Std-145 General Safety Audit Guidlines

OISD - GDN - 145
REVISION - 1
FOR RESTRICTED
CIRCULATION ONLY
GUIDELINES
ON
INTERNAL SAFETY AUDITS
(PROCEDURE AND CHECKLISTS)
OISD-GDN-145
Revision - 1
First Edition, July 1995
Amended Edition, September 2001
OIL INDUSTRY SAFETY DIRECTORATE

Government of India
Ministry of Petroleum and Natural Gas
1
OISD - GDN - 145
Revision - I
July, 1995
Amended Edition,
September 2001
FOR RESTRICTED
CIRCULATION ONLY
GUIDELINES
ON
(PROCEDURE AND CHECKLISTS)
Prepared by:
COMMITTEE ON “ INTERNAL SAFETY AUDITS”
OIL INDUSTRY SAFETY DIRECTORATE

2ND FLOOR, “KAILASH”
26, KASTURBA GANDHI MARG
New Delhi - 110 001.
2
NOTES
OIL INDUSTRY SAFETY DIRECTORATE publications are

prepared for use in the Oil and gas industry under Ministry of
Petroleum and Natural Gas. These are the property of Ministiry of
Petroleum and Natural Gas and shall not be reproduced or copied
and loaned or exhibited to others without written consent from OISD.
Though every effort has been made to assure the accuracy

and reliability of data contained in these documents, OISD hereby
expressly disclaims any liability or responsibility for loss or damage
resulting from their use.
These documents are intended only to supplement and not

replace the prevailing statutory requirements.
Note 3 in superscript indicates the

modification/changes/addition based on the
th
amendments approved in the 19 Safety Council
meeting held in September, 2001July, 1999
3
FOREWORD
Safety Audits have been conducted in the oil/gas
industry in one form or other. Generally, Safety Audits are of two
types viz. Internal Safety Audits and External Safety Audits. While
methodology to be adopted for carrying out the External Safety
Audits is separately dealt with, this document contains
guidelines for conducting Internal Safety Audits in a professional
manner and is expected to assist the industry further in
maintaining and improving the Safety.
Different aspects of the Internal Safety Audits

starting from the need of such Audits, methodology,
preparation of reports, follow up actions on the
recommendation of the Audit Reports have been covered in
Section I of this document- "Internal Safety Audit Procedures".
In addition, comprehensive Check Lists are given in

Section II of the Document covering typical areas in
the oil/ gas industry. These Check Lists would be
useful tool for undertaking in-depth and systematic
Internal Safety Audits and would go a long way in accelerating
audits to ensure that no aspect is overlooked while carrying out
such audits.
The present document on Internal Safety Audits (Proce-

dure and checklists) was revised by a Functional Committee con-
stituted from amongst members nominated by the industry for
the committee comprising of refining, marketing, pipelines and gas
processing disciplines.
It is hoped that the provision of this document, if

implemented objectively will go a long way in improving the safety in
the oil & gas industry.
This document will be reviewed periodically for

improvements based on the new experiences and better
understanding. Suggestions from users/industry members may be
addressed to:
The Co-ordinator
Committee on Internal Safety Audits
Oil Industry Safety Directorate
2nd Floor, “Kailash”
26, Kasturba Gandhi Marg
New Delhi - 110 001.
4
INTRODUCTION
This is the second edition of the OISD

Guidelines on Ìnternal Safety Audits' (Procedure and
Checklists), first edition of which was published in October,
1989.
The first edition was prepared by OISD and did not

have a regular Functional Committee. A Functional
Committee for the objective of revising the same was
therefore constituted.
The original document has been now revised to

include a new chapter on Internal Audit of cross-country
pipelines in order to make it broad based and
thoroughly updated with the experience gained during
the first round of External Safety Audits of refineries, gas
processing plants, Marketing terminals/LPG Bottling
Plants etc. As during the interim period a number of new
OISD Standards/ Guidelines have been published,
reference to the same has also been provided wherever
required.
With the issuance of this edition, the guidelines

contained in earlier edition stands revised.
5
SCOPE
These guidelines are applicable

for refineries/on-shore gas processing
units(excluding all oil-field operations)/ and
marketing installations. Items which may not be
applicable in Marketing have been separately
identified by an asterisk (*) mark. However, it
should be clearly understood that in addition to
check points contained in these guidelines locations
may like to further improve the checklist in order to
meet any specific requirements of the respective
safety policy of the concerned organisation.
In the case of terminals where no

pipeline transfer is taking place, chapters 1,2,3,5,6
and 9 would be applicable.
In the case of terminals where

pipeline transfer is taking place, chapters 1,2,3,5,6,9
and 10 will be applicable.
OISD-STD-144 on “ LPG
Bottling Plant Operations” has recommended a
periodicity of once a year for Internal Safety Audit of
individual LPG Plant (Marketing). The inspection
and Maintenance System as well as Electrical
Safety Audits are to be carried out based on Internal
Audit Checklists as stipulated in OISD-STD-144.
The OISD-145 guidelines are

exhaustive and therefore be adopted for carrying out
a comprehensive Internal Safety Audit of LPG
Bottling Plants (Marketing) for which chapters
1,2,3,7,8 will be applicable
6
COMMITTEE ON
ÌNTERNAL SAFETY AUDITS'
REVISION-I
--------------------------------------------------------------------------------------------------------------------------------------
NAME ORGANISATION
--------------------------------------------------------------------------------------------------------------------------------------
LEADER
Shri Barath Balan Hindustan Petroleum Corporation Ltd.

(Marketing)
MEMBERS
Shri M.N. Ahmed Indian Oil Corporation Ltd.

(R&P Division - Pipelines)
Shri S.K. Ray Ex-Official Bharat Petroleum Corporation Ltd.

( Marketing )
Shri T.S.Charvethia Bharat Petroleum Corporation Ltd.

( Refinery )
Shri S.N.Rao Indian Oil Corporation Ltd.

(Refineries & Pipelines Division)
Shri G.C.Sharma Bongaigaon Refinery & Petrochemicals Ltd
Shri M.Bhaskar Rao Hindustan Petroleum Corporation Ltd.

( Refineries )
Shri I.J.Shroff Hindustan Petroleum Corporation Ltd.

( Refineries )
Shri C.T.Ananthakrishnan Indian Oil Corporation Ltd.

(Marketing Division)
Shri K.Madhusudanan Cochin Refineries Ltd.
Shri D.Madhukar Rao Gas Authority of India Ltd.
MEMBER CO-ORDINATOR
Shri S.C. Gupta Oil Industry Safety Directorate
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In addition to the above, several other experts from Industry contributed on the preparation, review
and finalisation of this document.
7
OISD - GDN - 145
REVISION-I
GUIDELINES
ON
SECTION - 1 INTERNAL SAFETY AUDIT

PROCEDURE
SECTION - 2 INTERNAL SAFETY AUDITS

CHECKLISTS
8
SECTION - 1

PROCEDURES
9
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SECTION DESCRIPTION PAGE NO.
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1.0 INTRODUCTION
2.0 OBJECTIVES OF SAFETY AUDITS
3.0 SCOPE OF SAFETY AUDITS
4.0 TYPES OF SAFETY AUDITS
5.0 METHODOLOGY OF INTERNAL SAFETY AUDITS
5.1 Frequency of Audits
5.2 Formulation of multi-disciplinary Audit Teams
5.3 Duration of Audits
5.4 Use of Safety Audit Check Lists
5.5 Preparation before Site Visits for

Safety Audits
5.6 Briefing
5.7 Site Inspections
5.8 Discussions
5.9 Study of Documents
6.0 PREPARATION OF AUDIT REPORTS
7.0 FOLLOW UP OF AUDIT REPORTS
8.0 IMPLEMENTATION OF RECOMMENDATIONS
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10
PROCEDURES
1.0 INTRODUCTION
Identification of vulnerable areas and specific potential hazards, is one of the prime
function of loss prevention in oil industry. Safety audit is an important tool in undertaking this
function.
2.0 OBJECTIVES OF SAFETY AUDITS
While the basic aim of safety audits is to identify the areas of weaknesses and strengths,
safety audits are undertaken to meet different specific objectives viz.-
1. To identify any design deficiencies and also any weaknesses which might
have cropped up during modifications / additions of facilities.
2. To ensure that fire protection facilities and safety systems are well maintained.
3. To ensure that operating / maintenance procedures, work practices are as per

those stipulated in the manuals and standards, which might have degraded
with time.
4. To check on security, training, preparedness for handling emergencies

and disaster management etc.
5. To check the compliance of statutory regulations, standards, codes, etc.
6. As a social objective to cater to public opinion and concern for safe

environment. This also improves public relation of the organization.
3.0 SCOPE OF SAFETY AUDITS
A Safety Audit subjects various areas of a company's activities to a systematic critical

examination with the objective of minimizing loss. This includes all the components of the
system viz. management policy, attitudes, training, design (Process, Mechanical,
Electrical, etc.) aspect, layout and construction of the plant, operating Inspection &
Maintenance procedures, emergency plans, personal protection standards, accident records.
4.0 TYPES OF SAFETY AUDITS
Two types of Safety Audits are proposed to be carried out as below :
I) Internal Safety Audit

ii) External Safety Audit
11
Audit conducted by Internal Audit teams of the organisation is categorized as Internal Safety
Audit.The methodology for carrying out such Internal Safety Audit is described in greater detail
under paras 5.0 to 8.0. Internal Safety Audits will be coordinated by local management under
the overall direction from the Corporate Office.
External Safety Audits will be carried out by outside teams consisting of technical experts from other
organizations in oil industry, professional bodies and statutory authorities under the overall
coordination of OISD.
5.0 METHODOLOGY OF INTERNAL SAFETY AUDITS
5.1 FREQUENCY OF AUDITS:
All the facilities in a particular Refinery/Installation should be covered minimum once every
year. In case of LPG bottling plants the internal safety audit should be conducted minimum
once a year as per OISD-STD-144. However, facilities' design can be audited every 3 years or
after any major modification or additions. For this purpose, the individual organisation/ installation
should draw up a calendar in advance for carrying such audits for every calendar year which
should be made known to all the Departments and concerned Area Managers. The areas to be
audited should be clearly identified and logically grouped. The suggestive groupings in case of a
Refinery Installation are given below. Similar groupings can be done for other types of
Installations. However, this could be modified depending upon layout and complexity of the
individual installation.
Group -I All LPG Storage, filling & dispatch facilities.
Group – II All dispatch facilities like Tank-Wagon loading Tank - lorry loading, Bitumen
filling and dispatch facilities.
Group - III Oil Movement & Storage (OM&S)

(Rest of all the facilities other than those covered under Group I & II, including TEL
blending)
Group - IV PROCESS UNITS :
Sub Groups -
IV - A Atmospheric / Vacuum Units
IV - B Visbreaking, Coking, Bitumen Blowing Units.
IV - C Secondary Processing Unit like FPU / FCCU/HCU & H2 along with Treating
Units.
IV - D Naphtha HDS, Cat-Reforming, Kero / Diesel HDS etc.
IV - E N2 & Others.
Group - V Power House, Electrical Sub-stations, Water Block, Utilities, Effluent Treatment.
Group - VI Miscellaneous other facilities such as Workshops, Warehouse Laboratories etc.
Group - VII General Audit, Fire Fighting and Safety, Layouts etc.
9
5.2 FORMATION OF MULTI-DISCIPLINARY AUDIT TEAMS:
The Internal Audits should be carried out through multidisciplinary audits teams. The composition
of the Internal Safety Audit may vary depending on the Group and areas to be audited, however,
person(s) concerned should have necessary experience and background to undertake in-depth audit in
a particular discipline. A team of 4 to 5 experienced officers from various disciplines viz. Process /
Production, Maintenance / Inspection, Electrical, Instrumentation, Fire & Safety and with the
activity involvement of concerned Plant / Area Manager is suggested. One of the team members should
be nominated as the leader of the audit team. In multi-unit organizations, the team members could also
be drawn from the Head Office / Corporate Office and other operating Units under its control.
5.3 DURATION OF AUDIT
Depending on the nature of audit and type / complexity of the installations in the selected group, the
duration of internal safety Audit can be fixed. This may vary from 2 to 7 working days for facilities under
each group.
5.4 USE OF SAFETY AUDIT CHECK LISTS
Check lists are the most useful tool for undertaking systematic Safety Audit. Even for a skilled and
well qualified engineer a good check list would be necessary as a guide. Like a code of practice, a
Check List is a means of pooling the knowledge and hard won experience and ensures that no
important aspect is overlooked or forgotten. Such check lists help maintaining uniformity and speeding up
the audits.
In Section-II of this document, detailed model Checklist covering important areas are given. It is
suggested that oil industry members should adopt these model check lists for carrying out
Internal Safety Audits.
5.5 PREPARATION BEFORE SITE VISITS FOR INTERNAL SAFETY AUDITS:
Before the safety Audit team visits any particular facility for carrying out Safety Audit, it would be essential
to study all relevant documents as below to get complete picture :
- Layouts
- P & IDs
- Operating Manuals
- Maint. / Inspection Manuals
- Fire and Safety Manuals, etc.
Depending upon the nature of audit more emphasis can be given to study specific documents. All the
audit team members should study these documents in advance to know the details of the installation.
5.6 BRIEFING:
Before beginning of each audit, all concerned persons of the area/installation be briefed by the team leader
about the purpose of the audit. No impression should be left that audit will throw bad light on them.
5.7 SITE INSPECTIONS:
Most of the information could be gathered through site inspection using ready-made check lists. The
auditors should enter their observations under the remarks column and not simply state "yes" / "no".
Wherever necessary, observations should be recorded in separate sheet. Inspection should be carried out
accompanied by Installation / Plant Manager or the assigned officials.
10
5.8 DISCUSSIONS:
Further information can also be gathered through discussions (formal & informal), with site personnel and
Installation / Plant Manager, who is in-charge of the area or other site officers. The audit team should
interact with persons from various disciplines such as Production, Maintenance, Electrical,
Instrumentation, etc.. Formal discussions could be in the form of brief periodical sessions while informal
discussions could be over a cup of tea with personnel working in the area.
5.9 STUDY OF DOCUMENTS:
In addition to the documents which are already studied before inspection of the facilities, other
documents, such as Operating Instructions, Standing Orders, Log Books, Log sheets, Accident Records,
Minutes of Safety Committee Meetings etc. may also be studied as required.
6.0 PREPARATION OF AUDIT REPORTS
The work of the Internal Safety Audit item should be presented in the form of a Safety Audit Report
for each group which should contain observations & recommendations and also in brief the
modalities adopted in conducting audit and the names of the audit team members.
Before finalizing the report, the Safety Audit Team can give a presentation as feedback to the Operating /
Management personnel of the Area / Installation. Additions or deletions could be made in the
draft report based on the discussions and comments received during the presentation. This approach is
always constructive and does not undermine the technical competence of the audit team.
7.0 FOLLOW UP OF AUDIT REPORTS
Generally, the Internal Safety Audit Reports are submitted to the concerned authority who appoints the
audit team for undertaking needful follow up actions. Only the appointing authority should exercise
judgement in rejecting any of the recommendations. The appointing authority shall be of senior
management level ( General Manager and above ).
The crux of the safety audits lie in removing the weakness identified during the audit. Sometimes audit
reports identify only the problem / weakness, but not the solution.
In such cases, it would be necessary to undertake a detailed study of the specific area and to identify the
rectification measures. Wherever the necessary in-house expertise is not available for detailed studies,
help of consultants / professional bodies should be sought for.
8.0 IMPLEMENTATION OF RECOMMENDATIONS
The final and most important phase is the implementation of recommendations. A senior person should
be nominated for coordinating implementation of all accepted recommendation under a time bound
program. Senior management should review the progress of implementation of recommendations
periodically through Management Safety Committee meetings and other review meetings.
11
SECTION : 2
CHECKLISTS
12
SECTION : 2
INTERNAL SAFETY AUDIT

CHECKLIST
CONTENTS
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Sr. CHAPTER SAFETY AUDIT PAGE NOS.
CHECK LIST NO.
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1. GENERAL SAFETY AUDITS OISD-GDN-145-01 6 - 11
2. FIRE PROTECTION OISD-GDN-145-02 12 - 18
3. LAYOUTS OISD-GDN-145-03 19 - 23
4. PROCESS PLANTS OISD-GDN-145-04 24 - 33
5. OIL STORAGE AND MOVEMENT OISD-GDN-145-05 34 - 38
6. POL LOADING AND UNLOADING OISD-GDN-145-06 39 - 51
7. LPG BULK LOADING / OISD-GDN-145-07 52 - 59

UNLOADING
8. LPG BOTTLING AND DISPATCH OISD-GDN-145-08 60 - 68
9. ELECTRICAL SYSTEM OISD-GDN-145-09 69 - 79
10. CROSS - COUNTRY PIPELINES OISD-GDN-145-10 80 - 87
ANNEXURE 88
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13
OISD-GDN - 145-01
REVISION I
SAFETY AUDIT CHECKLIST No.OISD-GDN-145-01
GENERAL SAFETY AUDITS

CONTENTS
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1.0 ORGANISATION AND ADMINISTRATION
1.1 Management Philosophy

1.2 Procedures
1.3 Safety Audits
1.4 Safety Committee Meetings
1.5 Safety consciousness & Propagation
1.6 Work Permit System
1.7 Contingency/ Disaster Plan
1.8 Plant Security
2.0 INDUSTRIAL HAZARD CONTROL
2.1 House Keeping

2.2 Machine Guarding
2.3 General Safety features
2.4 Maintenance of Tools and Tackles
2.5 Materials handling
2.6 Personnel Protective Equipment
2.7 Toxic Materials and Occupational Health
3.0 EMPLOYEE TRAINING
4.0 FIRES, ACCIDENTS AND NEAR MISSES
4.1 Reporting formats

4.2 Reporting Procedures
4.3 Follow up of Recommendations
4.4 Maintenance of Records & Data
4.5 Review of Accidents Data
14
OISD-GDN-145-01
SAFETY AUDIT CHECKLIST
1.0 GENERAL SAFETY AUDITS
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ITEM AUDITOR REMARKS
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1.0 ORGANIZATION AND ADMINISTRATION:
1.1 MANAGEMENT PHILOSOPHY
a) Whether the declared safety policy is made

available to all concerned in written form ?
b) When updated last ?
c) Does the employees contribution towards safety

form a part of the appraisal system ?
1.2 PROCEDURES
a) Whether procedures are well defined and

manuals are available & accessible plant /
facility wise for the following functions ?
- Operation
- Inspection and maintenance
- Electrical
- Mechanical
- Instruments
- Civil
- Fire fighting & Safety
- Emergency and disaster management plans
b) When were these documents updated last ?
1.3 SAFETY AUDITS
a) When was last External/Internal Safety

Audit carried out ?
b) Whether accepted safety audit

recommendations are implemented with time
bound schedules ?
1.4 SAFETY COMMITTEE MEETINGS
Whether Safety Committee Meetings are held

regularly ?
15
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ITEM AUDITOR’S REMARK
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-
1.5 SAFETY CONSCIOUSNESS & PROPAGATION
a) Whether following items have been taken care of ?

Display of (in languages widely understood)
- sequence of operations where critical / batch

operations are performed.
- Safety posters/slogans.
- Safety precautions at strategic points
through sign boards.
b Whether fire & safety training programs are

conducted periodically and are in line with
OISD-STD-154 ?
c) Whether Safety awareness competitions

are held periodically ?
- Type
- Frequency
- Participants
Any other Motivation scheme exists ?
1.6 WORK PERMIT SYSTEM
Whether work permit system meet the requirements

of OISD Standards 105/137 ?
1.7 CONTINGENCY/DISASTER PLAN
a) Whether disaster management plans are

available for different possible types of
scenarios?
b) Whether all the concerned personnel are given

their individual copies?
c) Whether these copies are available at central

place, for emergency uses?
d) Whether these plans are approved by

concerned authorities ?
e) Are mock drills being conducted ?
f) Whether the feed back generated from mock

drills is utilized to improve the plans?
16
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5. Are responsibilities of various neighboring

industrial units, discussed and recorded ?
Whether the duties of various coordinators
and team members well defined ?
6. Are the following information included in the DMP

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1.8 PLANT SECURITY
a) Whether installation has boundary

wall/fence as per prescribed norms?
b) Whether gates are manned?
c) Whether identity badges/cards are issued and

worn by employees, visitors and contractors
personnel for admission to restricted areas?
d)How it is ensured that visitors/contractor personnel

do not trespass into non permitted areas?
e)Whether frisking is done for

contractor personnel / visitors / employees; if
so, how much percentage is covered under
each category?
f) Whether Crisis Management Scheme for BOMB

Threat exists?
g) Whether watch towers exist?
2.0 INDUSTRIAL HAZARD CONTROL
2.1 HOUSE KEEPING

Ratings *
1 2
- Operating areas - -
- Work shops - -
- Stores / godowns / yards - -
- Loading gantries - -
- Effluent treatment facilities - -
- Tank farms - -
- Storm water channels - -
- Utility block - -
- Electrical substation
- Fire water tank
- Any other areas - -
2.2 MACHINE GUARDING
- Rotary equipment in operating

areas - -
- Workshops - -
17
- Others - -
2.3 GENERAL SAFETY FEATURES

Check For:
- unprotected Floor openings
protected - -
- Slippery defective floors - -
- Stairway surfaces - -
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-- Inadequate illumination - -
- Ventilation - -
- Cross-overs over piping - -
- Platforms/Hand rails - -
- Walk ways in tank farm area - -
- All intrinsic safety devices - -
(For refinery,ref.to 1.7 of OISD-
145-04)
*Ratings:(Notation Followed)
1: Not meeting requirement

2: Meeting requirements satisfactorily
2.4 MAINTENANCE OF TOOLS AND

TACKLES
* Whether all lifting tools and tackles are

tested as per statutory requirements and
record maintained?
2.5 MATERIALS HANDLING( Mechanised/

manual)
Whether safe lifting methods and proper

protective equipment are used?
2.6 PERSONNEL PROTECTIVE EQUIPMENT
a) Whether requirements are identified as per

operating manuals / standards?
b) Are these readily available at the time need?
c) How periodically these are inspected and

records maintained?
d) Whether personnel are trained for effective

use?
2.7 TOXIC MATERIALS AND OCCUPATIONAL

HEALTH
a) Are there any toxic materials in use ?
18
b) Whether relevant personnel protective
equipment is available (Ref. Section 2.6) as
per requirement?
c) Is storage of toxic materials proper?
d) Is disposal of containers of toxic materials safe ?
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-
e) Is there display of Do's and Dont's for handling of
toxic chemicals?
f) How the Health monitoring is done. Whether

records are maintained ?
g) Is First Aid available for toxic chemicals handled?
h) Whether proper communication system exists?
i) Is there any monitoring of work environment for

toxic chemicals /gases etc. and records maintained
thereof? Whether material safety data sheet
displayed Note 3
3.0 EMPLOYEE TRAINING

-
a) Whether the training given for all employees
(operators / technicians / engineers) is in line with
OISD- STD-154 w.r.t following items :
- syllabi
- course materials
- class room/field on job training
- on job
- fire and safety
b) Whether Refresher courses are conducted for

technical personnel?
c) What is the evaluation and qualifying system?
d) How employees are Motivated for safety

performance?
e) How the contractor personnel are trained/briefed

w.r.t safety procedures?
f) Whether the T/T crew are trained as per the

C.M.V.Rule 9 ?
4.0 FIRES, ACCIDENTS AND NEAR MISSES
4.1 REPORTING FORMATS
19
Whether reporting formats as per OISD-GDN-107
are available for (preferably separate)?
- fires and explosions

- accidents causing injuries to personnel
and damage to equipments and
products (without the explosion/ fire)
- Near misses
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4.2 REPORTING PROCEDURES
a) Whether responsibilities are clearly defined as

regards to preparation of the reports?
b) Who receives the reports?
c) Whether all minor incidents and near misses as

reported to Safety Dept/Concerned authority?
4.3 FOLLOW UP OF RECOMMENDATIONS
4.3.1 Implementation
a) Whether responsibility is assigned for

implementing the recommendations?
b) Whether the recommendations are implemented

with time bound schedules?
c) How far the recommendations arising out of

previous accidents are implemented?
4.3.2 Dissemination
a) Whether the procedures /systems are

established & streamlined for dissemination of
information?
b) What is the MIS upto Chief Executives level

w.r.t information on fires, accidents and near
misses?
4.4 MAINTENANCE OF RECORDS & DATA
a) Accident statistics of last how many years

are available ?
b) If required, how fast any case history could

be located?
- w.r.t specific case

- based on particular area/type
20
4.5 REVIEW OF ACCIDENTS DATA
a) Is there any system to periodically review the

trends of accidents for taking necessary
actions ?
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-
b) Whether any review is under taken at top
management/ corporate level periodically, to
review the safety performance and new goals
are set up?
21
OISD-GDN-145-02
REVISION I
FIRE PROTECTION
CONTENTS
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1.0 PHILOSOPHY AND STANDARDS 13
2.0 FACILITIES 13
2.1 Fire water 13
2.2 Fire Hydrant System 14

2.3 Foam System 14
2.4 Fire Station 15
2.5 Fire Extinguishers 15
2.6 Fire Hoses and Accessories 15
2.7 Protective/ Safety Equipment 15
2.8 Others 15
3.0 PROCEDURES 16
3.1 Organisations 16
3.2 Disaster Management Plan 17
3.3 Inspection and Testing facilities 17
3.4 Training 17
3.5 Checklist for DMP 18
22
OISD-GDN-145-02
2. FIRE PROTECTION
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ITEM AUDITOR'S REMARKS
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In order to evaluate the adequacy of fire fighting

facilities and procedures, answers should be
obtained for the following four basic queries:
1. Are the facilities adequate and reliable

for anticipated fires ?
2.Is manpower available and effectively trained to

handle the fire fighting equipment.
3.Are emergency control procedures adequately

established.
Since the scope under each query is too broad and it

is difficult to give simple answers, these are
divided into a number of simpler items/ questions
which could be evaluated/answered with reasonable
clarity.
1.0 PHILOSOPHY AND STANDARDS
Does basic philosophy for designing the fire

fighting facilities follow OISD 116 (for
Refinery),OISD 117(for Marketing-POL) and OISD
144 (LPG bottling plants) as necessary ?
2.0 FACILITIES
Whether following facilities are provided

adequately and have the necessary efficacy.
2.1 FIRE WATER
2.1.1 Fire water storage
a.What is the capacity & how was it determined
b.Is it sufficient ? Is the storage AG/UG or other

wise ?
c.What are replenishment source ? Are they

adequate ?
d.What's the internal replenishment rate ?

23
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2.1.2 Fire Water Pump :
a. Is location away (from hazardous area) ?

b. What's the power source ? How many are diesel
& elect driven ?
c. What's the stand by philosophy ?
d. What's the capacity of each pump and at what
head ?
e. What's the priming system?
f. Is there any jockey pump ?
g. What's the capacity ? What's set pressure?
h. What's fire water pump starting system -
manual/auto ?
I. What's the condition of battery of diesel engine ?
j. What's the diesel fuel tank capacity (hrs) ?
k How frequently does jockey pump start ? How
long it runs ?
l. Are the fire water pumps/engines started &
observations logged as per OISD Std. 116/
117/144.
2.2 FIRE HYDRANT SYSTEM
Check and comment on the hydrant system layout

design position of hydrants/monitors, flow rate
pressure at the farthest point, condition of pipeline
etc. Please comment on the system as per the
following.
2.2.1 Network - Grid type/Closed type/Any other
2.2.2 Mains
a. What's the material of construction of

pipes ?
b. How corrosion protection is ensured ?
c. How is the sectionalising of hydrants system
?
d. How are the spacings between hydrants
e. Are monitors / hydrants properly distributed
in critical areas and all facilities covered ?
f. Are these hydrants/monitors easily
accessible and operable ?
g. Is the layout vulnerable at any points from
fire hazard
2.3 FOAM SYSTEM
a. What are the types of foam available?

b. What are the dilution potential and the
quantities ?
c. What are the storage arrangements and its
accessibility
24
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d. Do the coverage and application rate for

floating roof/fixed roof tanks meet OISD
norms ?
e. Are foam branch pipes, nozzles, wheeled

equipments available and adequate as per
OISD Stnadard ?
f. Proportioning equipment - suitability -

proper pick up
2.4 FIRE STATION
a. Is the location away from hazardous

areas ?
b. Are the no. and variety of fire vehicles
sufficient ?
c. Facilities on fire vehicles capacity,
pressure, flow proportioning system etc.
Daily starting of vehicles and other
check logs.?
2.5 FIRE EXTINGUISHERS
a. Are portable extinguishers meeting OISD

requirements ? Are they BIS approved ?
b. Whether periodical inspection, maintenance

and testing of fire extinguisher are
promptly carried out and proper
records maintained in line with OISD Std.?
c. Are replacement of extinguishers on shell

failure or hydrotest ensured and necessary
records available ?
d. Are quantity of cartridge and powder

sufficient at work site and spares available
in store in line with OISD Std. ?
e. What is the monthly consumption of

cartridge and product ?
f. Fire Extinguishers attached to all the

vehicles / position at various sites shall be
numbered and date of testing shall be
written on them Note 3
g. Fire Extinguishers attached to TTs should

also bear the TT number Note 3 .
2.6 FIRE HOSES AND ACCESSORIES

25
a. Are no of hoses sufficient w.r.t. no. of
hydrants in the system ?
b. Are the hose boxes strategically placed ?
c. Are the hoses easily removable during an
emergency ?
26
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d. Are the hoses periodically tested/ checked
and replaced?
e. Are the hose boxes painted fire red Note 3 as
per OISD Standard.?
f. Are adequate sand drums / buckets
available ?
g. Are all various types of nozzles/foam branch
pipes etc. provided as per OISD STD.?
h. Are the hoses BIS Approved Note 3

?
2.7 PROTECTIVE/SAFETY EQUIPMENT
Are safety appliances available in line

with OISD 116/117/144 Standard?
ADDITIONAL ITEMS : FACILITIES AT

PORT
Are the fire fighting facilities (fixed as

well as portable) provided at the port
meeting requirement as per OISD-STD-
156 ?
2.8 OTHERS
Whether the fire siren and fire alarm are

provided at strategic locations and are
audible up to the desired range ?
Whether siren codes are identified for

different types of fire/emergencies ?
2.8.1 Fire siren and fire alarm network (Electrical/

mechanical/ hand operated) Satisfactory
working.
Differentiation between different types of

fires / emergencies.?
Check the locn./range and report
- Within and to outside.

- Normal and emergency.
- Condition of radio communication
equipment.
- Availability of alternate power supply
during normal supply failure
- Inspection and maintenance schedule
- Training of the users.
2.8.2 Ambulance/Other means of transport and

First-Aid services with complete kit Note 3.
27
-
Contingency Plan for medical
emergency.
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- Evacuation, etc.
- First Aid training to personnel on shift.
2.8.4 Availability of emergency, lights in

critical areas.
2.8.5 Availability of special fire fighting

components aprons / suits / emergency
flood lights, power megaphones, etc.
3.0 PROCEDURES
3.1 ORGANIZATION
a. Whether the organogram of fire fighting

and other supporting services well defined
?
b. Is periodic fire drill conducted,
shortcomings observed and necessary
action initiated ?
c. Does location have well defined fire

order ?
Whether organogram has provision to meet

emergency situation during idle shift /
sundays and holidays.
d. Whether relevant fire order is displayed at

various work stations indicating station
employees role during fire / emergency ?
e. Whether following documents are

updated and displayed as reqd.
- Organogram
- Fire hydrants layouts and P & ID
diagrams
- Fire fighting procedures / manual
f. Whether layouts and organogram

displayed ?
3.2 DISASTER MANAGEMENT PLAN

(Ref.to new checklist for DMP)
a. Whether mutual aid schemes are made

with neighboring industries, local fire
brigades, etc.
28
b. Whether resource requirements are worked
out
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3.3 INSPECTION AND TESTING FACILITIES
Whether periodic inspection and maintenance /

testing is done and proper records maintained for
following :
a. Pumps
- Is flow vs. pressure meeting the

requirement ?
- Is lubrication periodically carried out ?
b. Hydrants
- Are pressure and flow at different

points adequate enough ?
- Are all valves easy to operate ?
c. How effective is the fire water spray

system ?
d. Is foam proportioning equipment in

working order ?
e. Whether hydrotesting and regular

inspection of fire gate mains undertaken
and records maintained ?
f. Whether various checks & records of

periodical running of Diesel engines
carried out?
g. FIRE HOSE AND ACCESSORIES
- Are hoses , nozzles, adapters, hose

holders, wrenches etc. inspected
regularly ?
h. Foam concentrate
- What is the inventory ? Are the

procurement / expiry date
record maintained?
- Whether protein foams churned

regularly and record maintained ?
3.4 TRAINING
29
Whether training provided fire crew / other
employees / CISF etc. is in line with OISD
std. 154?
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3.5 CHECKLIST FOR DMP
1. What is the frequency of DMP drill ? When was

it last conducted ? Whether the short comings
observed during drills were analyzed and action
taken to prevent repetition ?
2.Whether mutual aid schemes are planned with

neighboring units local fire brigade etc. ? Is the
scheme periodically discussed with members ?
Are they trained to fight fire in oil / gas
installation /
3. Whether the resources of the operating location

and the mutual aid members properly
tabulated ? Whether assessment of necessary
man power and equipment studied and action
taken for the shortfall ?
4. Whether organogram of various co-ordinators,

succession charts showing alternate persons
and sub-organisation chart well displayed ? ?
Name, address, telephone numbers (Off.and Res.

) of anchorages / key persons are to be clearly
shown.
a. Mutual aid members

b. Police, fire and district authorities.
c. Hospitals and doctors
d. Medical shops, ambulance, blood bank,
blood donors,
e. Water supply dept. water transporter, elect.
boards, railways, port trust, telephone
exchange.
f. Generator hire service, transport hire
service , welfare bodies, social organization
and catering services.
7. Is emergency control centre planned and

properly furnished / fitted to meet the
requirement ?
8. Whether DMP is based on MCA and risk

analysis ?
30
OISD-GDN-145-03
REVISION I
SAFETY AUDIT CHECK LIST No. OISD GDN-145-03
LAYOUTS
CONTENTS
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1.0 TOPOGRAPHY OF INSTALLATION 20
2.0 SURROUNDING OF THE INSTALLATION 20
3.0 INTER - DISTANCES 20
4.0 TANKFARMS 20
4.1 Grouping of tanks 20

4.2 Dykes 20
4.3 LPG storage 20
5.0 PROCESS UNITS 21
5.1 Location 21
5.2 Control room 21
5.3 Field 21
6.0 OTHER FACILITIES AND EQUIPMENT 21
6.1 Electrical power lines 21

6.2 Electrical switchgear 21
6.3 Roads 22
6.4 Administrative buildings/ workshops/canteen 22
6.5 Boiler plants 22
6.6 Gantries 22
6.7 Waste water facilities 22
6.8 Water cooling towers 22
6.9 Elevated platforms 22
6.10 Piping 22
6.11 Rail spurs 23
6.12 Fire hydrants/ monitors/ safety showers/ hose etc. 23
6.13 Compressors 23
6.14 Miscellaneous 23
-------------------------------------------------------------------------------------------------------------------------------------------------
OISD-GDN-145-03
31
LAYOUTS
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1.0 TOPOGRAPHY OF INSTALLATION
- Susceptibility for flooding

- Location of process units and tank
farms in undulating areas.
2.0 SURROUNDING OF THE INSTALLATION
- Flammables / Toxics/ Ignition sources

up/ down wind
3.0 INTER-DISTANCES
Code / standard/ regulations followed /deviated

(Ref.OISD-STD-118/144).
- Equipment/block/facility to boundary walls
- Block/facility to block/facility
- Equipment to Equipment switch in a block /

facility.
4.0 TANKFARMS
4.1 GROUPING OF TANKS
- Mixing of different class products in POL

tank farm
- Accessibility of tanks for fire fighting.
4.2 DYKES
- Aggregate capacity of tanks in each

Dyke / enclosure
- Capacity of Dykes with respect to

relevant group
- Construction and dimensions of dyke wall
- Routing / Cris- crossing of process /

fire hydrant lines inside dyked tank
farm
- Provision of fire walls.
32
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4.3 LPG STORAGE
- Orientation w.r.t. wind direction

- General state of terrain without depression /
large ditches
- No of vessels in each group and the aggregate

capacities
-Provisions of slope and spill collection shallow

pumps.
- Vapour trap
5.0 PROCESS UNITS
5.1 LOCATION
- Consolidated / Scattered
- Separation from tank farm/concentration of people
- Down wind from ignition sources
5.2 CONTROL ROOM
- Design for minimum occupancy

- Electrical area /equipment classification
- Upwind from sources of flammables / toxic
materials
- Easy approach to entrance and to fire fighting
facilities
-
Safety of control room from any blast situation
-
Emergency Light during power failure at Process
Control room. Note 3
5.3 FIELD
- Positioning of process equipment without stacking
- Segregation of equipment handling hazardous /

materials
- Adequacy of accessways for the movement of

equipment and people.
- Strategic location of fire fighting equipment
- Over head clearances for passage of heavy

equipment like cranes
- Adequate provision of oily water and storm

water sewers and catch pits.
- Packing and grinding of susceptible leaky areas

33
34
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6.0 OTHER FACILITIES AND EQUIPMENT
6.1 ELECTRICAL POWER LINES
- Rooting below / above ground
- Passing over critical facilities
- Separation from elevated structures which may

fall across power lines
- Location of power receiving station & layout hazard
6.2 ELECTRICAL SWITCHGEAR
- Upwind from flammable sources
- High ground in flooding areas
- Routes of overhead power cable and

instrument cable trays and their fire
protection/ fire proofing
6.3 ROADS
- Road widths and turning radii for movement

of large fire fighting vehicles .
- Separate entry points for employees and

product movement
- Layout of the roads for minimum truck traffic in

grass
- Accessibilities to each process unit/tank
- Crossing of pipe alleys
-
Concreted / asphalted (condition)
-
Process Plants and facilities shall have access
roads for fire tenders from at least two sides. Note 3
6.4 ADMINISTRATIVE BUILDINGS /WORKSHOPS/

CANTEENS
- Peripheral locations
- Separation from hazardous areas
- Upwind from sources of flammable / toxics
6.5 BOILER PLANTS
- Upwind and separation from sources of

flammable materials
35
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6.6 GANTRIES
- Peripheral location
- Downwind from ignition sources
- Separation from main line of rail / road
6.7 WASTE WATER FACILITIES
- Peripheral locations
- Down wind from ignition sources /

concentrations of people
- Any treatment facility to dischargeable water for

pollution control
6.8 WATER COOLING TOWERS
- Down wind from ignition sources/ concentration

of people
6.9 ELEVATED PLATFORMS
- Permanent platforms for all operating points
- Alternate routes for descent
- Landing at grade in safe locations
6.10 PIPING
- Head bumpers, shin splitters and tripping

hazards
- Personnel protection from hot lines
- Fire proofing of pipe racks.
6.11 RAIL SPURS
- Clearance for derailments
- No facility opposite the end of the spur.
6.12 FIRE HYDRANTS / MONITORS / SAFETY

SHOWERS / HOSE ETC.
- No obstruction for approach. Good path for

retreat
36
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6.13 COMPRESSORS
- Not in closed buildings
- Down wind from rest of unit
6.14 MISCELLANEOUS
- Location of fire station and fire pump
- Location of smoke booths
- Display of Layout drawing and display of

P & I DRAWING
-Check piping layout for minimum piping
- Greenscaping area
- Flood light towers & security towers
- Grading of various block facilities
- Storm water drains & easy drainage
- Height of flares is adequate
- TTL gantry and easy exit through the

product movement gate
- Provision of Truck parking area
37
OISD-GDN-145-04
REVISION I
SAFETY AUDIT CHECKLIST No.OISD GDN-145-04
PROCESS PLANTS
CONTENTS
---------------------------------------------------------------------------------------------------------------
----------------------------------------------------------------------------------------------------------------
1.0 GENERAL 25
1.1 Layout and Drainage 25
1.2 Fire Protection facilities 25
1.3 Housekeeping 26
1.4 Training 26
1.5 Inspection & Maintenance 26
1.6 Electrical 27
1.7 Instrumentation 27
2.0 PROCESS SUB-SYSTEMS 27
2.1 Control room 27
2.2 Pump House 28
2.3 Compressor house 29
2.4 Heat exchangers/ condensers/ coolers 29
2.5 Process vessels and columns 30
2.6 Process furnaces 30
2.7 Process piping 31
2.8 Relief and Disposal System 32
2.9 First aid 33
38
4.0 PROCESS PLANTS
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ITEM AUDITORS REMARKS
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1.0 GENERAL
1.1 LAYOUT AND DRAINAGE
a) OIDF-STD-118 ? (deviations, if any to be

specified)
b) Whether the location of the control room

& furnace meets the OISD-STD-118
c) Whether proper approach roads to the

plant have been provided ?
d) Whether ladders, platforms provided are

as per standard engineering practices and
can be considered adequate ?
e) Whether oil water sewers are adequately

sized and the manholes on these sewers
covered properly ?
f) Whether the plant surface drainage systems

are adequately sized and
properly maintained ?
g) Whether a closed blow down system has

been provided for draining of hydrocarbon
from the vessels / equipments with proper
pump out arrangement from underground
tank ?
1.2 FIRE PROTECTION FACILITIES
a) Whether the fire water network provided

is well designed (Ring type) and covers
all sides of the plant ? refer OISD116.
b) Whether the hydrants, water monitors are

provided from all sides of the plant ?And are
they located more than 15 meters away from
nearest hazard ?
c) Whether steam lancers have been provided

and are adequate ?
d) Whether all hydrants, monitors, hose

boxes are easily accessible ?
e) Whether adequate number of portable fire

extinguishers have been provided all over
39
the plant as per the OISD-116 ?
40
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f) Whether communication systems, fire alarms

and p.a. system have been provided ? Are
they working ?
g) Whether a copy of fire fighting manual is available

in the plant control room ?
h) Whether safety committee meetings are

conducted at plant level ? Is the
frequency adequate?
1.3. HOUSEKEEPING :
a) Whether the plant floors particularly in

pump house, heat exchanger areas are
regularly washed to avoid Oil Accumulation ?
Any visible Oil Accumulation on the floor, drains found ?
b) Are redundant pipes/valves/ pump foundations

/insulation debris removed from process area ?
c) Whether the general housekeeping in the

area can be considered as ;
- adequate
- not adequate
1.4 TRAINING
a) Are copies of updated operating manual,

fire & safety manual, disaster control
manual, standing instructions available
in the control room ?
b) Are the working personnel in the area

given thorough training on operations,
safety and fire fighting at the induction
stage ?
c) Whether subsequent refresher training

programs are organized-periodically?
d) Whether contractor employees are given

basic training on hazards of petroleum
products & safe practices ?
e) Whether the workers are using proper

personnel protective clothing such as
hand gloves, safety shoes, helmet, face
shield etc. ?
41
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-
1.5 INSPECTION & MAINTENANCE
a) Whether inspection of equipments/ tanks

/piping /safety valves etc. are carried
out as per schedules? Are history cards
maintained ? Refer OISD129 / OISD-127.
b) Whether all the modification works are

undertaken only with approved engineering
drawings ?
c) Whether a well designed work permit

system exists for the following and is
rigidly followed ;
Refer OISD-105.
- Hot/Cold work
- Energizing and de-energizing of electrical
Equipment.
- Excavation
- Vessel Entry
- Entry of Vehicle into battery area.
1.6. ELECTRICAL
a) Whether all motors, electrical fittings

in the plant are as per area
classification ? Is area classification
drawing available ?
b) Whether equipments properly earthed ?

readings taken periodically ? Are
records maintained ?
c) Whether illumination can be considered

adequate ?
d) Whether emergency lighting system has

been provided ?
e) Whether any interlocks bypassed and

recorded ?
1.7 INSTRUMENTATION:
a) Whether electronic instrumentation

provided are as per area classification?
b) Whether minimum safety instrumentation

provided for furnace, vessels,
compressors etc. and is well maintained ?
42
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c) Whether any schedule exists for checking
up of various interlocks, shutdown
systems ? Are such schedules followed
and recorded ?
d) Whether any process interlock bypassed

and recorded ?
e) Whether smoke / heat / gas / hydrocarbon

detectors are provided and are working ?
2.0 PROCESS SUB-SYSTEMS
2.1 CONTROL ROOM
a) Whether fire protection provided and

considered adequate ?
b) Whether updated P & I diagram available ?
c) Whether emergency shutdown controls are

available ?
d) Whether requisite PPE & first aid kit

available ?
e) Whether control room is blast proof, if

it is hazardous area ?
f) Whether the cable entry in the control

room is properly sealed ?
g) Whether control room pressurization has

been provided and working satisfactorily ?
2.2 PUMP HOUSE :
a) Whether the location of the pump house

with respect to furnace is as per OISD
118 ?
b) Whether hot pump have been segregated

from pump handling lighter hydrocarbons ?
c) Whether hot pumps are properly located

so as to prevent fire due to spillage of
hydrocarbon from over head ?
d) Whether piping arrangement w.r.t.

personnel's movement satisfactory ?
e) Whether hot pumps are properly insulated ?

(including the associated piping) ?
43
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f) Whether the hot pumps are provided with
warm up lines ?
g) Are vents / drains of hot pumps cooled

before discharge ?
h) Whether reciprocating pumps have proper

safety release system, if discharge is
blocked ?
i) Are the threaded joints on the pump

vents / drain lines found corroded?
j) Whether all pump drains are connected to

CBD and OWS ? Any of the drains found
congealed ?
k) Does the pump house floor drain have a

proper water seal to prevent
propagation of fire from OWS to pump
house ?
l) Are the auto start / stop of the pumps

(where applicable) checked as per
schedule and recorded ? Check at random ?
2.3 COMPRESSOR HOUSE
a) Whether the location is well ventilated ?
b) Whether the following are in working

condition ?
- Vibration monitoring system

- Anti surge device
- Speed control system
- Shut down system
- Lubrication system
c) Whether various alarms and signaling

systems are in working condition ?
d) Are the safety valves on the discharge

side of the compressor checked as per
schedule ?
e) Whether suction strainer is periodically

cleaned ?
f) Whether the compressor has a proper

depressurising system ? Is venting system proper ?
g) Whether there is a condensate collection

system at suction / discharge of the
compressor ? if so, is it functional ?
44
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h) Whether the compressor has nitrogen
inerting system ? if so,is it functional ?
i) Do compressor safety valve atmospheric

vents have nitrogen / steam purging
especially for hydrogen rich gases ?
2.4. HEAT EXCHANGERS/CONDENSERS/COOLERS
a) Are adequate nos. of high vents / low

points drains with proper isolation
provided ?
b) Whether provision for thermal relief/

thermal expansion has been provided ?
Are TSVs on line ?
c) Whether the insulation / cladding is

fully covering the exchanger ? Is
earthing proper ? Are supports fire
proofed ?
d) Does sacrificial anode exist for

coolers / condensers where different
metals are in contact ?
e) Whether the operating parameters and

test pressures have been tagged on the
equipment and is being operated within that?
f) Whether the over head condenser platform

is within reach for fire fighting and
does the overhead condenser platform
have two sets of staircases at either end ?
2.5 PROCESS VESSELS AND COLUMNS: (REFER OISD

STD-152)
a) Whether relief valves are periodically

tested and records maintained ?
b) Whether all the utility connections are

in working condition ?
c) Whether the vessel has been provided

with adequate safety instrumentation ?
d) Are the nozzles, nipples on idle drains

and vents capped / blinded ?
e) Whether vessel supports are fire proofed

and it is in proper condition ?
f) Whether insulation / painting is proper ?
45
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g) Do all columns have two sets of level
indicators ?
2.6 PROCESS FURNACES; (REFER OISD-STD-111)
a) Whether the pass flows are provided with

recorder and controller and are properly
working ?
b) Whether skin temperature and bridge

temperatures are recorded ?
c) Whether each main burner has a pilot

burner ?
d) Whether electric igniters are

provided for each burner and are they well
maintained?
e) Whether fuel oil supply header is properly

steam traced and insulated ?
f) Whether both oil and gas lines have proper

blinding facilities at the battery limit ?
g) Whether the furnace has a trip system /

flame out protection system ? Whether
on line testing of the same is done ?
h) Whether furnace has step ladder & monkey

ladders to reach each platform ? Is
alternative escape ladder available from
burner-valves platform ?
i) Whether safety wears such as safety goggles,

face shield etc. are used by operators regularly
while adjusting / viewing burners ?
j) Whether the location of the explosion door

can be considered safe ?
k) Is the snuffing and purging steam valve

manifold easily accessible ? Is it away
from fire radiation risk zone ?
Is the coil purging steam facility in line
with OISD-111 Annexure -1 ?
l) Whether the damper control system is

satisfactory ? Is position of damper
readable from ground level ?
m) Whether the control system for drop out

doors opening can be tested on line ?
46
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n) Whether the location and height of FD fan
air intake can be considered safe ?
o) Whether the furnace has a decoking system

which is operative ?
p) Whether noise level near the furnace is

within permissible limit ? Is it
monitored atleast once a year ?
q) Can the condensate draining, OWS line

connection & manhole location for the
furnace be considered safe ?
r) Whether the support structures are

properly fire proofed ?
2.7 PROCESS PIPING
a) Whether expansion loops / expansion joints

in working order ?
b) Whether TSVs provided are periodically

tested, records maintained ?
c) Whether pipe supports (sliding / spring

supports ) guides and anchors are in order ?
d) Does the piping slope towards drain points

/ knockout pots ?
e) Whether all piping above 60 deg. C surface

temperature have safety insulation ?
f) Whether continuity jumpers provided

between flange joints for LPG, naphtha,
ATF etc, (Refer OISD-STD-106 ).
2.8 RELIEF AND DISPOSAL SYSTEM
a) Whether the relief valves have been set

at 10% over normal operating pressure ?
b) Whether difference between set pressure

and the normal operating pressure is
maintained minimum 2.0 kg / sq.cmg ?
c) Whether safety valve has been installed

directly on the protecting equipment /
on the connected piping without any isolation
valve ?
d) Whether multiple safety valves have been

used ? if so, whether the set pressure
is within design pressure ?
47
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e) Whether any spare safety valves have
been used with isolation valves ? if so
what is the safe guard against inadvertent
closing of isolation valves of operating
safety valves ?
f) Whether any relief valve on hydrocarbon /

toxic gas services relieves to atmosphere ?
if so whether the following points are
considered :
- discharge vertically upward through

individual stack
- minimum exit velocity of 15.0 m/second.
- snuffing steam provided ?
g) Whether use of common atmosphere vent

stack for several relief valves is
observed ?
h) Whether any vent stack is observed

discharging at an elevation of less than
3m above the tallest structure, within 15m
radius
i) Whether acoustic insulation has been

provided on vents producing excessive
noise ?
j) Whether toxic vapors like SO2, phenol,

chlorine etc. are disposed through closed
system ?
k) Whether isolation valves with spectacle

blinds have been provided at the battery
limits of the plant ? if so whether their stems
are pointing downward to avoid
accidental closure ?
l) Whether unit knock out drums have been

provided ? if so , can it hold liquid discharge
for 5 - 10 minutes from a single contingency ?
m) Whether pumps with auto start / stop at

high / low level have been provided to
pump out the contents ?
n) Whether high / low level alarms for the knock out

pots have been provided in the control room ?
48
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o) Whether vapor depressurising system has
been provided for emergency situations
such as runaway reaction, exposure to
fire etc.?
2.9 FIRST AID
a) What is the percentage of shift employees

trained in first aid ? how many can provide
artificial resuscitation ?
b) Does every control room including pump

houses possess a first aid box, water gel
blanket and explosive meter ?
c) What is the accident record of the last

two years ?
d) All incidents requiring first aid should be recorded. Note 3
49
OIL STORAGE AND MOVEMENT
CONTENTS
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-
--------------------------------------------------------------------------------------------------------------------------------------
-
1.0 TANK FARM 35
2.0 TANKS 35
3.0 PIPING 36
4.0 OPERATING PROCEDURES 37
5.0 INSPECTION & MAINTENANCE 38
6.0 ADDITIONAL CHECK LIST ITEMS 38
50
5.0 OIL STORAGE AND MOVEMENT
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1.0 TANK FARM :
1.1 GENERAL :
a) Whether the location, layouts

interspacing in the tank farm meet
OISD-STD-118/statutory requirements?
b) Whether Dyke / fire walls meet

OISD-118 / statutory requirements ?
c) Whether the roads are

available around the tank farm for
movement for fire tenders ?
d) Whether piping in the dyke farm is

kept minimum ?
e) Whether any piping not connected

with the tanks to any individual
dyke is passing through it ?
f) Whether any hydrocarbon detection

system has been provided ? If so,
is it working satisfactorily ?
g) Whether house keeping in the area

is satisfactory and it is free of
any dry vegetation.
h) Whether communication system is

available in the tank farm areas.
i) Whether illumination in the area is

adequate / inadequate
j) What is the procedure adopted for

recovery and disposal of the tank
bottom sludges ?
51
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k) Whether leaded gasoline sludge if

any, buried into the tank farm with
clear demarcation ?
1.2 SEWERS :
a) Whether the tank farm closed

drains, drains are clear ?
b) Whether provision exists to divert

tank farm drainage either to storm
water or to oily water sewer ?
2.0 TANKS :
a) Whether tanks properly painted and

important specifications, are
marked on the tank ?
b) Whether all nozzles of 2" and above

sizes have been provided with
reinforcing pads with tell - tale
holes ?
c) Whether all tanks are provided with

circumferential railings ?
d) Whether the roof drain of floating

roof tanks is provided with a check
valve ?
e) Whether any alternative arrangement

to read / record level in the tanks
have been provided ?
f) Whether the tanks with steam heating

/ blanketing are provided with high
temp., high pressure indicator and
alarms ?
g) Whether any product is stored above

its flash point ? If yes what are
the additional safety consideration?
h) Whether the breather valves

provided matches the pumping in /
pumping out requirements of the
tank ?
i) Whether any depression due to tank

settlement observed on the tank pad
along the circumference ?
46
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j) Whether steam coils provided have

any flange connections inside the
tank ? Whether provision exists to
check oil leak through condensate
outlet line ?
k) Whether the tanks on ATF, Naphtha,

chemicals services are internally
coated ?
l) Whether fixed/semi-fixed foam system

are provided on all tanks storing A
class and B class products (18 M
and above for floating roofs ) and
also tanks storing C class products
of more than 40 m dia
(floating/fixed roof tanks) ?
m) Whether sprinkler systems are

provided on all fixed roof tanks as
per OISD norms ?
n) Whether Halon system is provided on

any tank. If so, whether
periodically the Halon system is
checked and records maintained ?
o) Whether the tanks are properly

painted and numbered ?
p) Whether flame arrestors are provided

on fixed roof storage tanks which
are likely to have explosive
mixture in the vapor space ?
q) Whether goose neck type vent

connections are provided with
suitable wire mesh to avoid birds
entry /formation of nests ?
r) Whether oil of proper viscosity is

used in oil breather valves ?
3.0 PIPING :
a) Whether pipe alleys properly graded

to ensure that no oil/water gets
accumulated below ?
47
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b) Whether pipe supports, anchors,
guides are in order ?
c) Whether pipes carrying heavy

products have been properly heat
traced and insulated ?
d) Whether proper color codings,

products identification marks have
been provided ?
e) Whether low point drains and high

point vents have been provided with
proper caps ?
f) Whether the tanks are having proper

manifolds and are located outside
the dyke ?
g) Whether Hammer blinds are provided

on the tank manifolds and are operable ?
h) Whether the floor under the

manifold are paved, have curb walls
and drains connected to OWS ?
i) Whether steam traps of tracer lines

are functioning properly ?
j) Whether any bolt is found missing

on flanges of hydrocarbon lines,
particularly of LPG, MS, Naphtha
etc.
k) Whether the redundant lines are

kept positively isolated with all the ends
plugged/blinded and actions are taken
to get them removed ?
4.0 OPERATING PROCEDURES :
a) Whether a copy of updated operating

manual with operating instructions,
blending etc. are available to all
concerned and a copy available in
the C/R.
b) Whether there is any possibility of

product contamination during tank
line up/changeover.
48
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c) Whether the blending pumps, lines

are segregated from other lines
with positive isolation during
blending operation ?
d) Whether periodical checks are made

for locating any leakage on tank,
floating roof valves, piping etc.
and recorded for rectification.
e) Whether the roof drain valves of

floating roof tanks are normally kept
open .
f) Whether pre- monsoon checks are

carried out.
g) Whether any blending of DP product

and NDP product is resorted to ? If
so, what are the procedures & safety
precautions taken.
h) Whether cross checking of auto level

gauge is done through manual gauge,
while the tanks are under operation.
i) Whether it is ensured during initial

filling a flow velocity of maximum
1 m/sec is maintained for products
like SKO, ATF ?
j) Whether use of nylon rope for

sampling was observed ?
49
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k) How it is ensured that side entry

mixers are operated only when liquid
level is above the blades ?
(Wherever applicable )
5.0 INSPECTION & MAINTENANCE :
a) What are the schedules of inspection

of tanks (floating / fixed) and
whether records maintained in-line
with OISD STD-129.
b) What is the frequency of inspection

of PV vents, relief valves, breather
valves, flame arrestors ? Whether
records are maintained in line with
OISD STD-129.
c) Whether any provision exists for

static electricity discharge ? What
is the frequency of inspection of
earthing connections and whether
records maintained.
d) Whether the pontoon covers are in

place and are in good condition ?
e) Whether foam/neoprene seals are

checked regularly for perfect
sealing and record maintained.
f) Whether any documented procedure

exists for tank cleaning ? What is
the methodology to ensure strict
adherence ?
g) Whether the ladders, stairways are

in good condition ?
h) Whether the pipeline relief valves

are kept relieving to tanks or to
outside ?
i) Whether any inspections are carried

out on repaired tanks before taking
them into operation ? Whether
inspection schedule of radar gauges
provided on storage tanks have been
followed. Note 3
j) What are the schedules for painting

of tanks ?
50
51
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k) Whether Nitrogen blanketing system
provided on any tank. If so, what
is the frequency of inspection &
whether records maintained ?
6.0 ADDITIONAL CHECKLIST ITEMS :
For detailed checklist on individual areas refer other OISD checklists as follows :
General Admn. & Organization OISD-GDN-145-01
Fire Fighting OISD-GDN-145-02
Layouts OISD-GDN-145-03
Electrical systems OISD-GDN-145-09
52
POL LOADING & UNLOADING
A. TANK WAGONS
CONTENTS
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1.0 FACILITIES AND SYSTEMS 40
1.1 Tank Wagon Gantry 40
1.1.1 General 40
1.1.2 Drainage 40
1.1.3 Miscellaneous 40
1.1.4 Electrical 40
2.0 OPERATING PROCEDURES AND PRACTICES 40
2.1 Placement of rakes and loading 40
2.2 Sick wagons 41
2.3 House keeping 41
53
OISD-GDN-145-06
6.0 POL LOADING & UNLOADING-TANK WAGONS
A. TANK WAGONS
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AUDITOR'S REMARKS
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1.0 FACILITIES AND SYSTEMS
1.1 TANK WAGON GANTRY
1.1.1 General
a. Whether proper facilities have been

provided for handling sick wagons ?
b. Whether the rail sleepers are of concrete

/ metallic construction ?
1.1.2 Drainage
Whether concrete flooring has been

provided below rail track and with proper
slope ?
1.1.3 Miscellaneous
Whether No-shunting device / caution

boards are provided to avoid movement of
wagons while filling / decantation is in
progress ?
1.1.4 Electrical
a. Whether the rail tracks are provided with

bonding strips and connected to well
maintained earthing system ?
b. Whether the diesel shunter used is

equipped with spark arrestors and proper
cooling of engine exhaust ?
2.0 OPERATING PROCEDURES AND PRACTICES
2.1 PLACEMENT OF RAKES AND LOADING
a. Whether the type of loco

used are :
-diesel
-steam
-electric
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b. If steam /diesel loco is used for placement

/removal of wagons whether safe distance from
first loading point is maintained by use of dummy
wagons ?
c. Whether replacement check is carried out to

ensure that platform , loading arms/hoses do
not hit the incoming rake ?
d. Whether the wagons are placed with master valve

closed and bottom sluice valve and cover plate
normally in opened position ?
e. Whether checks are made for any left over

materials, previous product & fitness of wagons
by operating staff on placement ?
f. Whether the TXR staff check / inspect each wagon

and issue a formal certificate prior to
loading ?
g. Whether wagons declared defective are shown on tally

sheets and also marked on the wagons ?
h. Whether Railways are informed in writing about

wagons found defective during loading ?
i. Whether the tightness of Master valve is checked by

TXR staff during this initial filling and in case of leak
declared as SICK WAGON ?
j. Whether, in case of open type wagons,pre-fabricated

fill pipes are available for use ?
k. Whether the following are ensured after completion of

loading :
- fill pipes (if exists) are properly capped
- Top covers are properly closed and sealed
- Bottom sluice valves fully closed

- Bottom cover plates are boxed up with
proper gaskets
l Whether any loose shunting is done ?
m Whether the shunting speed of 10 kmph

(Max.) is maintained ?
n Whether necessary caution boards

are displayed while loading / unloading
in progress ?
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2.2 Sick wagons
Whether the following are ensured before

removing the defective / sick wagons :
- Top lid covers closed

- bottom cover plate is kept
loose and hanging
- Checks made for any left out product
2.3 House keeping
a Whether the gantry floor, drain channels

are well maintained and tracks are regularly
washed to avoid oil accumulation ?
Any visible oil accumulation in the area ?
b Whether sand spreading is being done on

slippery working areas, railway tracks
etc. ?
c Whether Rly. tracks / sliding is free from unused

T.W. fittings ?
56
SAFETY AUDIT CHECKLIST No. OISD GDN-145-06
POL LOADING & UNLOADING -
B. TANK TRUCKS
CONTENTS
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1.0 FACILITIES & SYSTEMS 43
1.1 Headers & loading hoses 43
2.0 OPERATING PROCEDURES AND PRACTICES 43
2.1 Placement of trucks 43
2.2 Loading operations 43
3.0 VEHICLE CREW AND CHECK 43
4.0 ADDITIONAL CHECKLIST ITEMS 51
57
6.0 POL LOADING & UNLOADING - TANK TRUCKS
B. TANK TRUCKS
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1.0 FACILITIES AND SYSTEM
1.1 HEADERS & LOADING HOSES
Whether proper arrangement has been

provided for securing the hose nozzle
with truck manhole ?
a Whether facility is provided to

drain overfilled truck to a closed
system with proper pump out
arrangement ?
2.1 PLACEMENT OF TRUCK
a Whether any system exists to regulate

number of trucks coming at a time to loading
area ?
b Whether any parking / place has been

provided for the trucks near the loading area ?
c Whether the placement of trucks in the gantry

is allowed only on production of filling advice ?
d Whether any safety checks are carried out on the

trucks before issuing loading advice ?
2.2 LOADING OPERATIONS
a Whether it is ensured that the trucks,

loading hoses are properly connected to
earthing system before commencing
loading ?
b Whether decantation of any over filled

truck done to closed system (for DP)
and with close supervision ?
c Whether the following are ensured after

completion of loading :
- Fill pipes properly capped

- Top covers are properly closed and
sealed
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3.0 VEHICLE AND CREW CHECK
a Whether the vehicles design has been

approved by CCE ?
b Whether license and explosives

certificates are available in the vehicle ?
c Whether the vehicle is in good condition and the

RTO has issued a fitness certificate?
d Whether the vehicle has non-sparking

electrical fitting and external wiring through
conduits ?
e Whether the vehicle has a cut off master

switch for electrical system ?
f Whether there is facility to shut off the

drain valves in case of emergency ?
g Whether the vehicle has two fire

extinguishers ?
h Whether the gross and tare weight painted

on the vehicle tally with the permit
i Whether the vehicle has First Aid Box,

Tool Box and Emergency Lighting ?
j Whether there are any sources of ignition

like candles, etc in the vehicles ?
k Whether the vehicle has atleast a driver

and a cleaner as its crew member ?
l Whether the driver has a valid driving

license ?
m Whether the crew is trained for hazardous

nature of petroleum products, emergency
procedures, emergency communication etc ?
n Whether the driver has a copy of standing

instruction and TREM Card ?
o Whether the exhaust is wholly in front

of tank truck and has ample clearance
from Fuel oil system and combustible
material ?
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p Whether approved quality spark
arrestors provided on the engine
exhaust and Muffler / Silencer is
not cut off from the exhaust ?
q Whether each compartment of Tank is

fitted with independent PV vents with
minimum opening of 3 sq. cms. ?
r Whether vent openings are covered with

two layers of wire-mesh of size not less
than 11 mesh per centimeter ?
s Whether Tank Truck is conspicuously

marked on each side and rear, in bold
letters at least 7 cm high and on a
back ground of sharp contrasting
color. (The word "flammable " and name
of product are required to be marked )
as per UN code.
t Whether effective spark arrestors fitted

on air intake system of the engine ?
u Whether electric wiring is of heavily

insulated quality and adequate carry
maximum loads ?
v Whether suitable over current protection

in the form of fuses / automatic circuit
breakers etc. have been provided ?
w Whether all junction boxes are sealed

properly ?
x Whether electrical equipments like

generator switches, fuses and circuit
breakers are located inside the cabin
or engine compartment ?
y Whether battery is in easily accessible

position with a heavy duty switch
close by, to cut off the battery in
emergency ?
z Whether battery terminals have protective

rubber covers ?
aa) Whether vehicle's cabin is checked for

presence of any flammable/explosive
substance being carried by the crew ?
60
OISD-GDN-145-06 REVISION I
SAFETY AUDIT CHECKLIST OISD GDN-145-06
POL LOADING AND UNLOADING
C. COMMON CHECKLIST FOR LOADING AND

UNLOADING OF TWs & TTs
CONTENTS
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1.0 FACILITIES & SYSTEMS
1.1 Pump house
1.2 Structure & platforms
1.3 Headers and loading arms
1.4 Drainage
1.5 Miscellaneous
1.6 Electrical
2.1 Inspection & maintenance
2.2 Work Permit Systems
2.3 House keeping
2.4 Training
2.5 Miscellaneous
4.0 ADDITIONAL CHECKLIST
61
6.0 POL LOADING AND UNLOADING
C. COMMON CHECKLIST FOR LOADING AND

UNLOADING OF TWs & TTs
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1.0 FACILITIES AND SYSTEMS
1.1 PUMP HOUSE
a) Whether the pumps are numbered/name of

product handled written ?
b) Whether white oil and black oil pumps are

segregated ?
c) In case of common service pumps whether

these are properly grouped keeping
product quality (flash point) in view ?
d) Whether the hot pumps and the associated

piping are heat traced and properly
lagged ?
e) Whether delivery to suction bypass line /

recirculation line to storage tank has been
provided ?
f) Whether adequate ventilation exists (in case of

covered pump house) ?
g) What is the system of communication

between pump house, gantry and control
room during normal operation/emergency ?
h) Whether all the drains are routed to OWS

and the system has water seal to act as
fire barrier ?
i) Whether the idle loading headers, not in use

for long time, have been blinded off?
j) Whether P.D. meters (if provided) have

proper electrical fittings as per area classification ?
1.2 STRUCTURE & PLATFORMS
a) Whether easy access available to the

platform from both sides of the gantry ?
b) Whether escape ladders provided along

the platforms are adequate ?
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c) Whether the swing ladders are provided
with counter weight, security chain,
rubber pads and other safety features to
avoid frictional spark ? Are these in
good working condition ?
d) Whether the supporting columns are fire

proofed ?
e) Whether the gantry shed is covered with

asbestos sheet and has side protection ?
f) Whether the ladders from platform to the

top of the vehicles are provided with
railings/security chain, rubber pads and
other safety features to avoid
frictional spark ?
g) Whether handrails are provided on the

platform ?
1.3 HEADERS & LOADING ARMS
a) Comment as to how the loading

velocities are maintained within safe
limits ?
b) Whether shock eliminators are provided on

each header ?
c) Whether quick isolation valves/MOV provided

for emergency shut off of loading headers ?
Are they operable during emergencies ?
d) Whether color coding has been provided

for loading headers and individual
loading points?
e) Whether heavy oil headers are heat traced

and properly insulated up to loading valve ?
f) Whether product compatibility has been

considered in case of common loading arm ?
g) Whether any of the loading arms swivel

joints/valves are leaking, if so how
many ?
h) Whether proper arrangement has been

provide for securing the hose nozzle with
manhole and properly secured after loading
(T/T & T/W)?
i) Whether vacuum breaker is provided on the

loading arm ?
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j) Whether the rubber hose are of proper

diameter, length, quality and condition & meets
BIS norms?
k) Whether the idle loading headers/

loading arms not in use for long time
are blinded off ?
1.4 DRAINAGE
a) Whether oily water drains from the area

are connected to effluent treatment/disposal
facility (OWS)?
b) Whether a well designed system exists for

draining and transfer of heavy oils like
LSHS to avoid congealing of OWS system ?
c) Whether the heavy oily drain

collection system is steam traced ?
d) Whether concrete flooring has been

provided with slope towards drains to
avoid spillage accumulation ?
1.5 MISCELLANEOUS
a) Whether road barriers have been provided

in the gantry area to restrict entry of
unauthorized persons/vehicles ?
b) Whether smoking booths with CODE approval

have been provided for the area at safe
locations ?
c) Whether the electric lighters, installed in

the smoking booths, are well
maintained ?
1.6 ELECTRICAL
a) Whether all electrical fittings, welding

apparatus receptacles, lighting provisions,
etc. are as per hazard area
classification ?
b) Whether illumination in the gantry & pump

house is adequate ?
c) Whether ground level illumination is

provided and found adequate ?
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d) Whether the loading arms/hoses are having
proper electrical continuity provision and
earthing connection ?
e) Whether the loading headers/other pipes

laid on the rack are properly earthed ?
f) How frequently are the tests of bonding /

earthing carried out ? Any records
maintained ?
g) Whether the No. of earthing pits are

adequate and they are inter connected ?
h) Whether condition of FLP fittings are

periodically checked and records
maintained ?
i) Whether the motors are provided with

proper earthing.
j) Whether structure is earthed as per std.

and earth test done every year and
records maintained. Is the catwalk
antiskid ?
k) Whether earthing bosses with flexible

cable and robust clamping device have
been provided adjacent to loading points ?
a) Check and comment on earthing and bonding

practices during loading / unloading.
b) Whether initial filling is done at a slow rate

for safeguard against hazard off static
charges ?
c) Whether established communication system

exists between gantry & pump house to
control loading rates / pumping rate ?
d) Whether the loading operation is done under

the close supervision ?
f) Whether operator's constant attention is

there while the loading points have been
opened ?
g) Whether it is ensured that "no vehicle

entry" in the gantry area is permitted
during loading and unloading operations ?
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h) Whether initial loading is done at a rate

not exceeding 1 M/Sec, till the filling
pipe is completely submerged and
thereafter at the rate not exceeding 6
M/Sec ?
2.1 INSPECTION & MAINTENANCE
a) Whether any schedules exist for

lubrication for loading valves/swivel
joints and records are maintained ?
b) Whether schedules exist for inspection

the loading headers, arms/hoses, etc. ?
Whether records are maintained ?
c) Whether adequate inventories are

maintained for prompt replacement of
passing valves and damaged hoses ?
c) Whether all modification jobs are undertaken

only with approved engineering standards ?
2.2 WORK PERMIT SYSTEM
a) Whether as per OISD 105 (for Hot/Cold works

and OISD 137 for Electrical Equipment being
followed.
b) Whether display boards have been provided

at strategic locations covering key
safety instructions ?
c) Whether Emergency and Disaster Control

Plans for the area is available with
written procedures ?
2.3 HOUSE KEEPING
a) Whether the house keeping in the area can

be considered :
good ?
satisfactory ?
needs improvement ?
b) Whether hot water points/system points

provided for flushing/washing operations
& house keeping, or light hydrocarbons
are used ?
c) Whether the gantry floor are regularly

washed to avoid oil accumulation ? Any
visible oil accumulation in the area ?
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d) Whether the drain channels are cleaned &
well maintained ?
2.4 TRAINING (REFER OISD 154 STD.)
a) Whether subsequent refreshed

training programs are also organized
periodically ?
b) Whether contract employees (if any) are

given basic training on hazards of
petroleum products and safe
practices ?
c) Whether the workers are using required

personal protective wears ?
2.5 MISCELLANEOUS
a) Whether Operating Manuals/Standing

Instructions are available at site ?
a) Whether the fire water network

Provided is well designed (Ring type)
b) Whether isolation valves exist for

isolation of each section maintenance
c) Whether hydrants, long range water/foam

monitors are provided on both sides of
gantry and are they safely located ?
d) Whether all hydrants, monitors are easily

accessible ?
e) Whether proper approach roads exist for

Fire Tenders and Fire Fighting Equipment ?
f) Whether communication system like Fire

Alarms, PA system provided and are
working ?
g) Whether the communication system,

sprinklers are periodically checked
h) Whether any mock drills are conducted

for fire fighting ?
i) Whether adequate number of portable

extinguishers have been provided all
along the gantry ?
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j) Whether a copy of Fire Fighting manual is
available in the gantry control room ?
4.0 ADDITIONAL CHECK LIST ITEMS
a) For comprehensive check lists on

individual areas also refer OISD check
lists as indicated below:
b) General admn. organization OISD-GDN-145-01

Fire fighting OISD-GDN-144-02
Electrical Systems OISD-GDN-145-09
68
SAFETY AUDIT CHECKLIST No.OISD-145-07
LPG BULK LOADING & UNLOADING
CONTENTS
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1.0 BULK STORAGE AREA 53
2.0 PUMPS/ COMPRESSORS AREA 55
3.0 TANK WAGON GANTRY AREA 56
4.0 TANK TRUCK GANTRY AREA 58
5.0 TRAINING 59
69
7.0 LPG BULK LOADING & UNLOADING
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1.0 BULK STORAGE AREA:
1.1 GENERAL:
a) Whether the layout, area classification drawings

have been duly approved by CCE ?
b) Whether any new facilities (permanent or temporary

natural) have been installed Area they considered to
be safe.
c) Whether general house keeping in the area is satis-

factory ?
d) Whether storage vessels are insulated. If so, what

is the condition of insulation.
e) Whether five year hydraulic test records are avail-

able ?
f) Whether any signs of corrosion observed on

pipelines? Whether paintings are done as per
schedule ?
g) Whether all bolts of proper sizes are put on the

flanges or some are found missing or of smaller
sizes
i) Whether any portion of pipe length found buried

with soil or undergrowth?
1.2 RELIEF SYSTEM:
a) Whether relief system is adequately designed ?
b) Whether minimum two relief valves are provided in

each vessel?
c) Whether the relief valves are opened to flare /

atmosphere? Any steam connection given? Is
system opened to atmosphere?
d) Whether the relief valves are provided with isola-

tion valves?If so what is the system/ method to
avoid inadvertent closing of isolation valves ?
e) Whether the safety valves are periodically tested

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1.3 DRAINING
a) Whether water drain chamber has been provided

away from shadow of sphere ?
b) Whether the area under the sphere is having

concrete pavement with proper slope ?
c) Whether antifreeze valve provided on the drain line
d) Whether double block valves have been provided

on water draining line (quick shut off type near
the chamber and the other a globe valve) ?
e) Whether safety instructions for draining operations

have been prominently displayed?
f) Whether draining is done under constant

supervision ?
g) Whether sampling points are provided with duplicate

valves?
1.4 INSTRUMENTATION:
a) Whether level gauge of two types have been provided

for direct level measurement and counter checking?
b) Whether monitoring of levels of all the vessels are

done ?
c) Whether High Level alarms have been provided in

storage vessels and are in working conditions ?
d) Whether remote operated valves (ROVs) have been

provided on liquid outlets/inlets and are checked
for proper operations ?
1.5 FIRE AND SAFETY:
a) Whether gas detection system is provided in the

area and is working satisfactorily?
b) Whether capacity of fire water pumps and header

are adequately designed?
c) Whether sprinkler/Deluge system are provided on all

the vessels and are periodically tested for
satisfactory operation ?
d) Whether the sprinkler/Deluge Valve are remote

operated and are located 15M away from storage
vessels?
e) Whether the supports of the vessels are fire

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proofed?
f) Whether periodical checks are done with

explosive meters to detect any gas leaks?
1.6 ELECTRICAL:
a) Whether bonding strips have been used across the

flanges for electrical continuity ?
b) Whether all the electrical fittings in the area

meet area classification requirement?
c) Whether earthing connections are provided and are

properly maintained?
d) Whether illumination in the area is adequate?
2.0 PUMPS/COMPRESSORS AREA:
2.1 FACILITIES:
a) Whether the layout of the area meets statutory

requirements in terms of safety distance from
storage vessels, roads and other facilities?
b) Whether the pumps have double mechanical seals to

minimize leakage? Are the seals in good condition?
c) Whether recirculation line to storage vessels have

been provided?
d) Whether the venting is done through high

rise vents? Whether steam connections are
provided for atmospheric vents ?
e) Whether the drains/vents/sample points have double

isolation valves and are provided with caps?
f) Whether Gas Detection system has been provided in

the area and working satisfactorily?
2.2 ELECTRICAL:
a) Whether all the motors and other electrical

equipments such as terminal/junction boxes,
lighting fittings etc. are weather proof/
flameproof and are as per hazard area
classification requirements?
b) Whether the motors are provided with proper

earthing?
c) Whether illumination is adequate in the area ?

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2.3 GENERAL:
a) Whether all the equipments in the area are properly

painted?
b) Whether an established communication system exists

between the loading area and the pump area during
normal operation/emergency?
c) Whether safety instructions have been displayed?

(e.g. `NO SMOKING', `MEN AT WORK' etc.)
d) Whether all maintenance tools used in the area

are non sparking type?
2.4 FIRE PROTECTION:
a) Whether long range monitors/sprinkler system have

been installed to cover the area and are in good
working condition?
b) Whether adequate nos. of fire extinguishers have

been provided?
3.0 TANK WAGON GANTRY AREAS:
3.1 FACILITIES:
a) Whether the layout of the gantry meets statutory

requirements?
b) Whether the design, material selection and

installation of the gantry platform, loading
header, loading hoses etc. have been done as
per standard engineering norms adopting
proper safety guidelines of established norms.
c) Whether loading arm swivel joint gas seals are

periodically greased and maintained properly?
d) Whether high vent flame arrestors are cleaned

periodically?
e) Whether facilities have been provided to handle

leaky wagons in situ (Evacuation of T/Wagons)?
f) Whether emergency stop push button for loading

pumps exists in the gantry?
3.2 LOADING HEADERS AND ARMS:
a) Whether quick isolation valve/MOV has been provided

on the loading header and is operative?
b) Whether independent isolation valve provided on each
loading point?
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c) Whether loading velocities are maintained within

safe limits by providing restriction orifice on
each loading point ?
d) Whether loading headers are provided with proper

earthing/bonding connections?
e) Whether loading hoses not in use are stored

properly and open end is kept blinded?
f) Whether loading hoses are having any sign of

kinks/wears etc.?
g) Whether the following facilities are available on

each loading point ?
Excess flow check valve on the filling line
- vapor return line with check valve back to

storage vessel
- flexible hoses on filling vapor return line
h) Whether depressurising system has been provided

on the gantry header discharging to high vents/flare?
i) Whether temperature and pressure gauges have been

provided at convenient points ?
j) Whether the loading header is provided with ISV

relieving to high point vent ?
k) Whether proper capacity weigh bridge has been

provided on each spur of the gantry Any risk of
gas accumulation observed in the pit ?
l) Whether bonding strips as provided for

continuity of rail tracks ?
m) Whether bonding connectors (copper strips/wires

are provided for piping ?)
3.3 FIRE PROTECTION AND SAFETY :
a) Whether water sprinkler system has been provided

and working satisfactorily ?
b) Whether adequate nos. fire hydrants, long range

water monitors have been provided ?
c) Whether gas detector system have been provided

with alarm in the control room ?
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3.4 OPERATING PROCEDURE AND PRACTICES :
a) Whether updated operating manual

with loading/unloading procedures is available
In the control room and is well understood
by the operating crew ?
b) Whether the TXR staff check and issue fitness

certificates in writing for fitness of tank wagons ?
c) Whether checks are done for gaskets. "O" rings,

physical damage, any corrosion on tanker,
safety valve, thermometer etc. before commencement
of loading operation?
d) Whether the following are ensured before loading ?
- All engines nearby are switched off

- All hot jobs in the area are stopped
- Proper earthing connection are made
- All wagons are secured by hand brake
e) Whether it is ensured that non sparking tools

are used for connecting/disconnecting the hoses?
f) Whether used of any synthetic fiber material

was observed?
g) Whether loading hoses are periodically hydraulic

tested, discarded/replaced and records maintained?
h) Whether all hoses carry test code & date?
i) Whether constant supervision is ensured during

loading/unloading operation?
j) For detailed checklist for loading T/W pl.

refer to OISD-STD-144?
4.0 TANK TRUCK GANTRY AREAS
4.1 FACILITIES
a) Whether the truck loading facilities have

been installed as per CCE approved drawings?
b) Whether separate entry/exit gates exist for

the tank trucks?
c) Whether weigh bridge is available within the

Installation and is calibrated periodically
and maintained?
d) Whether the no. of trucks parked at the

gantry area is restricted?
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e) Whether facility available for evacuation/
decantation of defective/leaky trucks with
necessary high point vents with steam
connections?
f) Whether the following random checks are done

the tank trucks?
- Valid licenses
- fittings as per CCE such as flame arrestor,
fire screen etc.
- safety instruction booklet
g) Elimination of ignition sources like

loose wires, uncovered battery terminals etc.
Whether gas detection system has been
provided in the area & working satisfactory
4.2 OPERATION
a) Whether the vehicle engine is always shut

off during loading operations?
b) Whether it is ensured that earthing connection is

properly checked before connecting hoses to tank
truck?
c) Whether blank flanges are fitted on the truck

inlet flange and to the end of hoses when not in
use?
g) Whether loading arm open and is blinded when

not in use?
4.3 FIRE PROTECTION AND SAFETY
a) Whether water sprinkler system has been

provided and working satisfactorily?
b) Whether adequate nos. fire hydrants, long range

water monitors have been provided?
c) Whether gas detector system has been provided

with alarm in the control room?
d) Whether provision to start water sprinklers

from loading gantry/Control Room / Weigh
Bridge exists?
e) Whether water sprinkler system adequately covers

T/T bullet ?
f) Provision to stop pump from loading gantry / WB

Cabin ?
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5.0 TRAINING
a) Whether pocket size instruction booklets/manuals in

widely understood languages, have been issued to
all concerned employees ?
b) How it is ensured that loading operations such as

hose connection etc. are always done by plant
operators rather than tank truck crew ?
c) Whether operating procedures have been displayed

in vicinity of the tank loading bays ?
d) Whether protective gloves are being used by the

operating crew ?
e) Whether the vehicle crew has been trained on

hazardous nature of LPG and to handle emergency
situation ?
6.0 ADDITIONAL CHECKLIST ITEMS
For detailed checklist on specific areas refer

other OISD check lists as follows :
General (Organization Admn.

Training etc ) OISD-GDN-145-01
Fire fighting OISD-GDN-145-02
Gantry Operations OISD-GDN-145-06
Electrical OISD-GDN-145-09
BULK TT CHECKING :
How it is made sure that only TT fit for loading

are taken up for filling?(w.r.t. oxygen content
etc.)
For detailed checklist for loading TT pl .ref.to

OISD-STD-144.
77
SAFETY AUDIT CHECKLIST No.OISD GDN-145-08
LPG BOTTLING AND DISPATCH
CONTENTS
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1.0 GENERAL ORGANISATION AND ADMINISTRATION 61
2.0 MANPOWER AND TRAINING 61
3.0 CYLINDER STORAGE AREA 62
4.0 BOTTLING SHED 63
5.0 NEW AND DEFECTIVE CYCLINDERS 64
6.0 CYLINDER LOADING 65
7.0 SAFETY AND FIRE PROTECTION 66
9.0 SUGGESTED INSPECTIONS MAINTENANCE CHECKS 67
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LPG BOTTLING AND DISPATCH
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AUDITOR'S REMARKS
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1.0 GENERAL ORGANISATION AND ADMINISTRATION
a) Check for valid licenses of CCE pertaining

to the locations.
- Storage of LPG
- Storage of LPG cylinders
- Filling of LPG cylinders
b) Whether inter distances from/to admn. offices,

maintenance offices, check & change rooms,
smoking booths etc. are meeting safety
requirement.
c) Whether plant approach/access roads are well

maintained & at least one emergency exit
is provided.
d) Whether adequate no. of escape routes/staircases

available around each of the facilities viz.,
filling shed, cylinder storage area?
e) Whether fencing/boundary wall around the Plant

is in proper condition?
f) Whether truck parking area has been provided as

per OISD-STD-144.
g) Whether frisking of employees, contractor,

personnel and visitors ensured?
h) Whether work permit/clearance (for hot & cold

jobs) procedures followed as per approval?
i) Whether following manual/documents are

available and updated.
- LPG Operations Manual

- S&EP Manual
- Emergency/Disaster Control Plan
- Operation/Inspection/Repair Manual of
epuipment supplied by vendor.
- OISD Standards.
j) Whether updated P&ID drawings & layouts &

other facilities available?
k) Whether records of Daily Safety Check reports

are reviewed and corrective action taken?
l) Is the general housekeeping okay?

Any specific comments.
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2.0 MANPOWER & PLANNING
a) Whether supervisory/managerial cadre

staff fully trained in all aspects of LPG
Plant operations, Disaster Control/
Emergency handling?
b) Whether Safety Officer is available and

duly designated as safety officer.
Does he possess fire/safety engineering
qualifications and his duty list drawn
clearly?
c) Whether Training Programs are organized

periodically in LPG Operations fire
fighting/emergency handling etc. for:
- Regular Staff
- Tank Truck Operators/drivers
- Contractor Workmen
- Security Staff.
d) Whether operating manuals and standing

instructions are provided to working
personnel?
e) Whether safety booklets distributed to

all including contractor employees.
(English/Hindi/local language)?
f) Whether important Do's and Dont's

displayed prominently in operating areas?
3.0 CYLINDER STORAGE AREA
a) Whether Transfer of cylinders from/to

truck is done through
- Telescopic Conveyer/ Trolleys /Conveyers?
Any dropping, rolling, mishandling
noticed?
b) Whether Inspection/visual checks are done

to detect leaky/defective cylinders to
segregate spurious leaky/defective
cylinder?
c) Whether storage is segregated and marked

for?
- Spurious cylinders
- 5 year testing due cylinders
- Other defective cylinders
d) Whether cylinders stacked in vertical

position in tiers as per the norms?
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e) Whether stacking discipline with small

lots of 4 rows and 25 cylinder lengths
followed with a minimum access path of
1 M maintained on both sides of 4 rows.
f) Whether cylinders stacking areas are

periodically inspected for leakage with
explosimeter or probable leak detector?
g) Whether cylinder offload bay platform

provided with proper buffers?
i) Whether stacks of cylinder are identified

by markers to show empties, filed and
gas free cylinders?
j) Whether the daily stocks of cylinders

(empty/filled/defective) are displayed?
4.0 BOTTLING SHED
a) Whether cylinder washing facility

provided?
b) Whether filling/loading/unloading/storage
areas are adequately covered with mastic
coating on floors and pillars to avoid
accidental sparks?
c) Check for condition of mastic flooring.
d) Whether tare weight of the body is marked

distinctly on the body of the cylinder?
e) Whether empty cylinders are checked for

'o' ring presence?
f) Whether filling is done based on gross

weight?
g) Whether AUTO CUT OFF facility exists on

filling machines?
h) Whether filling head gun hoses are of

approved quality and periodically tested?
i) Whether proper earthing provided to?

a. Conveyers
b. Carousel units (bonding of filling
guns).
c. Unit filling Machines.
d. Evacuation units.
j) Check for accumulation of vapors in

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recess/pits in the area with the
explosimeter
k) Whether vapor extraction system with

suction points at carousel, evacuation
unit, valve change shed is provided and
in working condition?
- Whether standby blower is available?

- Whether carousel unit is interlocked
with vapor extraction system?
l) Whether accuracy of check scales being

checked daily and records maintained?
m) Whether filling machine check scales are

calibrated periodically and records
maintained?
n) Whether facilities are provided for

100% cross checking of weight of filled
cylinders? Are they in use?
o) Whether check weigh scales are -

calibrated periodically?
p) Whether CVT checks done after filling

forÒ' ring and valve defects?
q) Check for facilities:

- To check for conveyors
- To check defective cylinders
- To check 'O' Ring
- To check weight correction.
r) Whether bung leak/body leak checks are

done through in-line water bath for both
14.2. Kg. and 19 Kg. cylinders?
s) Whether capping/sealing facilities are

provided - Al foil/PVC seal?
t) Check for neck labels plastic/paper.
u) Whether tagging of overfilled/underfilled

cylinders done?
v) Check for leakage from carousel filling guns.
w) Whether persons working on carousel wear

hand gloves & safety shoes?
x) Whether Statistical Quality Control

checks (SQC) carried out & records
maintained? (See foot notes)
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y) Whether Movement of cylinders is done

through floor conveyers/trolleys?
statistical checks include
- Total No, of cylinders filled.

- Total No. of cylinders checked at
random.
- No. of cyls. found defective.
- % of cyls. found defective. in last
month
- Weight variation (Over filling)
- Weight variation (under filling)
- Valve leak
- Bung leak
- "O" Ring missing
- Defective "O" Ring (by CVT Test)
- 'Pressure Control valve' Filling
procedure
- Cyls. due for retesting
- Other minor defects
- Remarks if any.
5.0 NEW/DEFECTIVE/LEAKY CYLINDERS
a) Whether Purging facilities are available

for new/retested cylinders?
b) Whether Facilities provided for evacuation

of leaky/partially filled cylinder are
working satisfactorily?
c) Whether venting/cold flaring of LPG is

done at safe height - 2 meter above the
roof edge?
d) Whether Cold Repair facilities are

available? If so, are they at
appropriate location?
e) Whether wire mesh provided on cold flare

line?
f) Whether degassing facility provided in

cold repair shed? Is it 15 M away?
g) Whether cylinder repairs/valve change

etc are supervised?
h) Whether stock of leaky cylinders is below

the stipulated limits?
i) Whether Torque wrenches with proper

settings are used for valve removal
replacement (20 +/- 2 kg. Mt.)?
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j) Whether PTFE tape/paste used while fixing

valves?
k) Whether cylinders are checked for denting

are declared defective?
l) Whether records of defective cylinders

maintained supplierwise?
m) Whether records of leaky /defective

cylinders (company wise) detected during
filling/are maintained on daily basis with
following particulars:
- Cylinders filled
- Valve leak
- Bung leak
- Body leak
- "O" ring defect
- Spurious cylinders
n) Whether record of defective cylinders

returned by distributors is maintained on
daily basis?
o) Whether spurious cylinders and cylinders

declared as scrapes are destroyed by
crushing properly and records maintained?
6.0 CYLINDERS LOADING INTO TRUCK
a) Whether covered facilities/sheds provided

for positioning of trucks 15 M away from
storage shed for receipts / loading of
cylinders with sprinkler protection and
lighting?
b) Whether cylinders are loaded into trucks

through conveyers?
c) Whether cylinders stacked vertically

without protrusions?
d) Whether explosimeter checks are done

before releasing the truck?
e) Whether Loading/unloading of cylinders is

done in safe manner?
7.0 SAFETY & FIRE PROTECTION
a) Whether Contingency Plans are available

and updated for tackling major emergencies?
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b) Whether fire organisation chart is
prepared upto date and displayed?
c) Whether important telephone nos. of state

Fire Services/Police/Dist. Admn. /
Hospitals / other offices etc. are displayed?
d) Whether Fire/Emergency mock drills

conducted periodically?
e) Whether Fire Water Network provided

around the facilities is as per prescribed
norms and adequate?
f) Whether Pressure and flow are adequate at

farthest end?
g) Is system painted as per standard norms

(Hydrant pipelines - Red; risers/monitors
-yellow; & sprinkler system- Blue)
h) Whether hydrants/monitors are provided at

a minimum distance of 15 meters from the
sheds and provided for every 30 meters
distance?
i) Whether adequate No. of hydrants, long

range monitors etc. are provided and
periodically inspected and records
maintained?
j) Whether MV Spray Sprinkler System having

remote / local operated deluge valves
provided in the storage shed and in
working condition. Also whether in
critical areas like carousel evacuation
unit, valve change shed, automatic
detection of heat / flame for automatic
operation of sprinkler system provided?
k) Whether deluge valves are located 15

meters away from the limits of sheds and
protected by fire walls (One deluge valve
to cover an area of about 520 Sq. meters)?
l) Whether portable DCP Fire Extinguishers

are provided at appropriate location?
-2 Nos. 10 Kg. DCP FE per 200 Sq. Meters
area.
- 1 No. 100/70 Kg. DCP Mobile unit per
shed.
m) Whether gas monitoring system having

sensors to monitor gas leak near
carousel, evacuation unit, valve
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change shed provided? if so:
- Whether working satisfactorily?

- Whether periodically inspected and
records maintained?
n) Whether fire alarm/manually operated fire

siren and communication system consisting
paging system / flameproof telephones is
available & adequate?
o) Whether 'No smoking' and other cautions

sign in Hindi/English/local language
displayed at prominent places?
p) Whether Emergency lighting system

provided in strategic locations and is
working satisfactorily?
q) Whether Flame proof torches available?
8.0 ADDITIONAL CHECK LIST ITEMS
For detailed checklist on specific areas

refer other OISD check lists as follows:
General (Organisation
Admn. Training etc) OISD-GDN-145-01
Fire Fighting OISD-GDN-145-02
Gantry Operations OISD-GDN-145-06
Electrical OISD-GDN-145-09
86
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ITEMS AUDITORS REMARKS
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SUGGESTED INSPECTION & MAINTENANCE CHECKS
9.1 DAILY MAINTENANCE
a) Cleaning the cover plate of introduction device,

ejction device, air service units, filling guns, CVT
etc.
b) Water draining from filters of check

scales & filling gun.
c) Air leak control from check scale.
d) Checking/control of oil level in check

scale & filling gun.
e) Zero checking of Introduction

Device/Ejection Device, Air Service
Units, CVT etc.
f) Calibrations/Adjustments of devices
indicated in above.
g) Checking the sensitivity of check scales
h) Conducting test run/test filling to see

the performance of filling-gun, check
scales, introduction/ejection devices,
CVT etc.
9.2. WEEKLY MAINTENANCE
a) Oil topping in Air service unit/cleaning

of Air Filters.
b) Oil topping in dampers of in-line check

scales and calibration with standard
weights.
c) Cleaning of the bearings and suspensions

of Filling machines
d) Greasing & leakage control of

Introduction system & Ejection System.
e) Greasing/lubrication of :
- Central column
- Carousel Driving unit.
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9.3 QUARTERLY MAINTENANCE
a) Earthing strip tightness of equipment

like in-line control Check Scale & Filling
Machine.
b) Checking the filling hoses for stiffness

and replacement, if necessary.
c) Inspection of Gun hanger, ropes & pulley

inspections.
d) Inspection of wear & tear for knife edges

& bearing.
e) Calibration of filling machines with

standard weights.
f) Checking the level of Introduction system

& Ejection system.
9.4 ANNUAL MAINTENANCE
a) Overhauling of machines & replacement of

defective parts of filling machines,
check scales, introduction/ejection
system, central column & driving units.
b) Inspection of power cylinder of

introduction system & cleaning.
c) Inspection of ejection system for wear &

tear.
d) Inspection of rails of conveyer system

for setting &tightening of fish plate.
e) Inspection & adjustment for proper

functioning of Differential Pressure
valve.
88
SAFETY AUDIT CHECKLIST NO. OISD GDN-145-09
ELECTRICAL SYSTEM
CONTENTS
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1.0 SPECIAL REQUIREMENTS 70
2.0 SUBSTATION (EQUIPMENT & BUILDING) 71
3.0 SWITCHYARD AND OUTDOOR EQUIPMENT 73
4.0 CABLE NETWORK TERMINATIONS & JOINTS 73
5.0 MOTORS CONTROL STATIONS 74
6.0 LIGHTING INSTALLATIONS 75
7.0 EARTHING & BONDING 75
8.0 CAPTIVE GENERATION 77
9.0 BATTERY CHARGER/ UPS 78
10.0 ELECTRICAL HEAT TRACING 78
11.0 PORTABLE APPARATUS/ MOBILE 78

EQUIPMENT (ELECTRICAL /BATTERY OPERATED)
89
ELECTRICAL SYSTEM
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1.0 SPECIAL REQUIREMENTS
a) Whether main single line diagrams of

Electrical Power Distribution
"updated" and "As-built"?
b) Whether the Installations are duly

approved by the Chief Electrical
Inspectorate to Govt. for
energisation? (DGMS for Oil Field
Installations)
c) Is there any unauthorized

installation in operation including
temporary construction power
installations?
d) Whether action taken on IE inspector

visit report?
e) Whether electrical installations/repairs to

existing installations are being carried out
through licensed electrical contractors under
the supervision of Licensed Electrical
Supervisor (approved by State Govt.) As per
I.E. Rule No. 45)?
f) Are the electrical equipment installed conforming

to the Area Classification (IS:5572) approved by
CCE?
g) Whether there has been revision in

the hazardous area classification
from the original (due to
modifications/expansions etc.) and
the electrical equipment was
accordingly replaced to conform to
revised classification?
h) Whether the suggested remedial

measures given in the Accident Investigation
Reports, if any, have been implemented?
(Review the Accident Report of the last 5
years)?
i) Whether the list of electrical "authorized persons"

is being maintained (I.E. Rule No. 3) and
displayed?
j) Whether inspection of electrical equipment is

carried out, as per approved schedule (Review
the inspection records)?
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k) Whether approved work Permit System
is being followed?
l) Are the installations generally

rust/corrosion protected effectively?
(such as by using cadmium plated
Bolts/nuts, painting at regular
intervals etc)
m) Whether the substations / power

plant rooms/control room /MCC rooms
etc. are used as storage area for
scraps,oil drums, clothes, spares and such
other foreign materials
n) Are the flameproof features maintained intact

for flameproof equipment? (Any damages or missing
bolts /nut in the junction boxes/panel covers /terminal
boxes etc. convert the equipment to non-flameproof)
o) Whether flameproof telephones are used in the

classified hazardous areas?
p) Whether the Transformer & Switchyards are free

of vegetation/dry grass?
q) Whether all the electrical equipment( switchboards,

Relays, Motors, Transformers & Busducts etc.)
and junction / terminal boxes etc. are vermin proof?
r) Whether preventive Maintenance Schedules as

per OISD-STD-137 etc. carried out?
s) Whether CO2 fire extinguishers provided for

electric fires?
t) Whether sand-buckets provided?
2.0 SUBSTATION (EQUIPMENT & BUILDINGS)
a) Is the substation equipment freely

accessible for Operation, Inspection
and Maintenance?
b) Are the minimum clearances around

the equipment maintained as per I.E.
Rule 51?
c) Are all the substation equipment

provided with double earthing
connections?
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d) Are the live parts of equipment made

inaccessible from inadvertent
contacts? (by barriers/shrouds)?
e) Whether the rubber glove and mats

with voltage test seals are provided
in front of the switchboards and are
in good condition?
f) Whether the switchboards are

dust / verminproof? Is pest control
treatment given for substations?
g) Are any unused cable entries left open?
h) Have the protective relays been set

at the recommended values (as per the
design)?
i) Whether the fuses used are of HRC

Type and of ratings specified in the
single line diagrams ?
j) Whether each outgoing distinct

circuit from the switchboard is
separately controlled by a suitable
linked switch fuse or circuit breaker
of required capacity?
k) Whether circuit identification marks/

tags are provided or not?
l) Are the relays and meters tested for

proper functioning/calibration as per
approved schedule?
m) Whether the bus bars are provided with

distinct color identification ( Red,
Yellow, Blue and Black)?
n) Whether the conduits used for cable

entry are sealed and earthed?
o) Are the energized electrical equipment

provided with caution notices?
p) Is the substation building made

water tight and all the openings in
walls ( such as cable trench entry/
bus duct entry) sealed?
q) Whether any water stagnation is there

inside the cable trenches?
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r) Are all the power (H.T. & L.T) and
control cables in trenches properly
segregated?
s) Are the cables near the terminations

clamped?
t) Is there any combustible material

used for construction of substation
building?
u) Whether the cable trenches are

provided with concrete slabs /
chequered plates?
v) Are the earth electrodes periodically

tested and maintained properly?
w) Are the earth resistance of the grid

measured, checked and recorded
periodically?
x) Is the substation provided with

Emergency Lighting?
y) Is the substation provided with

telephone?
z) Is the trench sump pump ( for

dewatering ) in working condition
( wherever provided ) ?
aa) Are floors kept clean,free of tripping

hazards?
bb) Whether the switchgear rooms located

in the hazardous area are pressurized?
(if not, are these provided with
flameproof equipment)?
cc) Whether all panel doors are kept closed?
dd) Whether all the indicating lamps in

the Panel are in operating condition
(i.e. not fused)?
ee) Are the oil immersed starters filled

with oil to the required level and of
required dielectric strength?
ff) Whether shock restoration chart & First Aid Box provided?
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3.0 SWITCHYARD AND OUTDOOR EQUIPMENT.
a) Are the following components individually

earthed with two separate earthleads
( No. 8 SWG copper or equivalent)?
- Metal Frameworks
- A.B. Switches and circuit breakers
- D/O and H/G Fuses
- Poles/switches/insulator pins/stay
clamps
- Operating handle of the A.B. switch
b) Whether the vertical and horizontal

clearances from O.H. conductors are
maintained as per I.E. Rule (79)?
c) Are the earth electrodes provided in

sufficient number? Whether the
earth pits are properly maintained and
tests carried out as per schedule?
d) Whether the lightning arrestors are

connected after the A.B.switch, for
the protection of transformer/circuit
breaker?
e) Whether a separate earth electrode of

proper size is provided properly for
the lightning arrestors?
f) Is there O.H. shielding for lightning

protection and whether it is properly
maintained?
g) Whether there is locking arrangement

for the Transformer bay to prevent
entry to the yard by unauthorized
persons? If so, is it being followed?
h) Whether the doors of the gate are rusted

and need to be painted?
4.0 CABLE NETWORK/TERMINATIONS & JOINTS
a) Have the route markers and joint

location indicators been provided in
a permanent way throughout the Plant
and Off site areas?
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b) Whether the underground cables in
excavated trenches are laid at designed
depth with sand filling, brick
protection? (check at on Random trial
pit basis) Is u/g cable exposed at any
location?
c) Are the cables provided with

identification tags at intervals of
every 30 mts? (On Random Trial Pit
basis)
d) Whether all the cables throughout

their route protected mechanically
from any external damages?
e) Are the flameproof type terminations

for cables carried out in the
classified (Zone 1) areas?
f) Are the cable joints staggered and

having identification marks (when 2
or more cables laid in the same
trench)?
g) Is the oil seepage from process units

getting drained through or collected
in the cable trench/manholes?
h) Whether the armour of cables exposed at

the termination?
i) Are the cables directly taken to the

terminals without suitable cable
glands/clamps/armour earthing?
j) Are the cables above ground supported

with proper clamps?
k) Whether the cables :

(telephone/ power / lighting cables) are
taken through overhead system? (inside
Refinery / Process / Areas)? If so, what
is the arrangement?
l) Whether one run of earthing strip

fixed through the entire length of
cable Tray (wherever cable tray is
used) ?
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m) Whether proper mechanical protection

and water sealing arrangement
provided to cables especially at the
following locations:
- Road crossings
- Railway installations
- Cathodically protected u/g piping
- Water logged areas
- Drainage & other u/g facilities
- RCC structures/brick walls
- Where cables rise above ground
n) What are the fire protection arrangements

adopted for cables laid above ground?
o) Are the G.I. pipes (conduits) used for cable

entries (sleeves) sealed at both ends, and
conduits earthed?
p) Are all conduit ends for cables sealed at both

ends?
5.0 MOTORS CONTROL STATIONS
a) Whether there is annunciation facility in

case of failure of air supply ( wherever air
purging is used for flame proofness )? Is it
in working condition and monitored
regularly?
b) Is the approved inspection schedule

followed ? Records maintained?
c) Whether Terminal / junction Box properly

sealed / covered?
d) Is there any unauthorized modification

carried out ( by way of local fabrication etc.)
on the flameproof motors/control stations /
terminal boxes? ( to accommodate XLPE cable
termination etc.)
e) Whether the insulation resistance

values between phases and between
phases and earth of the motors are
within acceptable limits ? ( Select
a few critical motors at random)
f) Whether Emergency Isolating device

for the motor is installed near the
motor?
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g) Whether the double earthing provided

are from two separate distinct earth
connections of the grid?
h) Are the motors (75KW) provided with

spaceheater and local ammeters.
i) Whether painting of motor body

control station and supporting
structure are in good condition?
j) Whether there are motor guards

provided to prevent inadvertent
contact over the moving shaft?
k) Are the nameplates of Motors worn

out? Whether the inscriptions are
visible?
l) Whether the drive belts are

antistatic fire resistant type?
6.0 LIGHTING INSTALLATIONS
a) Whether separate distribution for

lighting system adopted from main
switchboard, through subdistribution/
fuse distribution & lighting panel final circuit boards?
b) Whether lighting provided is sufficient?

( compare with IES chart for required
levels of illumination at selected locations)?
c) Is there auto changeover system

provided for normal to emergency
system and if so, is it functioning
satisfactorily? (test this)
d) Whether the body of lighting fixtures

are separately earthed in addition to
cable armor earthing?
7. EARTHING & BONDING
a) Is the earthing carried out as per

IS:3043?
b) Is the earth leakage protection

wherever provided functioning
satisfactorily?
97
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c) Are the earth electrodes being tested

periodically? (Check the test records)
d) What is the grid resistance (in ohms)?

Is this periodically measured and recorded?
e) Whether all 3 phase equipments double

earthed and single phase equipment
single earthed?
f) Are all the loading arms earthed?
g) Is there earth continuity between the

flexible hoses and loading arms ?
h) Are the tanks, vessels, process

piping, steel columns, metallic
structures / sheds and buildings and
fencing etc. earthed?
I) Are the hardware used free from rust

or corrosion?
j) Are the Rail Tracks within the gantry

premises earthed and bonded?
k) Are the earthing connections to

lighting protection and electrical
system protection ( Neutral earthing
and body earthing) provided separately?
l) Whether there is any discontinuity of

earthing connections?
m) Whether the flexible wire used for

tanker body earthing ( TTL Gantry ) is
soldered to crocodile clips?
n) Whether crocodile clips have lost the

spring action causing improper grip
with the surface?
o) Whether earth jumpers across the pipe

flanges (of gantry piping) are provided?
p) Is the buried underground earth

conductors getting exposed at any
location?
98
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q) Whether the earth pits with chambers

are exposed and visible or is
embedded inside the loose earth?
r) Whether the earth strip connections

on the earth electrode are loose /
sheared off / tight?
s) Are the weigh bridge (truck) platforms

earthed?
t) Whether the earth strip joints are

having an overlapping equivalent to
the width of the strip (minimum) and
all the four sides are welded?
u) Whether all product and utility

pipelines earthed at every 25 meters
apart and also at the point where it
enters and leaves a shed, where
volatile liquids and vapors are handled?
v) Whether the earth strip runs

continuously through conveyers and
are the supporting structures also
earthed?
w) Whether all electronic equipments

which stores electrical energy are
properly earthed?
8.0 CAPTIVE GENERATION
a) Is the neutral of the generator

provided with an isolator?
b) Whether the neutral of the generator

is earthed by not less than two
separate and distinct earth
connections and whether the earthing
is after the isolator?
c) In case of High Voltage Generators

(Voltage above 650 V) whether the
neutral point is earthed by two
separate and distinct connections
with earth each having its own
electrode?
d) Whether the exposed wires near the

Generator/Generator to switch board
is in metallic conduit and the
conduit earthed?
99
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e) Whether the control panel for the

generator is earthed with two
separate and distinct connections with
earth?
f) Whether the generator panels are made

vermin proof?
g) Whether more than one generator is

provided, whether provision of
individual breakers are kept for
paralleling arrangement?
h) Whether danger notice is provided for

the generator enclosure?
i) Whether location (where generator is

installed ) is dry and dust free and
nearer to the loads?
j) Whether provided with fire and weather

proof enclosure with ventilation?
k) Whether the exhaustprovision

provided is away from the enclosure?
l) Whether control panel is available

near to the generator, equipped with all
protections ( short circuit, overcurrent,
and earthfault)?
m) If synchronized with grid, whether

effective measures are available to
prevent backfeeding?
n) For Prime Mover where fuels like

Naphtha, LSHS are used additional
safety precautions should be taken.
9.0 BATTERY / CHARGER/UPS
a) What is the type of battery used?
b) Whether the Battery room is clean and

well ventilated? Are the floors acid
proof?
c) Whether exhaust fans provided ?
100
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d) Are the cell voltage, specific

gravity of cell, and level of the
electrolyte being checked and
recorded as per approved schedules?
e) Is there any corrosion on terminals /

connectors?
f) Whether all the safety equipment

(Rubber apron, goggles, acid proof
hand gloves etc.) are available?
g) Is the operation of UPS satisfactory?

(Test for critical services)
h) Whether trickle charger working and

checked properly.
10.0 ELECTRIC HEAT TRACING
a) Whether all indication lamps are

functioning properly in the panel to
ensure healthiness of tracer circuits.
b) What is the automatic control or

protection provided for temperature
raising above allowable limit?
(Especially at hazardous areas) Is
this being tested periodically for
proper functioning.
c) Are there damages to insulation /

traces?
d) Is the system water tight?
101
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11.0 PORTABLE APPARATUS/MOBILE EQUIPMENT

(ELECTRICAL BATTERY OPERATED)
a) Is the electrical system of the

portable apparatus/mobile equipment
provided with Intrinsically safe /
flameproof features when required
to be taken to the classified hazardous
areas? ( check test certificates)
b) Are safe voltage (24 volts) being

maintained for use of portable
appliances such as hand lamps, torches,
etc. (used for inspection / testing) especially
in classified areas?
c) Whether the flexible cables used for

portable tools are free from damages
and consisting of too many joints?
Are the cables protected from
mechanical damages ( by providing
metallic sleeves etc.)?
d) Whether the cables used for portable

tools/equipment are 3 core for single
phase and four core for three phase
equipment respectively? Whether the 3rd /
4th core is used to earth the metallic
body/screen covering of the cable?
e) Are the power cables used for

portable equipment such as welding
machines, generators, switchboards
etc., provided with 'armoring' and
`gland' type terminations? Is the
armoring bonded to earth?
f) Are the portable tools/equipment

being checked every time before use
that there is no earth leakage? Is it
ensured safe to use, by a "competent"
person before issuing.
g) Whether ELCB provided for portable

equipment?
h) Are the portable equipment, including

the electrical system in the mobile
equipment / vehicles (Battery Operated),
and test instruments and tools
inspected regularly?
102
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i) Whether all wiring and current carrying parts

of an industrial electric truck, so constructed
and enclosed as to protect from mechanical
damages?
j) Whether any uninsulated current carrying part is

exposed especially on the outer surface of the truck?
k) Whether all the components are accessible for

maintenance/repairs?
l) Whether the battery has the protection by

means of a non combustible enclosure?
m) Are the Battery terminals provided with protective

rubber gloves?
n) Whether the battery enclosure is provided with

sufficient ventilation to minimize the possibility of
accumulation of explosive hydrogen air mixtures
above the battery?
o) Are there reported accidents due to improper

maintenance / the wrong use/wrong selection etc.
of Portable tools/Mobile equipment (Electrically
operated) in the last 2 years? (if so, verify the
accident investigation reports and
compliance of recommendations)
p) Whether connecting a welding machine

the return path of the welding
machine is directly connected to the work
piece with proper insulation?
103
10.0 CROSS-COUNTRY PIPELINE
CONTENTS
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1) COATING CONDITION 81
2) CATHODIC PROTECTION 81
3) POWER SUPPLY TO CP STATION 82
4) ULTRASONIC THICKNESS SURVEY 82
5) INTERNAL CORROSION 82
6) PIGGING 82
7) INHIBITOR INJECTION 83
8) CPL/EWP SURVEY 83
9) SOIL TESTING 84
10) MAINLINE VALVE 84
11) HYDROSTATIC TESTING 84
12) PIPELINE PATROLLING 84
13) TELECOMMUNICATION & TELEMETRY 84
14) SINGLE BUOY MOORING SYSTEM 86
15) CONTINGENCY PLANS 87
16) DOCUMENTATION 87
104
ELECTRICAL SYSTEM
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1.0 COATING CONDITIONS:
1.1 Is rolling plan for pearson, coating conductance

and current drainage surveys made? Yes/No
1.2 If 'yes' is the schedule maintained Yes/No
1.3 Coating Condition (Survey report Satisfactory /

to be checked not Satisfactory
1.4 Type of coating and its application method .....
2.0 CATHODIC PROTECTION:
(No. of C.P. Stations .....Nos.)
2.1 After revisioning of coating whether PSP

readings are recorded and monitored to
observe improvements Yes/No
2.2 Periodic calibration of AC & DC volt

meter/Ammeter and PSP Meter of CP Units Yes/No
2.3 Number of insulating joints .....Nos.
2.4 Dielectric strength of Insulation Joints Satisfactory/

Not satisfactory
2.5 Is schedule made for inspection of
insulation joints/couplings (yearly) Yes/No
2.6 No. of test lead points for PSP Survey ..... Nos.
2.7 Condition of test led points
2.8 Is schedule made for PSP survey Good/Bad

(PSP readings at feeding points) (PSP readings at
Test lead points quarterly) Yes/No
2.9 If 'yes' the findings Satisfactory/

Not Satisfactory
2.10 If 'not satisfactory, any action plan
drawn for correcting the deficiencies
on short term and long term basis? Yes/No
2.11 (a) Effectiveness of C.P. (To check

PSP profile graphs in conjunction Satisfactory / Not Satisfactory
with CP station reports) Not Satisfactory
(b) Is any stretch of pipeline left

cathodically unprotected for a period more
than one year Yes/No
105
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2.13 If 'YES' any action taken/plan drawn

for correcting the deficiencies Yes/No
2.14 Is the C.P. unit connected with

the earthing electrode ? Yes/No
2.15 Is the earthing resistance of

C.P. earthing electrode taken & record
maintained Yes/No
2.16 Are all the C.P. units provided

with the lightening arrestors Yes/No
2.17 Whether Lightening arrestor grid and

Equipment Earthing grids are segregated Yes/No
2.18 Safety aspects for fault condition

due to AC/DC power system -------
2.19 Is the ground bed circuit resistance

record maintained ? Yes/No
2.20 Is the di-electric strength of C.P. transformer

oil checked ? Yes/No
3.0 POWER SUPPLY TO CP STATION
3.1 Inspection of source .....
3.2 Power availability of CP

stations, average ........hrs./day
3.3 Condition of back up power Satisfactory/

supply, if any. Not Satisfactory
4.0 ULTRASONIC THICKNESS SURVEY
4.1 Is schedule made and followed for

thickness survey of mainline at :
4.1.1 Exposed section of Pipelines Yes/No
4.1.2 Sharp pipe bends/Riser bends Yes/No
4.2 If 'Yes", the findings Satisfactory/ Not satisfactory
4.3 If 'NOT SATISFACTORY', any

action plan for correcting
the deficiencies drawn Yes/No
4.4. Is two yearly schedule made for

thickness survey of unprotected
pipeline section from I/F to
scrapper launcher/receiver Yes/No
106
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5.0 INTERNAL CORROSION
5.1 Whether coupons are installed Yes/No
5.2 If yes, corrosion rate < 1 MPY 1 to 4.9 MPY/

> 4.9 MPY
5.3 Whether Electrical Resistance

probes are installed Yes/No
5.4 If yes, corrosion rate ? .....
6.0 PIGGING
6.1.0 Descaling
6.1.1 Is schedule made for pigging ? Yes/No
6.1.2 And,is followed Yes/No
6.1.3 Is pig residue/dirty product

analysis carried out? Yes/No
6.1.4 If yes, what is the value of

a) Fe 0 % by mass .....
b) Water, % by mass .....
c) pH value .....
d) Acidity, mg KOH/gm, .....
6.1.5 Based on pig residue analysis Satisfactory/Not satisfactory

internal condition of pipeline
6.2.0 Intelligent Pigging
6.2.1 Is any IPS survey carried

out ? Yes/No
6.2.2 If no, any schedule made for

carrying out the survey (once in
five years). Yes/No
6.2.3 If the survey has been carried

out, findings of the survey,
(To check the reports). Satisfactory /Not satisfactory
6.2.4 If not satisfactory, any

action plan has been drawn
to implement the recommendations Yes/No
7.0 INHIBITOR INJECTION
7.1 Is inhibitor injection being

done and records maintained Yes/No
107
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7.2. Average dosing of corrosion

inhibitor injection ...PPM/day
8.0 CPL/EWP SURVEY
8.1 Is any CPL/EWP SURVEYS CARRIED OUT Yes/No
8.2 If No, any schedule made for Yes/No

Carrying out the survey
(once in five years)
8.3 If the survey has been carried out,

what are the findings (To check the report) Satisfactory/Not Satisfactory
8.4 If not satisfactory, any action plan has been

drawn to implement the recommendations. Yes/No
9.0 SOIL TESTING
9.1 Soil samples within ROW being

tested once in five years. Yes/No
9.2 Is there any industrial affluent

flowing over the ROW Yes/No
9.3 If `yes', said sample tested to

determine the efficacy of the
existing coating of the pipe lines. Yes/No
9.4 Variations observed in soil resistivity .....
10.0 MAINLINE VALVE

(NO. OF MAINLINE VALVES .... NOS.)
10.1 Is schedule made for maintenance
of mainline valve Yes/No
10.2 If `yes', schedule followed and

valves operating freely. Yes/No
10.3 Supply to Motor Operated Valves

(MOV) available Yes/No
10.4 MOV working Locally/Remotely
11.0 HYDROSTATIC TESTING
11.1 Whether all repaired piping system are being

tested in accordance with OISD - 141&API -
1110 Yes/No
11.2 Whether sufficient number of pipe lengths, pretested

and kept at vulnerable locations for replacement
if required Yes/No
108
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12.0 PIPELINE PATROLLING
(Total length of Pipeline .....km)
12.1 Is the schedule made for
12.1.1 Ground Patrolling by Patrolman

each segment twice in a week
by physical walking. Yes/No
12.1.2 Helicopter surveillance

once in a month Yes/No
12.1.3 Right of way inspection and

maintenance of above ground
structures along ROW once
in a year Yes/No
12.1.4 Inspection of Pipeline crossings at
12.1.4.a Rail/Road Bridge and suspended

crossing (exposed pipeline)
quarterly Yes/No
12.1.4.b Road/Highway crossing

quarterly Yes/No
12.1.4.c Submerged river crossing

before and after monsoon Yes/No
12.2 If reply to the above is yes,

whether various reports filled/
monitored regularly and proper
checks on line patrolman
exercised ...
13.0 TELECOMMUNICATION & TELEMETRY

(NO.OF REPEATER STN...NOS)
13.1 Availability of Power supply Yes/No
13.2 If no, (other than load shedding)

corrective action taken Yes/No
13.3 Whether all the lights and

fans are working ? Yes/No
13.4 State Electricity Board Energy

Meter working ? Yes/No
13.5 Energy Meter Readings being noted Yes/No
13.6 All the Radio Parameters as per

109
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format are being checked Yes/No
13.7 Whether all the Radio Units are

in working condition ? Yes/No
13.8 If no, number of faulty units ... Nos.
13.9 Whether Engineering order wire

(E.O.W) working. Yes/No
13.10 Whether Rooms are in dust

free condition Yes/No
13.11 Whether all the parameters of

charger are properly working. Yes/No
13.12 Whether all the Battery voltages are

(should be above 2 volts)being checked Yes/No
13.13 Sick cells, if any, are being

identified and corrective action taken Yes/No
13.14 Whether specific Gravity of all the

cells recorded in a register Yes/No
13.15 Sufficient reserve of distilled

water available Yes/No
13.16 Check for the proper running

of D.G. Set carried out. Yes/No
13.17 Auto change over working ? Yes/No
13.18 Is it free from leakages ? Yes/No
13.19 Whether Diesel Tank of DG

set is full Yes/No
13.20 Whether all the alarms are

in working order ? Yes/No
13.21 Whether no. of fire buckets/

extinguishers adequate and
in working order ? Yes/No
13.22 Whether aviation tower lights

are in working condition ? Yes/No
13.23 Whether twilight switches

are in working condition ? Yes/No
13.24 Whether the tower painting is

done as per rolling plan ? Yes/No
13.25 Check the resistance of lightning

110
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arrestor (better than 2 ohms)
13.26 Whether Telecommunication link

VHF/UHF/Microwave/Fiber optics
is available ? Yes/No
13.27 Whether all the desired telesupervisory

signals are passed on to master control
station through remote terminal Unit
(RTU) and data monitored? Yes/No
13.28 Functional test of telecommunication/

telemetry system are being carried
out daily Yes/No
13.29 Telecommunication / Telemetry

equipments are being inspected
as per manufacturer's recommendations Yes/No
13.30 Pressure/Temperature/Flow recorder

charts are in working order and
are being checked for its safe limits Yes/No
13.31 Maintenance and inspection of

safety instrumentation are being followed
as per OISD-153. Yes/No
13.32 Whether Unauthorized Entry Alarm /

Signal system is in working condition? Yes/No
14.0 SINGLE BUOY MOORING SYSTEM
14.1 Whether the following items are being

inspected daily and records kept ?
- Free floatation of buoys Yes/No
- Draft Yes/No
- Free movement of rotating assembly Yes/No
14.2 Whether following items are being inspected

weekly and records kept ?
- Mooring ropes and ancillary equipments Yes/No

- Batteries Yes/No
- Navigational aids Yes/No
14.3 Whether visual inspection of buoys

and equipments for external corrosion
is carried out on monthly basis ? Yes/No
14.4 Whether following item are being inspected

on quarterly basis ?
- Anchor chains of buoys for wear

tear and tension Yes/No
- Fenders for damage Yes/No
111
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- Draft of buoys Yes/No
- Hose configuration Yes/No
- Hose with respect to PLEM Yes/No
- Sacrificial anodes Yes/No
- Swivel joints and turn tables Yes/No
14.5 Whether following items are being

inspected annually ?
- Expansion joints Yes/No

- Oil swivel seals Yes/No
14.6 Whether inspection of Hoses are

being done as per the requirements
of OISD-STD-135 Yes/No
15.0 CONTINGENCY PLANS:
15.1 Is there updated contingency

plans for emergencies at ?
- Installations Yes/No
- Mainlines Yes/No
- Off-shore facilities Yes/No
15.2 Is the contingency plans(s)

displayed in conspicuous place ? Yes/No
15.3 Are all the employees familiar

with it ? Yes/No
15.4 Is the list of Mainline emergency

equipments/tools available ? Yes/No
15.5 Are the mainline emergency equipments/

tools stacked separately and marked for
easy identification ? Yes/No
16.0 DOCUMENTATION
16.1 Whether the basic datas and parameters

of the Pipelines/SBM system layout,
length, diameter etc. are available in
Pipeline installation ? Yes/No
16.2 Whether complete route strip map

showing all the details of the
passage of the pipeline and all
isolation M/L valve locations
are available on record in
Pipeline installation? Yes/No
16.3 Whether list of various codes to

which Pipeline and SBM systems ?
112
ANNEXURE
CHECKLIST FOR SAFETY IN LABORATORIES

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1. Whether fire extinguishers are adequately positioned.
2. Whether important instructions, emergency procedures

displayed.
3. Whether fittings in storehouse for returnable petroleum samples

are of flameproof nature.
4. Whether ELCB/ECB installed in the main power switch board.
5. Whether samples of Class 'A' petroleum products in air

tight containers.
6. Whether emergency lighting available.
7. Whether the switches/plug sockets for various equipments

intrinsically safe.(Lab bench or near ground level)
8. Whether system exists for switching off all equipments at

the end of the day.
9. Whether any emergency siren button provided in the Lab.
10. Whether the on-site emergency plan includes possibility of

a fire in the Lab.
11. Whether the drainage system has been provided with a

oil trap.
12. Whether proper ventilation/exhaust system exists in the

fume chamber area.
13. Whether the height of the chimney in the fume chamber is

sufficient.
14. Whether entry to the Laboratory area is restricted.
15. Check the condition of Test benches & cupboards.
16. Is vacuum system adequate and working properly.
17. Are all Gas Cylinders kept outside buildings and kept
properly secured.
18. Is the condition of the utility lines healthy.
113
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OISD - GDN - 145

OIL INDUSTRY SAFETY DIRECTORATE

OIL INDUSTRY SAFETY DIRECTORATE

OIL INDUSTRY SAFETY DIRECTORATE publications are

Though every effort has been made to assure the accuracy

These documents are intended only to supplement and not

Note 3 in superscript indicates the

Different aspects of the Internal Safety Audits

In addition, comprehensive Check Lists are given in

The present document on Internal Safety Audits (Proce-

It is hoped that the provision of this document, if

This document will be reviewed periodically for

This is the second edition of the OISD

The first edition was prepared by OISD and did not

The original document has been now revised to

With the issuance of this edition, the guidelines

These guidelines are applicable

In the case of terminals where no

In the case of terminals where

The OISD-145 guidelines are

Shri Barath Balan Hindustan Petroleum Corporation Ltd.

Shri M.N. Ahmed Indian Oil Corporation Ltd.

Shri S.K. Ray Ex-Official Bharat Petroleum Corporation Ltd.

Shri T.S.Charvethia Bharat Petroleum Corporation Ltd.

Shri S.N.Rao Indian Oil Corporation Ltd.

Shri G.C.Sharma Bongaigaon Refinery & Petrochemicals Ltd

Shri M.Bhaskar Rao Hindustan Petroleum Corporation Ltd.

Shri I.J.Shroff Hindustan Petroleum Corporation Ltd.

Shri C.T.Ananthakrishnan Indian Oil Corporation Ltd.

Shri K.Madhusudanan Cochin Refineries Ltd.

Shri D.Madhukar Rao Gas Authority of India Ltd.

Shri S.C. Gupta Oil Industry Safety Directorate

SECTION - 1 INTERNAL SAFETY AUDIT

SECTION - 2 INTERNAL SAFETY AUDITS

INTERNAL SAFETY AUDITS

2.0 OBJECTIVES OF SAFETY AUDITS

3.0 SCOPE OF SAFETY AUDITS

4.0 TYPES OF SAFETY AUDITS

5.0 METHODOLOGY OF INTERNAL SAFETY AUDITS

5.1 Frequency of Audits

5.2 Formulation of multi-disciplinary Audit Teams

5.3 Duration of Audits

5.4 Use of Safety Audit Check Lists

5.5 Preparation before Site Visits for

5.7 Site Inspections

5.9 Study of Documents

6.0 PREPARATION OF AUDIT REPORTS

7.0 FOLLOW UP OF AUDIT REPORTS

8.0 IMPLEMENTATION OF RECOMMENDATIONS

2.0 OBJECTIVES OF SAFETY AUDITS

3. To ensure that operating / maintenance procedures, work practices are as per

4. To check on security, training, preparedness for handling emergencies

5. To check the compliance of statutory regulations, standards, codes, etc.

6. As a social objective to cater to public opinion and concern for safe

3.0 SCOPE OF SAFETY AUDITS

A Safety Audit subjects various areas of a company's activities to a systematic critical

4.0 TYPES OF SAFETY AUDITS

Two types of Safety Audits are proposed to be carried out as below :

I) Internal Safety Audit

5.0 METHODOLOGY OF INTERNAL SAFETY AUDITS

5.1 FREQUENCY OF AUDITS:

Group -I All LPG Storage, filling & dispatch facilities.

Group - III Oil Movement & Storage (OM&S)

Group - IV PROCESS UNITS :