked and maintained by a qualified person?

PRESSURE VESSELS (FIRED ANDUNFIRED)

Give details of the plants, piping and vesselswhich are operated at a pressure greater thanthe atmospheric pressure ?How is it ensured that the working pressureinside the pressure vessels/pressure plants willnot exceed their maximum working pressure

for which it is designed?What means of isolating the pressure vesselsor means to prevent rise in pressure areinstalled ?What standards/codes of practice are adoptedfor design, fabrication, operation andmaintenance of the pressure vessels andrecords maintained?How are the pressure vessels tested ? Givedetails.Is there any competent person for testing thesepressure vessels ? Give details.How are the recorded results verified ?Give details of safety devices available forthese pressure vessels ?Whether log book for pressure vessel andpressure plant has been maintained ?

NEW EQUIPMENT REVIEW

What is the system for effecting any change inthe existing plant, equipment or process?Whether it is approved by the appropriatecompetent authority ?

Whether the P & I diagrams and other relateddocuments are updated accordingly?

LIFTING MACHINES & TACKLE

Whether all the lifting machines are markedwith their S.WL.?

Are all the examinations and testsdocumented in the prescribed form ?

Are all the examinations and tests carried outand certified by competent person(s) ? Givedetails.

Are adequate lifting tackles provided at all theplaces where it is required ? Give details.Are the trained operators engaged foroperating the equipment ? Give details.

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201.

202.

203.

204.

205.

206.

207.

208.

209.

210.211.

212.

213.

214.

215.216.

217.

218.

219.

What is the system of training such 220.operators ? 221.4re all the lifting machines and tacklesnaintained in good conditions and recordmaintained ?

222.

MOBILE EQUIPMENT ANDVEHICULAR TRAFFIC

223.

Are all the mobile equipment in goodcondition 224.? 225.Are trained drivers engaged for fork-lift trucks?What is the system for identifying these driversfrom other drivers ?What system do you adopt to assess theirstandard of driving as poor/fair/ satisfactory/good ?Are there adequate number of warning

signs/signals ?Are the hazards associated with transportationwithin the plant identified and safety measuretaken ? Give details.

226.227.

228.

229.230.

ACCESS

Is adequate safe access provided to all placeswhere workers need to work ?Are all such access in good condition ?Are portable access platforms necessary ? If yes:

i) Are these sufficient ?ii) Are these regularly inspected ?

iii) Are these readily available?iv) Are these provided with toe-boards and

railings ?

231.

232.

233.

234.

Oiling and greasing points:i) Are these located and extended to safe

place clear of moving parts ?ii) Are these easily accessible?

iii) Are these liable to drip into walkways?iv) Whether such workers were trained and

whether they are provided with fit-tightclothings and register is maintained ?

Are all drain covers in good condition andfitting flush ?

235.236.237.

238.

239

240

MATERIAL HANDLING

Are there adequate storage facilitiesavailable ?Are these areas clearly defined ?Are all racks and steel ages in goodcondition ?Have you adequate equipment for handlingmaterials ?

241242

243.

244.

Do the workers know the hazards associatedwith manual material handling ?Where manual handling is necessary, are theworkers been trained ?

245.

I

IS 14489 : 1998

10 they practice this ?10 workers follow safe procedures for storage,f materials ?Whether contractor workers are trained insafety ?What is the system for handling over plant to

:he maintenance department and receivingsack ?1s the system consistently applied ?What is the system for the preventive andpredictive maintenance and how do youEnsure its effectiveness ? Give details.

TANK STORAGE VESSEL AREA

Whether it is pressure vessel or not.Give storage vessels designation (exceedingthreshold quantities specified in MSlHC, Rules1989).

Give the names of storage materials in each ofthem.What are the vessel sizes (capacity in tonnes)?What is the material of construction for eachvessel and what standards followed indesigning/fabricating the vessel?What are the operating pressure andtemperature?What are the vessels location? (Please indicateon-site plan or plot plan)Indicate whether vessels are above ground/underground.

If ny of the tanks storing flammable material,whether electrical installations are flameproofor not?Are these storage vessels bundedidyked?If yes, what is the capacity of the bunds/dykes?Are the vessels properly bonded and earthedand whether periodically checked and recordmaintained?How are vessels isolated in the event of amishap?Are the vessels fitted with remotely controlledisolation valves?Are vessels provided with emergency vent,relief valve, bursting disc, level indicator,pressure gauge, overflow line?Where do such vZnts discharge?Are the vessels provided with alarms for high,level, high temperature and high pressure?Are stand by empty tanks provided foremptying in case of emergencies?What are the provisions made for firefighting/tackling emergency situations aroundthe storage vessels?Has any consequence analysis been carried outfor these vessels?

(If yes, give details)

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IS 14489 : 1998

246

247

248

249

250

251

252

253

254

255

256

257

258

259

260

What periodical testings are carried out on thevessels to find out the integrity of the vessels?

Whether these tests are certified by theapproved competent persons?

Whether log sheets are filled up on daily basis

for recording the parameters of thesevessels?

ON-SITE GAS CYLINDERS STORAGEAREA

What are the various gas cylinders used in theplant? (give details).

What are the storage facilities?

What are the measures taken for combatingany emergency in the cylinders storage area?

Are valid licenses available for storing all these

cylinders?Whether integrity test certificates are obtainedfrom the suppliers of the cylinders?

COMMUNICATION SYSTEMADOPTED IN PLANT

Are public addresssystem available in all plantareas?

Are public address systems provided withuninterrupted power supply?

Whether public address system is checkedperiodically for its proper functioning?

Is there any hot line provided to fire station?

What is the means of communicatingemergency in the plants?

TRANSPORTATION

What potentially hazardous -materials aretransported to or from the site (includingwastes)?

What modes of transport are used:i) Road?

ii) Rail?

iii) Pipelines?

261.

262.

263.

264.

265.

266.

267.

268.

269.

270.

271.

272.273.

274.

275.

276.

277.

278.

ROAD

Does the company employ_licenced vehicle ofits own/outside sources?Are the loading/unloading procedures on- siteand safety precautions displayed?Are loaded tankers or trucks parked in aspecific area on-site?Do all truck and tanker drivers carry TREMcard or instruction booklet?Do all truck and tanker drivers get training inhandling emergencies during transport?

RAIL

What hazardous materials are transported byrail?Does the company have a direct siding on site?

Are tankers or others wagons used intransportation?

PIPELINES

What materials are transported to and from thesite by pipeline?Are the pipelines underground oroverground?Are corrosion protection measuresemployed in pipelines?Whether intermediate booster pumps are used?What is the maximum, minimum and

average transfer rates?Are the pipelines extended in the publicdomain?Are the pipelines dedicated for each type ofchemicals?Are the pipelines fitted with safetyequipment such as leak detectors, automaticshut-off valves, etc?What is the frequency and method of testing ofthe pipeline?Is there written procedure for tackling leakagesin pipeline?

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IS 14489 : 1998

SHRI K. C. GlNTA

Members

SHRI PREM BAWUASHRI B. VIJAY K~MAR (Rlternccte)

SHRI BHAGWATI PRASADSHRI SATISI-I CHANDER Alternure)

DR A. K. BORALSIIRI R. SRINIVASAN A/&r-flute)

DR D. R.CHAWLASHRI M. K. BANERJEE (Alrernute)

DIRECTOR MINES SAFETY)SHRI A. K. R~DRA (Alrejncrre)

SHRI V. K. GOELSHRI M. L. AHUJA (A ter/lcJte)

SHRI J. P. GOENKASHRI N. DUITA Alft~tt~te)

SHRI M. KANTSHRI KIRIT MARU Alternute)

SHRI G. S. KASHYAPDR V. K. JAIN

SHRI K. SENGUPTA Atre,no/e)SHRI M. K. MALHOTRA

SHRI H. N. MIRASHIDR A. S. GHOSHAL

SHRI R. H. BIIALEKAR (Alternate)

SHRI A. K. ACHARYASHRI P. K. NAIR (Alferrrufe)

SHRI S. K. MUKHERJISHRI A. K. GHOSH Alrerncrte)

SHRI L. C. GU~TASHRI H. S. RAWAT Alterncue)

SHRI S. NARAYAN

SHRI M. SRIVASTAVA

SHRIS. N. MATH~JR Alrernclte)

SHRI H. N.Gu~A

SHRI R. P. BHANUSHALI Akrnufe)SHRI M. R. SAMPATH

SHRI 0. N. DAGA A / ~ c v N c J ~ ~ )

DR S. SADULLASHRI G. SWAMINATtiAN Akrnute)

REPRESENTATIVESHRI P. N. SANKARAN

SHRI V. K. SRIVASTAVA Alternure)

SHRI G. P. YADAVSHRI N. JAIPAL Alternate)

SHRI R. K. PODDARDR R. S. RAJACOPALAN,

Director (Chem)

ANNEX D

( Foreword

COMMITTEE COMPOSITION

Industrial Safety Section4 Committee,CHD 8

Represeninq

National Safety Council, Mumhai

Hindustan Aeronautics Ltd. Bangalorc

Employees State Insurance Corporation, Calc utta

Ministry of Defence(DGQA), New Delhi

Department of Industrial Policy nnd Promotion, New Delhi

Directorate General of Mines Safety, Dhanhad

Central Boiler Board, New Delhi

Mining, Geological and Metallurgical Institute of India, Calcutta

Safety Appliances Manufacturers Ass ociation, Mumhai

Office of the Development Commissioner ( .%I), New Delhi

Standing Committee on Safety for Steel Industry, SAIL, Ranchi

Directorate General Factory Advice Services and Lahour Institute, Mumbai

Factory Inspectorate, Government of Maharashtra, Mumb aiChief Controller of Explosives, Nagpur

Central Mining Research Ins titute, Dhanbad

Standing Fire Advisory Council, New Delhi

Airport Authority of India (National Airpor t Authority), New Delhi

Bhahha Atomic Research Centre, MumhaiMinistr y of Petroleum and Natural gas (Oil Industries Safety Directorate),

New Delhi

National Safety Council, Mumbai

Indian Cotton Mills Federation, Mumhai

Central Leather Research Institute. Chennai

Confederation of Indian Industries, New Delh i

Indian Space Research Organization. Shriharikota

National Institute of Occupational Health, Ahmedabad

Larsen and Touhro Ltd (ECC Consumers Group), Chen nai

Director General, BIS Ex-officio Member)

Member Secretmy

SHRI S. MAZUMDERJoint Director (Chem), BIS

( Confinurd ON p~,qe I6

15

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Code of Practice on Industrial Safety Subcommittee, CHD 8:4

SHKI H. N. GuPT.4M~lUX~,i

SHRI M. K. MALHOTRA

DR V. K. JAIN

SHKI K. SENGIIWA (Almxcm)

DR A. S. GIIOSHAI.

SIIKI R. H. HIIALEKAR Atetmrf

DIREcTOR (MINES SAFETY)

SCIRI A. K. RClURA (~//m~fe)

StiRi H. N. MIKASHISHRI S. K. MUKHERIEE

SHRI A. K. GHOSH (/t/fcmtrW)

SIIRI M. SRIVASTAVA

SHRI S. C. GUPTA (~/tC,W/e)

REPRESENTATIVE

SIIRI R. K. POnlIAR

DR S. CHATTOPADHYAY

SIIRI K. K. DUFTA (Altemccte)

,&PRT.SI.NIATlVE

SHRI A. K. ROHATGI

DR S. NAND

SHRI A. H. LAL

SHRI P. CIIINNA (/tfteWfUW)

DR P. K.GIIOSII

SHRI H. N. SRIIIAKI

DK T. K. CIIATTER1T.E (A/tcr.rwrc)

REPRESEWATIVE

National Safety Council. Mumbai

Directorate General Factory Advice Services and Lahour Institute. MumhaiStanding Committee on Safety for Steel Industry, SAIL. Ranchi

Chief Controller of Explosives, Nagpur

birectornte General of Mines Safety, Dhanbad

Factory Inspectorate. Government of Mahnr:L

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Bureau of Indian Standards

BIS is a statutory institution established under the Bureau of Indian Standards Act, 1986 to promoteharmonious development of the activities of standardization, marking and quality certification of goodsand attending to connected matters in the country.

Copyright

BIS has the copyright of all its publications. No part of these publications may be reproduced in any formwithout the prior permission in writing of BIS. This does not preclude the free use, in the course of

implementing the standard, of necessary details, such as symbols and sizes, type or grade designations.Enquiries relating to copyright be addressed to the Director (Publications), BIS.

Review of Indian Standards

Amendments are issued to standards as the need arises on the basis of comments. Standards are alsoreviewed periodically; a standard along with amendments is reaffirmed when such review indicates thatno changes are needed; if the review indicates that changes are needed, it is taken up for revision. Usersof Indian Standards should ascertain that they are in possession of the latest amendments or edition byreferring to the latest issue of BIS Handbook and Standards: Monthly -Additions.

This Indian Standard has been developed from Dot : No. CHD 8 ( 730 ).

Amendments Issued Since Publication

Amend No. Date of Issue Text Affected

BUREAU OF INDIAN STANDARDS

Headquarters:

Manak Bhavan, 9 Bahadur Shah Zafar Marg, New Delhi 1 IO 002Telephones : 323 01 31,323 33 75,323 94 02

Regional Offices :

Central : Manak Bhavan, 9 Bahadur Shah Zafar MargNEW DELHI I 10 002

Eastern : l/l4 C. LT. Scheme VII M, V. I. P. Road, ManiktolaCALCUTTA 700 054

Northern : SC0 335-336, Sector 34-A, CHANDIGARH 160 022

Southern : C. I. T. Campus, IV Cross Road, CHENNAI 600 1 13

Western : Manakalaya, E9 MIDC, Marol, Andheri (East)MUMBAI 400 093

Branches : AHMADABAD. BANGALORE. BHOPAL. BHU %ANESHWAR. COIMBATORE.

Telegrams : Manaksanstha(Common to all offices)

Telephone

1

323 76 17323 38 41

{

337 84 99,337 85 61337 86 26,337 91 20

1

60 38 4360 20 25

1

235 02 16, 235 04 42235 15 19,235 23 15

832 92 95, 832 78 588327891.8327892