Oisd GDN 145

Sr.
Number:OISD/DOC/2013/172
Page No. I
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 & Natural Gas
8th Floor, OIDB Bhavan, Plot No. 2, Sector 73, Noida 201301 (U.P.)
Website: www.oisd.gov.in
Tele: 0120-2593800, Fax: 0120-2593802
Sr.Number:OISD/DOC/2013/172
Page No. II
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

8th Floor, OIDB Bhavan,
Plot No. 2, Sector - 73
Noida 201301 (U.P.)
Page No. III
Preamble
Indian petroleum industry is the energy lifeline of the nation and its continuous performance is
essential for sovereignty and prosperity of the country. As the industry essentially deals with
inherently inflammable substances throughout its value chain upstream, midstream and
downstream Safety is of paramount importance to this industry as only safe performance at all
times can ensure optimum ROI of these national assets and resources including sustainability.
While statutory organizations were in place all along to oversee safety aspects of Indian petroleum
industry, Oil Industry Safety Directorate (OISD) was set up in 1986 Ministry of Petroleum and Natural
Gas, Government of India as a knowledge centre for formulation of constantly updated world-scale
standards for design, layout and operation of various equipment, facility and activities involved in this
industry. Moreover, OISD was also given responsibility of monitoring implementation status of these
standards through safety audits.
In more than 25 years of its existence, OISD has developed a rigorous, multi-layer, iterative and
participative process of development of standards starting with research by in-house experts and
iterating through seeking & validating inputs from all stake-holders operators, designers, national
level knowledge authorities and public at large with a feedback loop of constant updation based on
ground level experience obtained through audits, incident analysis and environment scanning.
The participative process followed in standard formulation has resulted in excellent level of
compliance by the industry culminating in a safer environment in the industry. OISD except in the
Upstream Petroleum Sector is still a regulatory (and not a statutory) body but that has not affected
implementation of the OISD standards. It also goes to prove the old adage that self-regulation is the
best regulation. The quality and relevance of OISD standards had been further endorsed by their
adoption in various statutory rules of the land.
Petroleum industry in India is significantly globalized at present in terms of technology content
requiring its operation to keep pace with the relevant world scale standards & practices. This
matches the OISD philosophy of continuous improvement keeping pace with the global
developments in its target environment. To this end, OISD keeps track of changes through
participation as member in large number of International and national level Knowledge Organizations
both in the field of standard development and implementation & monitoring in addition to updation
of internal knowledge base through continuous research and application surveillance, thereby
ensuring that this OISD Standard, along with all other extant ones, remains relevant, updated and
effective on a real time basis in the applicable areas.
Together we strive to achieve NIL incidents in the entire Hydrocarbon Value Chain. This, besides
other issues, calls for total engagement from all levels of the stake holder organizations, which we, at
OISD, fervently look forward to.
Jai Hind!!!
Executive Director
Page No. IV
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 (Procedure and checklists) was revised
by a Functional Committee constituted 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

8th Floor, OIDB Bhavan,
Plot No. 2, Sector - 73
Noida 201301 (U.P.)
.
Page No. V
NOTE
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 Ministry 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 amendments approved in the 19th Safety Council
meeting held in September, 2001July, 1999
Page No. VI
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.
Page No. VII
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
Page No. VIII
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

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

( Refineries )
Shri I.J.Shroff

( Refineries )
Shri C.T.Ananthakrishnan

(Marketing Division)
Shri K.Madhusudanan
Cochin Refineries Ltd.
Shri D.Madhukar Rao
Gas Authority of India Ltd.
MEMBER CO-ORDINATOR
Shri S.C. Gupta
-------------------------------------------------------------------------------------------------------------------------------------In addition to the above, several other experts from Industry contributed on the preparation, review
and finalisation of this document.
Page No. IX
OISD - GDN - 145

REVISION-I
GUIDELINES
ON
SECTION - 1
SECTION - 2
INTERNAL SAFETY AUDIT

PROCEDURE

CHECKLISTS
Page No. X
SECTION - 1

PROCEDURES
-------------------------------------------------------------------------------------------------------------------------------------SL. NO.
DESCRIPTION
PAGE NO.
-------------------------------------------------------------------------------------------------------------------------------------1.0
INTRODUCTION
1
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
2
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
-----------------------------------------------------------------------------------------------------------------------
Page No. 1
OISD GDN 145

PROCEDURES

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

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

environment. This also improves public relation of the organization.
for
handling emergencies and
for safe
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
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.
OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.
Page No. 2
OISD GDN 145

PROCEDURES
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 /

Units.
FCCU/HCU & H2 along with Treating
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.
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.
OISD GDN 145
Page No. 3

PROCEDURES
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.
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.
OISD GDN 145
Page No. 4

PROCEDURES
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.
OISD GDN 145
Page No. 5

PROCEDURES
SECTION : 2
CHECKLISTS
Page No. 6
OISD GDN 145

PROCEDURES
SECTION : 2
INTERNAL SAFETY AUDIT
CHECKLIST
CONTENTS
----------------------------------------------------------------------------------------------------------------------Sr.
CHAPTER
SAFETY AUDIT
PAGE NOS.
CHECK LIST NO.
------------------------------------------------------------------------------------------------------------------------------------------------1.
GENERAL SAFETY AUDITS
OISD-GDN-145-01
8
2.
FIRE PROTECTION
OISD-GDN-145-02
16
3.
LAYOUTS
OISD-GDN-145-03
23
4.
PROCESS PLANTS
OISD-GDN-145-04
30
5.
OIL STORAGE AND MOVEMENT
OISD-GDN-145-05
41
6.
POL LOADING AND UNLOADING
OISD-GDN-145-06
57
7.
LPG BULK LOADING /

UNLOADING
OISD-GDN-145-07
65
8.
LPG BOTTLING AND DISPATCH
OISD-GDN-145-08
73
9.
ELECTRICAL SYSTEM
OISD-GDN-145-09
84
10.
CROSS - COUNTRY PIPELINES
OISD-GDN-145-10
99
ANNEXURE
108
---------------------------------------------------------------------------------------------------------------------------------------
Page No. 7
OISD GDN 145

PROCEDURES
OISD-GDN - 145-01
REVISION I
SAFETY AUDIT CHECKLIST No.OISD-GDN-145-01
GENERAL SAFETY AUDITS

CONTENTS
--------------------------------------------------------------------------------------------------------------------------SECTION
DESCRIPTION
PAGE NO.
-----------------------------------------------------------------------------------------------------------------------1.0 ORGANISATION AND ADMINISTRATION
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
Management Philosophy
Procedures
Safety Audits
Safety Committee Meetings
Safety consciousness & Propagation
Work Permit System
Contingency/ Disaster Plan
Plant Security
2.0 INDUSTRIAL HAZARD CONTROL

2.1
2.2
2.3
2.4
2.5
2.6
2.7
House Keeping
Machine Guarding
General Safety features
Maintenance of Tools and Tackles
Materials handling
Personnel Protective Equipment
Toxic Materials and Occupational Health
8
8
8
8
8
9
9
9
10
10
10
10
10
11
11
11
11
3.0 EMPLOYEE TRAINING
12
4.0 FIRES, ACCIDENTS AND NEAR MISSES
12
4.1
4.2
4.3
4.4
4.5
Reporting formats
Reporting Procedures
Follow up of Recommendations
Maintenance of Records & Data
Review of Accidents Data
12
12
12
12
13
OISD GDN 145
Page No. 8

PROCEDURES
OISD-GDN-145-01
SAFETY AUDIT CHECKLIST
1.0 GENERAL SAFETY AUDITS
-----------------------------------------------------------------------------------------------------------------------ITEM
AUDITOR REMARKS
------------------------------------------------------------------------------------------------------------------------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 ?
OISD GDN 145
Page No. 9

PROCEDURES
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
------------------------------------------------------------------------------------------------------------------------------------------------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
place, for emergency uses?
d)
Whether these
plans
concerned authorities ?
are
central
approved
by
e) Are mock drills being conducted ?

f)
Whether the feed back generated from mock

drills is utilized to improve the plans?
OISD GDN 145
Page No. 10

PROCEDURES
-----------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
------------------------------------------------------------------------------------------------------------------------------------------------1.8 PLANT SECURITY
a) Whether
installation
has
wall/fence as per prescribed norms?
boundary
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
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
Ratings *
1
2
-
- Rotary equipment in operating

areas
- Workshops
- Others
-
2.2 MACHINE GUARDING
2.3 GENERAL SAFETY FEATURES

Check For:
- unprotected Floor openings
protected
- Slippery defective floors
- Stairway surfaces
-------------------------------------------------------------------------------------------------------------------------------------------------OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
OISD GDN 145
Page No. 11

PROCEDURES
ITEM
AUDITORS REMARK
-------------------------------------------------------------------------------------------------------------------------------------------------- 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 OISD145-04)
*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 ?
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 ?
OISD GDN 145
Page No. 12

PROCEDURES
ITEM
AUDITORS REMARK
------------------------------------------------------------------------------------------------------------------------------------------------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
performance?
are
Motivated
for
safety
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
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
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
OISD GDN 145
Page No. 13

PROCEDURES
------------------------------------------------------------------------------------------------------------------------------------------------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
a)
Implementation
Whether responsibility is assigned

implementing the recommendations?
for
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
4.5 REVIEW OF ACCIDENTS DATA
a) Is there any system to periodically review the
trends
of accidents for taking necessary
actions ?
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
OISD GDN 145
Page No. 14

PROCEDURES
------------------------------------------------------------------------------------------------------------------------------------------------b) Whether any review is under taken at top

management/ corporate level periodically, to
review the safety performance and new goals
are set up?
Page No. 15
OISD GDN 145

PROCEDURES
OISD-GDN-145-02
REVISION I

FIRE PROTECTION
CONTENTS
--------------------------------------------------------------------------------------------------------------------------SECTION
DESCRIPTION
PAGE NO.
-----------------------------------------------------------------------------------------------------------------------1.0
PHILOSOPHY AND STANDARDS
16
2.0
FACILITIES
16
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
Fire water
Fire Hydrant System
Foam System
Fire Station
Fire Extinguishers
Fire Hoses and Accessories
Protective/ Safety Equipment
Others
16
17
17
18
18
18
19
19
3.0
PROCEDURES
20
3.1
3.2
3.3
3.4
3.5
Organisations
Disaster Management Plan
Inspection and Testing facilities
Training
Checklist for DMP
20
20
21
21
22
OISD GDN 145
Page No. 16

PROCEDURES
OISD-GDN-145-02
2. FIRE PROTECTION
-------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITOR'S REMARKS
--------------------------------------------------------------------------------------------------------------------------------------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
for anticipated fires ?
and
reliable
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 ?
OISD GDN 145
Page No. 17

PROCEDURES
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
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
2.2.2
a.
b.
c.
d.
e.
f.
g.
2.3
a.
b.
c.
d.
Network - Grid type/Closed type/Any other

Mains
What's the material of construction of pipes
?
How corrosion protection is ensured ?
How is the sectionalising of hydrants system
?
How are the spacings between hydrants
Are monitors / hydrants properly distributed
in critical areas and all facilities covered ?
Are
these
hydrants/monitors
easily
accessible and operable ?
Is the layout vulnerable at any points from
fire hazard
FOAM SYSTEM
What are the types of foam available?
What are the dilution potential and the
quantities ?
What are the storage arrangements and its
accessibility
Do the coverage and application rate for
floating roof/fixed roof tanks meet OISD
norms ?
OISD GDN 145
Page No. 18

PROCEDURES
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
------------------------------------------------------------------------------------------------------------------------------------------------e.
Are foam branch pipes, nozzles, wheeled

equipments available and adequate as per
OISD Stnadard ?
f.
Proportioning equipment - suitability proper pick up
2.4
a.
FIRE STATION
Is the location away from hazardous
areas ?
Are the no. and variety of fire vehicles
sufficient ?
Facilities on fire vehicles capacity,
pressure, flow proportioning system etc.
Daily starting of vehicles and other
check logs.?
b.
c.
2.5
a.
FIRE EXTINGUISHERS
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

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

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

Are no of hoses sufficient w.r.t. no. of
hydrants in the system ?
Are the hose boxes strategically placed ?
Are the hoses easily removable during an
emergency ?
b.
c.
consumption
of
OISD GDN 145
Page No. 19

PROCEDURES
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
----------------------------------------------------------------------------------------------------------------------------------------------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
fires / emergencies.?
of
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.
-
Contingency Plan for medical

emergency.
OISD GDN 145
Page No. 20

PROCEDURES
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
------------------------------------------------------------------------------------------------------------------------------------------------- Evacuation, etc.
- First Aid training to personnel on shift.
2.8.4
Availability of
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
?
Is
periodic
fire
drill
conducted,
shortcomings observed and
necessary
action initiated ?
b.
c.
emergency,
lights
in
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.
b.
Whether resource requirements are worked

out
OISD GDN 145
Page No. 21

PROCEDURES
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
------------------------------------------------------------------------------------------------------------------------------------------------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
Whether training provided fire crew / other
employees / CISF etc. is in line with OISD
std. 154?
OISD GDN 145
Page No. 22

PROCEDURES
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
------------------------------------------------------------------------------------------------------------------------------------------------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 ?
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
?
Name, address, telephone numbers (Off.and Res.
) of anchorages / key persons are to be clearly
shown.
a.
b.
c.
d.
e.
f.
Mutual aid members

Police, fire and district authorities.
Hospitals and doctors
Medical shops, ambulance, blood bank,
blood donors,
Water supply dept. water transporter, elect.
boards, railways, port trust, telephone
exchange.
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 ?
Page No. 23
OISD GDN 145

PROCEDURES
OISD-GDN-145-03
REVISION I
SAFETY AUDIT CHECK LIST No. OISD GDN-145-03
LAYOUTS
CONTENTS
-------------------------------------------------------------------------------------------------------------------------------------SECTION
DESCRIPTION
PAGE NO.
------------------------------------------------------------------------------------------------------------------------------------------
1.0
TOPOGRAPHY OF INSTALLATION
24
2.0
SURROUNDING OF THE INSTALLATION
24
3.0
INTER - DISTANCES
24
4.0
TANKFARMS
24
4.1
4.2
4.3
Grouping of tanks
Dykes
LPG storage
24
24
25
5.0
PROCESS UNITS
25
5.1
5.2
5.3
Location
Control room
Field
25
25
25
6.0
OTHER FACILITIES AND EQUIPMENT
26
6.1
Electrical power lines
26
6.2
Electrical switchgear
26
6.3
Roads
26
6.4
Administrative buildings/ workshops/canteen
26
6.5
Boiler plants
26
6.6
Gantries
27
6.7
Waste water facilities
27
6.8
Water cooling towers
27
6.9
Elevated platforms
27
6.10
Piping
27
6.11
Rail spurs
27
6.12
Fire hydrants/ monitors/ safety showers/ hose etc.
27
6.13
Compressors
28
6.14
Miscellaneous
28
-------------------------------------------------------------------------------------------------------------------------------------------------
OISD-GDN-145-03
OISD GDN 145
Page No. 24

PROCEDURES

LAYOUTS
------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITOR'S REMARKS
------------------------------------------------------------------------------------------------------------------------------------------------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
relevant group
to
- Construction and dimensions of dyke wall

- Routing / Cris- crossing of process /
fire hydrant lines inside dyked tank
farm
- Provision of fire walls.
OISD GDN 145
Page No. 25

PROCEDURES
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
------------------------------------------------------------------------------------------------------------------------------------------------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
capacities
aggregate
-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 sewers and catch pits.
water
and storm
- Packing and grinding of susceptible leaky areas

OISD GDN 145
Page No. 26

PROCEDURES
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
------------------------------------------------------------------------------------------------------------------------------------------------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

product movement
for
employees
and
- 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
flammable materials
sources of
OISD GDN 145
Page No. 27

PROCEDURES
ITEM
AUDITORS REMARK
------------------------------------------------------------------------------------------------------------------------------------------------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
concentrations of people
ignition
sources /
- 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
OISD GDN 145
Page No. 28

PROCEDURES
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
-----------------------------------------------------------------------------------------------------------------------------------------------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
Page No. 29
OISD GDN 145

PROCEDURES
OISD-GDN-145-04
REVISION I
SAFETY AUDIT CHECKLIST No.OISD GDN-145-04

PROCESS PLANTS
CONTENTS
--------------------------------------------------------------------------------------------------------------SECTION
DESCRIPTION
PAGE NO.
---------------------------------------------------------------------------------------------------------------1.0
GENERAL
30
1.1
Layout and Drainage
30
1.2
Fire Protection facilities
30
1.3
Housekeeping
31
1.4
Training
31
1.5
Inspection & Maintenance
32
1.6
Electrical
32
1.7
Instrumentation
32
2.0
PROCESS SUB-SYSTEMS
33
2.1
Control room
33
2.2
Pump House
33
2.3
Compressor house
34
2.4
Heat exchangers/ condensers/ coolers
35
2.5
Process vessels and columns
35
2.6
Process furnaces
36
2.7
Process piping
37
2.8
Relief and Disposal System
37
2.9
First aid
39
OISD GDN 145
Page No. 30

PROCEDURES

4.0 PROCESS PLANTS
----------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARKS
-----------------------------------------------------------------------------------------------------------------------------------------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

been provided for draining of
from the vessels / equipments
pump out arrangement from
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
the plant as per the OISD-116 ?
system has
hydrocarbon
with proper
underground
OISD GDN 145
Page No. 31

PROCEDURES
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
-------------------------------------------------------------------------------------------------------------------------------------------------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. ?
OISD GDN 145
Page No. 32

PROCEDURES
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
------------------------------------------------------------------------------------------------------------------------------------------------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 ?
OISD GDN 145
Page No. 33

PROCEDURES
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
------------------------------------------------------------------------------------------------------------------------------------------------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) ?
OISD GDN 145
Page No. 34

PROCEDURES
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
------------------------------------------------------------------------------------------------------------------------------------------------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 ?
OISD GDN 145
Page No. 35

PROCEDURES
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
------------------------------------------------------------------------------------------------------------------------------------------------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 ?

OISD GDN 145
Page No. 36

PROCEDURES
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
------------------------------------------------------------------------------------------------------------------------------------------------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 ?
OISD GDN 145
Page No. 37

PROCEDURES
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
------------------------------------------------------------------------------------------------------------------------------------------------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 ?
OISD GDN 145
Page No. 38

PROCEDURES
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
------------------------------------------------------------------------------------------------------------------------------------------------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 ?
OISD GDN 145
Page No. 39

PROCEDURES
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
------------------------------------------------------------------------------------------------------------------------------------------------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
Page No. 40
OISD GDN 145

PROCEDURES

CONTENTS
-------------------------------------------------------------------------------------------------------------------------------------SECTION
DESCRIPTION
PAGE NO.
-------------------------------------------------------------------------------------------------------------------------------------1.0
TANK FARM
41
2.0
TANKS
42
3.0
PIPING
43
4.0
OPERATING PROCEDURES
44
5.0
46
6.0
ADDITIONAL CHECK LIST ITEMS
47
OISD GDN 145
Page No. 41

PROCEDURES

5.0
----------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITOR'S REMARKS
----------------------------------------------------------------------------------------------------------------------------------------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 ?
OISD GDN 145
Page No. 42

PROCEDURES
------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
--------------------------------------------------------------------------------------------------------------------------------------------------
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 ?
OISD GDN 145
Page No. 43

PROCEDURES
------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
-------------------------------------------------------------------------------------------------------------------------------------------------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 ?
OISD GDN 145
Page No. 44

PROCEDURES
------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
-----------------------------------------------------------------------------------------------------------------------------------------------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.
OISD GDN 145
Page No. 45

PROCEDURES
------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
-------------------------------------------------------------------------------------------------------------------------------------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 ?
OISD GDN 145
Page No. 46

PROCEDURES
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
-------------------------------------------------------------------------------------------------------------------------------------------------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
Note 3
followed.
j)
What are the schedules for painting

of tanks ?
OISD GDN 145
Page No. 47

PROCEDURES
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
-------------------------------------------------------------------------------------------------------------------------------------------------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
OISD GDN 145
Page No. 48

PROCEDURES
POL LOADING & UNLOADING

A. TANK WAGONS
CONTENTS
-------------------------------------------------------------------------------------------------------------------------------------------------SECTION
DESCRIPTION
PAGE NO.
-------------------------------------------------------------------------------------------------------------------------------------------------1.0
FACILITIES AND SYSTEMS
49
1.1
Tank Wagon Gantry
49
1.1.1
General
49
1.1.2
Drainage
49
1.1.3
Miscellaneous
49
1.1.4
Electrical
49
2.0
OPERATING PROCEDURES AND PRACTICES
49
2.1
Placement of rakes and loading
49
2.2
Sick wagons
51
2.3
House keeping
51
Page No. 49
OISD GDN 145

PROCEDURES
OISD-GDN-145-06
6.0
POL LOADING & UNLOADING-TANK
WAGONS
A. TANK WAGONS
-------------------------------------------------------------------------------------------------------------------------------------------------AUDITOR'S REMARKS
-------------------------------------------------------------------------------------------------------------------------------------------------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

bonding strips and connected to
maintained earthing system ?
with
well
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
a.
PLACEMENT OF RAKES AND LOADING

Whether the type
used are :
of
loco
-diesel
-steam
-electric
OISD GDN 145
Page No. 50

PROCEDURES
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
-------------------------------------------------------------------------------------------------------------------------------------------------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
Whether any loose shunting is done ?
Whether the shunting speed of 10 kmph

(Max.) is maintained ?
Whether necessary caution boards

are displayed while loading / unloading
in progress ?
OISD GDN 145
Page No. 51

PROCEDURES
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
-------------------------------------------------------------------------------------------------------------------------------------------------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 ?
OISD GDN 145
Page No. 52

PROCEDURES
SAFETY AUDIT CHECKLIST No. OISD GDN-145-06

POL LOADING & UNLOADING B. TANK TRUCKS
CONTENTS
-------------------------------------------------------------------------------------------------------------------------------------------------SECTION
DESCRIPTION
PAGE NO.
-------------------------------------------------------------------------------------------------------------------------------------------------1.0
FACILITIES & SYSTEMS
53
1.1
Headers & loading hoses
53
2.0
53
2.1
Placement of trucks
53
2.2
Loading operations
53
3.0
VEHICLE CREW AND CHECK
54
OISD GDN 145
Page No. 53

PROCEDURES

6.0 POL LOADING & UNLOADING - TANK TRUCKS
B. TANK TRUCKS
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITOR'S REMARKS
-------------------------------------------------------------------------------------------------------------------------------------------------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 ?
Whether any parking / place has been

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

is allowed only on production of filling advice ?
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 ?
Whether decantation of any over filled

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

completion of loading :
Fill pipes properly capped

Top covers are properly closed and
sealed
OISD GDN 145
Page No. 54

PROCEDURES
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
-------------------------------------------------------------------------------------------------------------------------------------------------3.0 VEHICLE AND CREW CHECK
a
Whether the vehicles design has been

approved by CCE ?
Whether
license and explosives
certificates are available in
the
vehicle ?
Whether the vehicle is in good condition and the

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

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

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

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

extinguishers ?
Whether the gross and tare weight painted

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

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

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

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

license ?
Whether the crew is trained for hazardous

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

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

of tank truck and has ample clearance
from Fuel oil system and combustible
material ?
OISD GDN 145
Page No. 55

PROCEDURES
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
-------------------------------------------------------------------------------------------------------------------------------------------------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. ?
Whether vent openings are covered with

two layers of wire-mesh of size not less
than 11 mesh per centimeter ?
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.
Whether effective spark arrestors fitted

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

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

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

properly ?
Whether electrical equipments like

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

position with a heavy duty switch
close by, to cut off the battery in
emergency ?
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 ?
Page No. 56
OISD GDN 145

PROCEDURES
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
-------------------------------------------------------------------------------------------------------------------------------------------------SECTION
DESCRIPTION
PAGE NO.
-------------------------------------------------------------------------------------------------------------------------------------------------1.0 FACILITIES & SYSTEMS
57
1.1
Pump house
57
1.2
Structure & platforms
57
1.3
Headers and loading arms
58
1.4
Drainage
59
1.5
Miscellaneous
59
1.6
Electrical
59
2.0
60
2.1
Inspection & maintenance
61
2.2
Work Permit Systems
61
2.3
House keeping
61
2.4
Training
61
2.5
Miscellaneous
62
3.0
62
4.0
ADDITIONAL CHECKLIST
63
OISD GDN 145
Page No. 57

PROCEDURES

6.0 POL LOADING AND UNLOADING
C. COMMON CHECKLIST FOR LOADING AND
UNLOADING OF TWs & TTs
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITOR'S REMARKS
------------------------------------------------------------------------------------------------------------------------------------------------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 ?
OISD GDN 145
Page No. 58

PROCEDURES
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
-------------------------------------------------------------------------------------------------------------------------------------------------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
a)
b)
HEADERS & LOADING ARMS

Comment as to how the loading
velocities are maintained within safe
limits ?
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)
i)
Whether proper
arrangement has been
provide for securing the hose nozzle with
manhole and properly secured after loading
(T/T & T/W)?
Whether vacuum breaker is provided on the
loading arm ?
OISD GDN 145
Page No. 59

PROCEDURES
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
-------------------------------------------------------------------------------------------------------------------------------------------------j)
k)
1.4
Whether the rubber hose are of proper

diameter, length, quality and condition & meets
BIS norms?
Whether the idle loading
headers/
loading arms not in use for long time
are blinded off ?
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

the smoking booths, are well
maintained ?
1.6
in
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 ?
OISD GDN 145
Page No. 60

PROCEDURES
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
-------------------------------------------------------------------------------------------------------------------------------------------------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 ?
OISD GDN 145
Page No. 61

PROCEDURES
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
-------------------------------------------------------------------------------------------------------------------------------------------------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
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
a)
HOUSE KEEPING
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 ?
OISD GDN 145
Page No. 62

PROCEDURES
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
-------------------------------------------------------------------------------------------------------------------------------------------------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 ?
3.0
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 ?
OISD GDN 145
Page No. 63

PROCEDURES
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
-------------------------------------------------------------------------------------------------------------------------------------------------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

Fire fighting
Layouts
Electrical Systems
OISD-GDN-145-01
OISD-GDN-144-02
OISD-GDN-145-03
OISD-GDN-145-09
OISD GDN 145
Page No. 64

PROCEDURES
SAFETY AUDIT CHECKLIST No.OISD-145-07
LPG BULK LOADING & UNLOADING

CONTENTS
-------------------------------------------------------------------------------------------------------------------------------------------------SECTION
DESCRIPTION
PAGE NO.
-------------------------------------------------------------------------------------------------------------------------------------------------1.0
BULK STORAGE AREA
65
2.0
PUMPS/ COMPRESSORS AREA
67
3.0
TANK WAGON GANTRY AREA
68
4.0
TANK TRUCK GANTRY AREA
70
5.0
TRAINING
72
6.0
ADDITIONAL CHECKLIST ITEMS
72
OISD GDN 145
Page No. 65

PROCEDURES

7.0 LPG BULK LOADING & UNLOADING
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITOR'S REMARKS
-------------------------------------------------------------------------------------------------------------------------------------------------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 satisfactory ?
d)
Whether storage vessels are insulated. If so, what

is the condition of insulation.
e)
Whether five year hydraulic test records are available ?
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 isolation valves?If so what is the system/ method to
avoid inadvertent closing of isolation valves ?
e)
Whether the safety valves are periodically tested

OISD GDN 145
Page No. 66

PROCEDURES
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
-------------------------------------------------------------------------------------------------------------------------------------------------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

OISD GDN 145
Page No. 67

PROCEDURES
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
-------------------------------------------------------------------------------------------------------------------------------------------------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 ?

OISD GDN 145
Page No. 68

PROCEDURES
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
-------------------------------------------------------------------------------------------------------------------------------------------------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?
Whether independent isolation valve provided on each
loading point?
b)
OISD GDN 145
Page No. 69

PROCEDURES
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
-------------------------------------------------------------------------------------------------------------------------------------------------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 ?
OISD GDN 145
Page No. 70

PROCEDURES
ITEM
AUDITORS REMARK
-------------------------------------------------------------------------------------------------------------------------------------------------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?
OISD GDN 145
Page No. 71

PROCEDURES
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
-------------------------------------------------------------------------------------------------------------------------------------------------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 ?
OISD GDN 145
Page No. 72

PROCEDURES
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
-------------------------------------------------------------------------------------------------------------------------------------------------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

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
Layouts
OISD-GDN-145-03
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.
Page No. 73
OISD GDN 145

PROCEDURES
SAFETY AUDIT CHECKLIST No.OISD GDN-145-08

CONTENTS
-------------------------------------------------------------------------------------------------------------------------------------------------SECTION
DESCRIPTION
PAGE NO.
-------------------------------------------------------------------------------------------------------------------------------------------------1.0
GENERAL ORGANISATION AND ADMINISTRATION
74
2.0
MANPOWER AND TRAINING
75
3.0
CYLINDER STORAGE AREA
75
4.0
BOTTLING SHED
76
5.0
NEW AND DEFECTIVE CYCLINDERS
78
6.0
CYLINDER LOADING
79
7.0
SAFETY AND FIRE PROTECTION
79
8.0
81
9.0
SUGGESTED INSPECTIONS MAINTENANCE CHECKS
82
OISD GDN 145
Page No. 74

PROCEDURES

-------------------------------------------------------------------------------------------------------------------------------------------------AUDITOR'S REMARKS
-------------------------------------------------------------------------------------------------------------------------------------------------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)
k)
l)
Whether updated P&ID drawings & layouts &

other facilities available?
Whether records of Daily Safety Check reports
are reviewed and corrective action taken?
Is the general housekeeping okay?
Any specific comments.
OISD GDN 145
Page No. 75

PROCEDURES
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
-------------------------------------------------------------------------------------------------------------------------------------------------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?
OISD GDN 145
Page No. 76

PROCEDURES
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
-------------------------------------------------------------------------------------------------------------------------------------------------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

OISD GDN 145
Page No. 77

PROCEDURES
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
-------------------------------------------------------------------------------------------------------------------------------------------------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)
OISD GDN 145
Page No. 78

PROCEDURES
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
-------------------------------------------------------------------------------------------------------------------------------------------------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.)?
OISD GDN 145
Page No. 79

PROCEDURES
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
-------------------------------------------------------------------------------------------------------------------------------------------------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

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?
vertically
OISD GDN 145
Page No. 80

PROCEDURES
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
-------------------------------------------------------------------------------------------------------------------------------------------------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
OISD GDN 145
Page No. 81

PROCEDURES
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
-------------------------------------------------------------------------------------------------------------------------------------------------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
Layouts
OISD-GDN-145-03
Gantry Operations
OISD-GDN-145-06
Electrical
OISD-GDN-145-09
OISD GDN 145
Page No. 82

PROCEDURES
----------------------------------------------------------------------------------------------------------------------ITEMS
AUDITORS REMARKS
-------------------------------------------------------------------------------------------------------------------------------------------
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.
OISD GDN 145
Page No. 83

PROCEDURES
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
-------------------------------------------------------------------------------------------------------------------------------------------------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.
Page No. 84
OISD GDN 145

PROCEDURES
SAFETY AUDIT CHECKLIST NO. OISD GDN-145-09

ELECTRICAL SYSTEM
CONTENTS
-------------------------------------------------------------------------------------------------------------------------------------------------SECTION
DESCRIPTION
PAGE NO.
-----------------------------------------------------------------------------------------------------------------------------------------------1.0 SPECIAL REQUIREMENTS
85
2.0 SUBSTATION (EQUIPMENT & BUILDING)
86
3.0 SWITCHYARD AND OUTDOOR EQUIPMENT
89
4.0 CABLE NETWORK TERMINATIONS & JOINTS
89
5.0 MOTORS CONTROL STATIONS
91
6.0 LIGHTING INSTALLATIONS
92
7.0 EARTHING & BONDING
92
8.0 CAPTIVE GENERATION
94
9.0 BATTERY CHARGER/ UPS
95
10.0 ELECTRICAL HEAT TRACING
96
11.0 PORTABLE APPARATUS/ MOBILE

EQUIPMENT (ELECTRICAL /BATTERY OPERATED)
97
OISD GDN 145
Page No. 85

PROCEDURES

ELECTRICAL SYSTEM
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITOR'S REMARKS
-------------------------------------------------------------------------------------------------------------------------------------------------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)?
OISD GDN 145
Page No. 86

PROCEDURES
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
-------------------------------------------------------------------------------------------------------------------------------------------------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

electric fires?
t)
Whether sand-buckets provided?
extinguishers provided for
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?
OISD GDN 145
Page No. 87

PROCEDURES
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
-------------------------------------------------------------------------------------------------------------------------------------------------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?
OISD GDN 145
Page No. 88

PROCEDURES
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
-------------------------------------------------------------------------------------------------------------------------------------------------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?
OISD GDN 145
Page No. 89

PROCEDURES
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
-------------------------------------------------------------------------------------------------------------------------------------------------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
earth pits are properly maintained and
tests carried out as per schedule?
the
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?
OISD GDN 145
Page No. 90

PROCEDURES
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
-------------------------------------------------------------------------------------------------------------------------------------------------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) ?
OISD GDN 145
Page No. 91

PROCEDURES
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
-------------------------------------------------------------------------------------------------------------------------------------------------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?
OISD GDN 145
Page No. 92

PROCEDURES
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
-------------------------------------------------------------------------------------------------------------------------------------------------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?
OISD GDN 145
Page No. 93

PROCEDURES
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
-------------------------------------------------------------------------------------------------------------------------------------------------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?
OISD GDN 145
Page No. 94

PROCEDURES
------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
-------------------------------------------------------------------------------------------------------------------------------------------------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?
OISD GDN 145
Page No. 95

PROCEDURES
------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
-------------------------------------------------------------------------------------------------------------------------------------------------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 exhaust provision

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 ?
OISD GDN 145
Page No. 96

PROCEDURES
------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
-------------------------------------------------------------------------------------------------------------------------------------------------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?
OISD GDN 145
Page No. 97

PROCEDURES
------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
-------------------------------------------------------------------------------------------------------------------------------------------------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?
OISD GDN 145
Page No. 98

PROCEDURES
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
--------------------------------------------------------------------------------------------------------------------------------------------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

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?
by
Page No. 99
OISD GDN 145

PROCEDURES

10.0 CROSS-COUNTRY PIPELINE
CONTENTS
-------------------------------------------------------------------------------------------------------------------------------------------------SECTION
DESCRIPTION
PAGE NO.
-------------------------------------------------------------------------------------------------------------------------------------------------1)
COATING CONDITION
100
2)
CATHODIC PROTECTION
100
3)
POWER SUPPLY TO CP STATION
101
4)
ULTRASONIC THICKNESS SURVEY
101
5)
INTERNAL CORROSION
102
6)
PIGGING
102
7)
INHIBITOR INJECTION
102
8)
CPL/EWP SURVEY
103
9)
SOIL TESTING
103
10)
MAINLINE VALVE
103
11)
HYDROSTATIC TESTING
103
12)
PIPELINE PATROLLING
103
13)
TELECOMMUNICATION & TELEMETRY
104
14)
SINGLE BUOY MOORING SYSTEM
106
15)
CONTINGENCY PLANS
107
16)
DOCUMENTATION
107
Page No. 100
OISD GDN 145

PROCEDURES

ELECTRICAL SYSTEM
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITOR'S REMARKS
-------------------------------------------------------------------------------------------------------------------------------------------------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

to be checked
Satisfactory /
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
(PSP readings at feeding points) (PSP readings at
Test lead points quarterly)
2.9 If 'yes' the findings
2.10 If 'not satisfactory, any action plan
drawn for correcting the deficiencies
on short term and long term basis?
2.11 (a) Effectiveness of C.P. (To check
PSP profile graphs in conjunction
with CP station reports)
(b) Is any stretch of pipeline left
cathodically unprotected for a period more
than one year
Good/Bad
Yes/No
Satisfactory/
Not Satisfactory
Yes/No
Satisfactory / Not Satisfactory

Not Satisfactory
Yes/No
Page No. 101
OISD GDN 145

PROCEDURES
------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
-------------------------------------------------------------------------------------------------------------------------------------------------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 ?
2.15 Is the earthing resistance of
C.P. earthing electrode taken & record
maintained
Yes/No
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
3.3 Condition of back up power
supply, if any.
.....
........hrs./day
Satisfactory/
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
Page No. 102
OISD GDN 145

PROCEDURES
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
-------------------------------------------------------------------------------------------------------------------------------------------------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
If yes, what is the value of

a)
Fe 0 % by mass
b)
Water, % by mass
c)
pH value
d)
Acidity, mg KOH/gm,
.....
.....
.....
.....
6.1.4
6.1.5
Based on pig residue analysis

internal condition of pipeline
6.2.0
Intelligent Pigging
6.2.1
Is any IPS survey carried

out ?
Yes/No
If no, any schedule made for

carrying out the survey (once in
five years).
Yes/No
6.2.2
6.2.3
6.2.4
If the survey has been carried

out, findings of the survey,
(To check the reports).
If not satisfactory, any
action plan has been drawn
to implement the recommendations
Satisfactory/Not satisfactory
Satisfactory /Not satisfactory
Yes/No
7.0 INHIBITOR INJECTION

7.1 Is inhibitor injection being
done and records maintained
Yes/No
Page No. 103
OISD GDN 145

PROCEDURES
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
-------------------------------------------------------------------------------------------------------------------------------------------------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

Carrying out the survey
(once in five years)
Yes/No
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

11.0
Locally/Remotely
HYDROSTATIC TESTING
11.1 Whether all repaired piping system are being

tested in accordance with OISD - 141&API 1110
11.2 Whether sufficient number of pipe lengths, pretested
and kept at vulnerable locations for
replacement
if required
Yes/No
Yes/No
Page No. 104
OISD GDN 145

PROCEDURES
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
-------------------------------------------------------------------------------------------------------------------------------------------------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.
12.1.2 Helicopter surveillance
once in a month
12.1.3 Right of way inspection and
maintenance of above ground
structures along ROW once
in a year
Yes/No
Yes/No
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
Whether all the lights and

fans are working ?
Yes/No
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
13.3
13.4
Page No. 105
OISD GDN 145

PROCEDURES
------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
-------------------------------------------------------------------------------------------------------------------------------------------------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
Whether Rooms are in dust

free condition
Yes/No
Whether all the parameters of

charger are properly working.
Yes/No
13.10
13.11
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
Whether specific Gravity of all the

cells recorded in a register
Yes/No
Sufficient reserve of distilled

water available
Yes/No
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
Whether all the alarms are

in working order ?
Yes/No
Whether no. of fire buckets/

extinguishers adequate and
in working order ?
Yes/No
Whether aviation tower lights

are in working condition ?
Yes/No
Whether twilight switches

are in working condition ?
Yes/No
Whether the tower painting is

done as per rolling plan ?
Yes/No
13.14
13.15
13.16
13.20
13.21
13.22
13.23
13.24
13.25
Check the resistance of lightning

Page No. 106
OISD GDN 145

PROCEDURES
------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
-------------------------------------------------------------------------------------------------------------------------------------------------arrestor (better than 2 ohms)
13.26
13.27
13.28
13.29
13.30
13.31
13.32
Whether Telecommunication link

VHF/UHF/Microwave/Fiber optics
is available ?
Yes/No
Whether all the desired telesupervisory

signals are passed on to master control
station through remote terminal Unit
(RTU) and data monitored?
Yes/No
Functional test of telecommunication/

telemetry system are being carried
out daily
Yes/No
Telecommunication / Telemetry
equipments are being inspected
as per manufacturer's recommendations
Yes/No
Pressure/Temperature/Flow recorder
charts are in working order and
are being checked for its safe limits
Yes/No
Maintenance and inspection of

safety instrumentation are being followed
as per OISD-153.
Yes/No
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
Draft
Free movement of rotating assembly
Yes/No
Yes/No
Yes/No
14.2 Whether following items are being inspected

weekly and records kept ?
- Mooring ropes and ancillary equipments
- Batteries
- Navigational aids
Yes/No
Yes/No
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
Fenders for damage
Yes/No
Yes/No
Page No. 107
OISD GDN 145

PROCEDURES
------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
------------------------------------------------------------------------------------------------------------------------------------------------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
Oil swivel seals
Yes/No
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
Mainlines
Off-shore facilities
Yes/No
Yes/No
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 ?
OISD GDN 145
Page No. 108

PROCEDURES
ANNEXURE
CHECKLIST FOR SAFETY IN LABORATORIES
-------------------------------------------------------------------------------------------------------------------------------------------------ITEM
AUDITORS REMARK
-------------------------------------------------------------------------------------------------------------------------------------------------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.

Oisd GDN 145

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OISD - GDN - 145

Oil Industry Safety Directorate

OISD - GDN - 145

COMMITTEE ON INTERNAL SAFETY AUDITS

OIL INDUSTRY SAFETY DIRECTORATE

OIL INDUSTRY SAFETY DIRECTORATE

Note 3 in superscript indicates the modification/changes/addition

These guidelines are applicable for refineries/on-shore gas

Hindustan Petroleum Corporation Ltd.

Indian Oil Corporation Ltd.

Shri S.K. Ray

Ex-Official Bharat Petroleum Corporation Ltd.

Bharat Petroleum Corporation Ltd.

Indian Oil Corporation Ltd.

Bongaigaon Refinery & Petrochemicals Ltd

Shri M.Bhaskar Rao

Hindustan Petroleum Corporation Ltd.

Hindustan Petroleum Corporation Ltd.

Indian Oil Corporation Ltd.

Cochin Refineries Ltd.

Shri D.Madhukar Rao

Gas Authority of India Ltd.

Oil Industry Safety Directorate

OISD - GDN - 145

INTERNAL SAFETY AUDIT

INTERNAL SAFETY AUDITS

INTERNAL SAFETY AUDITS

OBJECTIVES OF SAFETY AUDITS

SCOPE OF SAFETY AUDITS

TYPES OF SAFETY AUDITS

METHODOLOGY OF INTERNAL SAFETY AUDITS

5.1 Frequency of Audits

5.3 Duration of Audits

5.4 Use of Safety Audit Check Lists

5.5 Preparation before Site Visits for Safety Audits

5.7 Site Inspections

5.9 Study of Documents

PREPARATION OF AUDIT REPORTS

FOLLOW UP OF AUDIT REPORTS

OISD GDN 145

INTERNAL SAFETY AUDITS

OBJECTIVES OF SAFETY AUDITS

To ensure that operating / maintenance procedures, work practices are as per

To check on security, training, preparedness

To check the compliance of statutory regulations, standards, codes, etc.

As a social objective to cater to public opinion and concern

handling emergencies and

3.0 SCOPE OF SAFETY AUDITS

4.0 TYPES OF SAFETY AUDITS

OISD GDN 145

5.0 METHODOLOGY OF INTERNAL SAFETY AUDITS

All LPG Storage, filling &

Oil Movement & Storage (OM&S)

Sub Groups IV - A Atmospheric / Vacuum Units

Bitumen Blowing Units.

IV - C Secondary Processing Unit like FPU /

FCCU/HCU & H2 along with Treating

IV - D Naphtha HDS, Cat-Reforming, Kero / Diesel HDS etc.

Power House, Electrical Sub-stations, Water Block, Utilities, Effluent Treatment.

Miscellaneous other facilities such as Workshops, Warehouse Laboratories etc.

General Audit, Fire Fighting and Safety, Layouts etc.

5.2 FORMATION OF MULTI-DISCIPLINARY AUDIT TEAMS: