THIRD PARTY SAFETY

AUDIT REPORT

Oriental Carbon & Chemicals ltd.

Address: Part of survey no. 141, paiki of mouje, Mundra SEZ,
Mundra-370421, (Kutch).Gujarat, India.

September -2020

Auditor: M/s. B. J. Chauhan & Associates.

1
 INDEX

NO. CONTENTS PAGE NO

1 EXECUTIVE SUMMARY 4
2 AUDIT PROFILE 5
3 TYPES OF PRODUCT 7
4 HEALTH AND SAFETY POLICY 8

5 SAFETY AND HEALTH ORGANISATION 9

6 ACCIDENT REPORTING, INVESTIGATION AND ANALYSIS 11

7 SAFETY INSPECTIONS 12
8 SAFETY EDUCATION AND TRAINING 13
9 FIRST AID 15
10 OCCUPATIONAL HEALTH CENTRE 16
11 GENERAL WORKING CONDITION 17
12 HAZARD IDENTIFICATION AND CONTROL 19
13 TECHNICAL ASPECT-Safe Operating Procedures 20
14 WORK PERMIT SYSTEM 21
15 WASTE DISPOSAL SYSTEM 22
16 PERSONAL PROTECTIVE EQUIPMENT (PPE) 23
17 FIRE PROTECTION 24
18 EMERGENCY PREPARDNESS 26
19 PLANT LAYOUT AND AREA CLASSIFICATION 27
20 STATIC ELECTRICITY 28

21 PRESSURE VESSELS (Fired and Unfired) 29

22 NEW EQUIPMENT REVIEW 30

23 LIFTING MACHINES & TACKLES 31

24 MOBILE EQUIPMENT AND VEHICULAR TRAFFIC 32

2
 25 ACCESS 33

26 MATERIAL HANDLING 34

27 TANK STORAGE VESSEL AREA 35

28 ON-SITE GAS CYLINDERS STORAGE AREA 37

29 COMMUNICATION SYSTEM ADOPTED IN PLANT 38

30 TRANSPORTATION 39

31 OBSERVATION ATS GLANCE 41

32 ANNEXURES 44

3
 1. EXECUTIVE SUMMARY

▪ The management of ORIENTAL CARBON & CHEMICALS LTD., Mundra SEZ, Kutch
had approached B.J. Chauhan & Associates, Adipur‐Kutch to conduct a Safety Audit
of their unit at Mundra SEZ, Kutch.

▪ Accordingly engineers from BJC&A had visited the plant on 24 th of September 2020.
The audit focused on the following aspects of the safety system.

▪ The factory is manufacturing Insoluble Sulphur.

▪ The Occupational Safety and Health Audit is conducted as per the methodology
prescribed under IS14489: 1998.

4
 2. AUDIT PROFILE

Scope:To establish, plan conduct and document the audit on Occupational Safety
&Health System of ORIENTAL CARBON &CHEMICALS LTD.Mundra SEZ, Kutch.

Auditee: ORIENTAL CARBON & CHEMICALS LTD.

Part of SurveyNo. 141,paiki of mouje Mundra SEZ
Ta: Mundra,District: Kutch, Gujarat – 370 421.

1. Occupier : Mr. Arvind Goenka

2. Factory Manager : Mr. Alok Gupta

3. Safety In charge : Mr. Anand Lakhani

4. H.R.Head : Mr. Rajesh Verma

5. Strength : 500 (as per factory license)

Audit Goals:

➢ To provide and assess to your OS&H system against the standard system.
➢ To identify areas for improvement.
➢ To determine the conformity of the implemented OS&H system.

5
Objectives:

➢ To carry out a systematic, critical appraisal of all potential hazard involving

personnel, plant and operating methods.
➢ To ensure that OS&H system fully satisfy the legal requirements and those of the
company’s written safety policy, objectives and progress.

Audit Plan: 24thSeptember,2020

Audit Methodology:

➢ Execution of the Audit

➢ Opening Meeting with Management Team.
➢ Plant round
➢ Record Checking
➢ Observation and Recommendations
➢ Closing meeting with Technical Persons
➢ Submission of Safety Audit report

Audit Report Retention:

➢ Two years from the Report Date

Auditor: M/s. B. J. Chauhan & Associates, Adipur,Kutch.

Auditee:________________ Auditor:________________

6
 3. TYPES OF PRODUCT

No
Details

The factory is manufacturing Insoluble Sulphur at its plant at Mundra

1 SEZ, Kutch.

7
 4. HEALTH & SAFETY POLICY

Does the organization have a health Yes Attached herewith.

1 and safety policy? (If yes, please
attach one copy)
Who has signed the health safety Mr. Arvind Goenka (occupier)
2
policy? (Indicate his position)
Whether it is prepared as per Yes
3 guidelines of the statutory
provision?
When was the safety policy declared 01.08.2013
4
and adopted?
Whether the policy is made known Yes
5
to all?
What was the date of updating the
6 01.04.2019
policy?
(A) Safety Department:

Does the factory have a safety Yes

1.
department?
If yes, furnish the following
2.
information:
(i) Head of the safety Manager
Department
(a) Name Mr. Anand Lakhani
(b) Designation Manager
(c) Qualification Diploma in Chemical, PDIS, PDIE
(d) Experience 21 years
(e) Status Management
(f ) Name of Safety Officer Mr. Vivek Vaidya
( g) Qualification M.Sc.
(ii) Strength of the safety 06 person
department including safety
and staff
Does the head of safety Reporting to Unit Head (Sr. GM)
3. department/safety officer reports to
the chief executive?
What additional duties the safety EHS officer looks after safety, fire and
4.
officer is required to do? environment, health related jobs only
What is the power of safety officer He Can stop work immediately.
5.
for unsafe condition or unsafe act?

8
(B) Safety Committees:

5. SAFETY
Does the organization have&a HEALTH ORGANISATION
safety Yes
1
committee(s)?
Is the tenure of the safety Yes
2
committee(s) as per the statue?
How are the members of safety Nominated
3 committee (s) selected (elected /
nominated)
How often are the meetings of Quarterly, Last meeting done on 16.09.2020.
4
safety committee(s) held?
What are the subjects? Are the House Keeping, Unsafe Actions / Conditions,
problems discussed in the meetings? PPE's, Mock drill, Maintenance of safety
5
(Attach a copy of agenda and equipment etc.
minutes of the last meetings )

9
 How are the recommendations of Time bounded, Timeline decided during
6
the committee(s) implemented meeting.
Are the minutes forwarded to the Yes
trade union(s) and chief executive
and occupier?
How the management plays their Yes
active roles in supporting and
8
accepting the committee(s)
recommendations
How are the safety committee(s) Yes. Through various competitions,
members apprised of the latest suggestion schemes etc.
9
developments in safety, health and
environment?
(c) Safety Budget:

1 What is the annual safety budget? As and when as per requirement

How much budget has been utilized Data available with EHS Dept.
2
till date?
3 How is the safety budget arrived at? From past expenses
Does this budget get reflected in the Yes
4
annual report of the company?

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 6. ACCIDENT REPORTING, INVESTIGATION AND ANALYSIS

1 Whether the accident data for the Available

last one year for the reportable and
non-reportable accident available?
Is there any system of classifying Yes (analyzing through trade chart)
2 and analyzing the near-miss
incidents and accidents?
Are all near-miss incidents and Yes
3 accidents reported and
investigated?
4
By whom the accident statistics and By EHS Department
data are maintained?
5
How is the top management During safety committee meeting
apprised of these data?
6
Is the accident statistics effectively Yes
utilized? If Yes, how?
What nature of injuries occurred First Aid Injury, data available with EHS
7
during the last one year? Department
8 How do you ensure implementation By discussion, inspection, training,
of the recommendations to avoid different types of safety reports, and
the recurrence of the Incidents and corrective and preventive actions

11
 accidents?

1. What types of safety inspections

7. SAFETY Internal audit for ISO 45000 (OHSMS) are
areINSPECTIONS

12
 carried out and what are their carried out. Internal audit as per IS
frequencies? 14489 shall be carried out at interval of
every six months.
1. Multi-disciplinary Audit - Yearly
2. Constructive Appraisal Plant -
Quarterly
3. By Plant Manager - Monthly

2. Is there any system of internal Yes (monthly safety audit)

inspection?
3. Who does the inspection? Senior member team and safety team

4. Are the check-lists prepared for

these inspections? Safety item-wise, Yes
for example, housekeeping, fire
protection, etc.

5. To whom the recommendations are Safety committee and respective plant

submitted? HOD

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 8. SAFETY EDUCATION AND TRAINING
A. Training:
1. Is there any training department? Yes, HR department conducting
training
2. Is there any program of induction Yes
training?
3. Mention the duration of induction For new joining employee – half day
training for each category of For contractor worker – 01 hour
employees. For visitor – 10 minutes
4. What infrastructure facilities with Conference Room with audio visual support
audiovisual support are available for Training / Meeting available.
for training?
5. Do the programs cover the plant Training calendar available.
safety rules, hazard
communication and other safety
rules?
6. Whether the training programs Yes, in local language
are conducted in the local
language.
B. Safety Communication /Motivation/ Promotion:

Does the factory have safety Yes, Every Plant, Direct Suggestion of
1. worker through HOD.
suggestion schemes? Give Details.
Does your factory participate in No
2. National Awards / Suggestion
Schemes?
Has your factory been awarded Yes, award for best safety practices at SEZ unit
3.
during last five years?
Are safety contests organized in Drawing competitions, essay & slogan
4. the Factory? Give Details writings etc. shall be organized during
safety week.
What are the publications of your No, publications. Publications shall be
organization? Do they include included such as safety booklet, pocket
5. information on safety and health size safety policy, etc. as per Sub‐rule 3 of
subjects? rule 68‐K of GFR.
Is the literature on safety and Yes
6. health available to the
employees?
How is the safety and health Notice Board, display, slogan, etc.
7.
publicized in your factory?
(i) Bulletin Boards? Yes. Updated.
(ii) Past serious No

14
 accidents?
(iii) Newsletter? No.
(iv) Others? Specify Posters, slogan, banner, e-mail.
Does the organization celebrate Yes .
8. safety day/week or organize
safety exhibition?
C. Periodic Training and Retraining:
On job training imparted at the time of
Are all the employees trained and
1. what is the frequency of such joining , Monthly& need base training to
training? be provided as per the calendar year.
Do the training programs cover Yes. Basic safety training topics covered.
2.
safety and health aspects?
Do the trained supervisors train Yes. Training plan available.
3. their own employees in safety and
health aspects?
Do the retraining performed Yes, specific need based trainings were
4. whenever new hazards/process provided whenever a process change.
changes are followed / introduce?
How Many employees have been Almost 100% of the employees have
5. trained in safety and health in the been trained in last five years.
last one year?
How do you ensure that the By training feedback and supervision.
training is put to use by the
6.
employees trained in safety and
health?

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 9. FIRST AID

Is adequate number of first aid Yes .10 no first aid boxes provided in
1.
boxes provided? plant department wise.
Is there any ambulance room? Yes Ambulance & company vehicles
2.
available 24X7 in case of emergency.
Are qualified /trained first aid Yes, training was given and records were
3. person available in each shift? maintained.

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 10. OCCUPATIONAL HEALTH CENTER

1. Whether occupational safety and Yes. Provided with First Aid Box with
health center is provided or not? Medicines, Examination Table, Chair,
etc.
2. Does it conform to the provisions Male nurse available 24x7
of the existing legislation?
3. Are the Medical Attendants / Yes. Doctor available Part time in
Doctors available in each shift? Factory.

4. Is ambulance van available in each Yes Ambulance & company vehicles

shift? available 24X7 in case of emergency.
5. Any liaison with the nearest Yes. Doctor available in nearby Factory,
hospitals? Give Details Adani Hospital, MIMS Hospital,
Mundra.

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A. House Keeping 11.
: GENERAL WORKING CONDITION
Are all passages, Floors and the Yes. Man segregation is provided through
1. stairways in good condition? walkways. Demarcation needs to be
improved.
Do you have the system to deal Yes.
2. with the spillage?
Do you have sufficient disposal bins Yes. Dedicated bins are arranged, also
3. clearly marked and whether these spittoons of sound material shall arrange as
are suitably located? per section 20 of Factories Act.
Do you have adequate localized Yes, Periodic Environment Monitoring is
extraction and scrubbing facilities carried out as per Form 37 of GFR.
4. for dust, fumes and gases? Please
specify.
Whether walkways are clearly No. Walkways should be marked clearly.
5. marked and free from obstruction?
Do you have any inter- Yes.
6. departmental competition for good
housekeeping?
Has your organization elaborated Yes.
good housekeeping practice and
7.
standards and made them known
to the employees?
Are there any working conditions, Yes, however, all solutions which will spill and
which make the floors slippery? If soil the floor were cleaned with suitable
8.
so, what measures are taken to sorbents made available in the plant. Efficient
make them safe? floor cleaning programs was in place.
Does the company have adequate Yes, all internal roads were kept clean,
9. measures to suppress polluting dust however all incoming trucks and load carriers
arising out from road transport? are covered
B. Noise:
Are there any machines/ Process DG. Compressors.
1. generating noise? Specify

Was any noise study conducted? Yes, regular monitoring of noise was
2. conducted for ambient and shop floor area by
third party and records were maintained
Which are the areas having high- DG Set, Compressors Area.
3.
level noise?
4. Have engineering and Yes, usage of PPEs[ear muff and ear plug] was
administrative controls been compulsory
implemented to reduce noise

18
 exposure below the permissible
limits.
If there a system of subjecting all Yes, annual medical checkup includes
those employees to periodic audiometric test conducted at various
5.
audiometric test who work in high different frequencies
level noise areas?
Whether the workers are made Yes
6.
aware of the effects of high noise?
Whether any personal protective Yes, ear muff and ear plug
7. equipment along with ear muffs
/plugs are included and used.
C. Ventilation:
Whether natural ventilation is Adequate
1.
adequate?
Whether dust/ fumes/hot air is Yes, fumes
2.
generated in the process?
Is there any exhaust dilution Natural ventilation
3. ventilation system in any section of the
plant?
Are periodic / preventive maintenance Yes
4. of ventilation system carried out and
record is maintained?
Does any ventilation system re- Yes, recirculation done as per design
5.
circulate the exhaust air in work areas?
Is the work environment assessed and Yes
6.
monitored?
Whether personal protective Yes. Dust Mask, Nose Mask, and protection
7. equipment is given to workers exposed equipment provided.
to dust /fumes and Gases?
D Illumination:
Was any study carried out for the Yes. Carried out by Electrical Dept. and
1.
assessment of illumination level? third party.
Is there any system of periodical Yes. Maintenance done regularly.
cleaning and replacing the lighting
2. fittings/lamps in order to ensure that
they give the intended illumination
levels?
Are the workers subject to periodic Yes, Medical examinations is carried out &
3. optometric tests and records records available in Form 32& 33.
maintained? Give details.

12. HAZARD IDENTIFICATION AND CONTROL

19
 Are all the hazards areas identified? Yes. All hazard areas are identified.
1.
What are the types of hazards Noise, fire and explosion
2. (physical Noise, heat, chemical-fire,
explosion, toxic, release, etc.?)
What steps have been taken to Hazards and its control prepared and given
prevent these hazards? in emergency plan.
3.

Are there any safety inter-locks, Yes

4. alarms and trip system? Give
Details.
Are these tested periodically? How Yes
5. often? Please specify.

Are there any ambient monitoring Installed as per GPCB norms

6. devices with alarms – for leakage of
hazardous materials? Give details.
Are safety audit or any other Safety Audit carried out earlier in 2019.
studies carried out and the Recommendations implemented.
7.
recommendations implemented?
Give details.
What has been the major No Modification. Factory plans are
modifications done in Plant/process approved by competent person
8. and has the approval of the
competent authority concerned
taken?
What decision and monitoring Ambient air monitoring and work place
equipment are available and used monitoring carried out by third party
9. for checking the environment
conditions in and around the plant?
Give details.

13. TECHNICAL ASPECT (Safe Operating Procedure)

20
 Are written safe operating Available
1. procedures available for all
operations?
Whether the written safe operating Yes, majority SOP available in English and
procedures displayed of made local or national language
2.
available and explained in the local
language to the workers?
Whether the safe operating Yes
3. procedures are prepared jointly by
the plant and safety departments?
What system is used to ensure that Through management of change
the existing safe operating
4.
procedures are updated? Give
details.
Have the workers been informed of Yes
the consequences of failure to
5.
observe the safe operating
procedures?
Are contractor workers educated and Yes, internal trainings are carried out.
6. trained to observe safety and
workplace?
Whether contractor’s workers are No
7. permitted on process /operations?
Give details.

14. WORK PERMIT SYSTEM

21
 What necessary type of work permits Yes. Hot work permit, Height work
exits in your factory? Give Details. permit, Confined space entry permit,
Civil work permit, Non-routine lifting and
1. shifting work permit, Work in CS2 &
other flammable chemicals are carried
out.
What are the hazardous chemicals Raw Sulphur, CS2, FO,HSD.
2.
handled?
Are the Keys kept for individuals Yes
locks which are used for electric
3.
lockouts with the supervisors
concerned?

15. WASTE DISPOSAL SYSTEM

22
 Is identification done for various Yes. Wastes classified as per Hazardous
types of wastes? waste Management Rules & GPCB
1.
Consolidated consent and authorization
available with the organization.
2. What are their disposal modes? As per GPCB norms
What are the system / measures As per GPCB norms
3. adopted for controlling air /
water /land pollution?
What is the system of effluent As per GPCB norms
treatment plant and whether it is
4
approved by the competent
authority?

5. How are the treated effluent used? Treated effluent is used in Gardening.

16. PERSONAL PROTECTIVE EQUIPMENT (PPE)

23
 Has a list of required PPE for each List of PPEs available
area operation been developed and
1.
the required PPE is made available
to the workers?
Are the safety department and the Yes
2. workers consulted in the selection of
PPE?
Have the workers been trained for Yes, regular training given to all workers
3.
proper use of PPEs?
What is the system of replacement? Replacement by returning PPE
4.
What are the arrangements for safe Separate lockers provided
5. custodies storage of PPE provided to
the workers?
Are contractor’s workers provided Yes. Contractor is providing PPE's to
6. with the required PPE? Who is contract workmen.
responsible? Give details.
Are the PPE conforming to any Yes. As per IS standards
7.
standard? Give details.
Give the details of PPE and also Data available with EHS Department
8. specify the responsibility for their
inspection and maintenance?

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 17. FIRE PROTECTION

25
 Indicates the location, number Total 233 nos. Fire Extinguishers & 82
1. (Quantity) and types of portable Fire Hydrant points are provided.
fire extinguishers available. List attached as Annexure III
Is the firefighting system and Yes. Firefighting equipment confirms to
equipment approved, tested and BIS standards.
2.
maintained as per relevant
standard?
What is the inspection and Maintained by EHS Department by On
maintenance schedule of the quarterly basis.
3.
extinguishers? Who performs these
functions?
t4. Which areas of the plant are Entire plant was covered by fire
covered by fire hydrants? Indicate hydrant network
the locations of the hydrant points
and how the required pressure
maintained in the system and
ensured.
What is the capacity of dedicated Total 1reservoir available with
water reservoir for supply to the 576KL,Main source is through water
5.
hydrants? What is the source of supplyAdani Waters.
water?
I. How is the power supply to the Diesel engine operated fire pump
fire hydrant pump ensured? available with alternate power option
6. II. What is the alternate source of from D G Set.
supply in case of power failure?
Give details.
Are all personnel conversant with Yes. Periodic trainings & mock drills are
7. the fire prevention and protection carried out to train the personnel.
measure?
What percentage of plant Majority of staff has been trained for
personnel and staff and officers, use of fire extinguishers.
8. has been trained in the use of
portable fire extinguishers? Give
Details.
Do you have fixed or automatic fire Fixed system available. But no
9. fighting Installations in the any automatic fire fighting system is
section of your plant? available.
Are the fire alarms adequate and Yes.
10.
free from obstruction?
Do you have fire department? If Yes
11.
yes, give details.
12 What is the system for conducting Mock drills are conducted every 2
mock drill? Give details. months
Do you have any mutual aid Yes. Mutual aid is available with
scheme with any of your neighboring industries.
13.
neighboring industry or any local
organization?
Do you have any system of color Yes, as per IS 2379
14. coding for all the pipelines for
hazardous chemical?
26 How many major and minor Data available with EHS Department
incidents/ fire were there in the
15.
factory during the last one year?
Give department /Plant wise.
Have all the fires/ incidents been Data available with EHS Department
16. investigated and corrective actions
taken? Give break up.
 18. EMERGENCY PREPAREDNESS

27
 Is there an On-site emergency plan for Yes, available
1. your Factory?

What is the frequency of conducting Quarterly done, records available

2.
mock drills on-site emergency plan?
What are the number and location of ECC-1 and Assembly point-2
emergency control center, assembly
3.
points?

Whether emergency team or the key Yes

4.
personnel Identified?
Are suitable and adequate protective Yes
5. and rescue equipment available?

How is the emergency communication By internal phones, mobiles, siren

6. with local bodies and other
organizations ensured? Give Details.
What is the medical emergency OHC provided
7.
response system? Give details.
How many emergency alarm systems Yes, electrical siren, manual siren and
is/are Available? Give details. PA system
8.

28
 19. PLANT LAYOUT AND AREA CLASSIFICATION

What is the system of classification Not Applicable

of hazardous zones in the plant for
1.
electrical installations? Please
specify.
Whether periodic inspection and Yes. Carried out by qualified persons.
preventive maintenance of
2. electrical installations is done by a
qualified person and record is
maintained?
Whether plant layout with area No
3. classification has been displayed at
appropriate places?

29
 20. STATIC ELECTRICITY

Whether the processes and Yes, in CS2, HSD transfer line

1. equipment generate and
accumulate static charge?
Whether all such equipment Yes
2.
properly bonded and earthed?
How is electrical resistance earth Yes. Last done in 2020
circuits maintained? Are any
3.
periodic inspection done and
recorded?
Are adequate earthing Yes
arrangements made at the terminal
4
points where hazardous chemicals
are handled through pipes?

30
 21. PRESSURE VESSELS (Fired and Unfired)

Give details of the plants piping Air receiver

and vessels which are operated at
1.
a pressure greater than the
atmospheric pressure?
How is it ensured that the working Safety valve, pressure gauge, PRV, vents
pressure inside the pressure
2. vessels /pressure plants will not
exceed their maximum working
pressure for which it is designed?
What means of isolating the PRV and safety valve
pressure vessels or means to
3.
prevent rise in pressure and
installed?
What standards /codes of practice As per IS code
are adopted for design,
4 fabrication, operation and
maintenance of the pressure
vessels and records maintained?
How is the pressure vessels As per GFR and by competent person
5
tested?
Is there any competent person for Yes. The same is carried out by
6 testing these pressure vessels? recognized competent Person. Records
are available.
How are the recorded results By checking reports
7
verified?
Give details of safety devices Safety valve, pressure gauge, Pressure
available for these pressure relied valves provided as per
8
vessels? recommendation mentioned in GFR &
SMPV Rules.
Whether logbook for pressure Yes
9 vessels and pressure plant has
been maintained?

31
 22. NEW EQUIPMENT REVIEW

What is the system for effecting any Yes, approval by Competent authority
change in the existing plant,
1. equipment or process? Whether it is
approved by the appropriate
competent authority?
Whether the P & I diagram and Yes .
2. other related documents are
updated accordingly?

32
 23. LIFTING MACHINES & TACKLES

Whether all the machines the Yes

1.
marked with their S.W.L?
Are all the examinations and tests Yes. Records maintained as per Form 10
2. documented in the prescribed GFR.
form?
Are all the examinations and tests Yes. The tests are carried out by
3 carried out and certified by competent persons.
competent persons(s)? Give details.
Are adequate lifting tackles Yes.
4 provided at all the places where it is
equipment?
Are the trained operators engaged Operators are trained & qualified to
5 operate the equipment.
for operating the equipment?
What is the system of training to Training provided
6
such operators?
Are all the lifting machines and Yes. Records maintained as per Form 10
7 tackles maintained in good GFR.
conditions and record maintained?

33
 24. MOBILE EQUIPMENT AND VEHICULAR TRAFFIC
Is all the mobile equipment in good Yes.
1.
condition?
Are trained drivers engaged for fork- Yes.
2.
lift trucks?
Are there adequate numbers of Yes.
3
warning signs/signals?
Are the hazards associated with Safety training to be provided to
4 transportation within the plant workers.
identified and safety measure taken?

34
 25. ACCESS

Is adequate safe access provided to all Yes. Provided in compliance with

1
places where workers need to work? Section 16 of GFR.
2 Are all such in good condition? Yes.
Are portable access platforms Yes
3
necessary? If yes
(a) Are these sufficient? Yes
(b) Are these regularly inspected?
(c) Are these readily available?
(d) Are these provided with toe-guards
and railings
Oiling and Greasing Points
(a) Are these located and extended to Yes
safe place?
(b) Are these easily accessible? Yes
4 (c) Are these liable to drip into walk No
ways?
(d) Whether such workers were Yes
trained and whether is
maintained?
Are all drain covers in good conditions Yes.
5
and fitting flush?

35
 26. MATERIAL HANDLING

Are there adequate storage facility Yes

1.
available
2. Are these areas clearly defined? Yes
Are all racks and steel cages in good Yes
3
condition?
Have you got adequate equipment for Yes, forklift, trolley, etc.
4
handling materials?
Do the workers know the hazards Yes.
5 associated with manual material
handling?
Where manual handling is necessary Yes
6
are the workers been trained?
Do workers follow safe procedure for Yes.
7
storage of Materials?
Where contractor workers are trained Yes.
8
in safety?

36
 27. TANK STORAGE VESSEL AREA

Whether it is pressure vessel or not. Yes, N2 tank only

1.
Give the names of storage materials Insoluble Sulphur, CS2, raw
2. in each of them. Sulphur, LDO, FO, HSD, Kerosene
What are the vessels sizes (Capacity Raw Sulphur-2500MT, CS2-40MT,
3 in tones)? HSD-30KL, FO-30KL, LDO-30KL,
Kerosene 50kL
What is the material of construction Details available with concern
for each vessels and what standards department
4
followed in designing/fabricating the
vessel?
What are the operating pressure and Atmospheric Pressure and
5
temperature? Temperature.
Indicate whether vessels above Above ground
6
ground/underground.
If any of the tanks storing flammable Yes.
7 materials, whether electrical
installations are flameproof or not?
Are these storage vessels bunded/ Yes
8
dyked?
If yes, what is the capacity of the Adequate
9
bunds / dykes?
Are the vessels properly bonded and Yes
10 earthed and whether periodically
checked and recorded maintained?
How are the vessels isolated in the By valves
11
event of a mishap?
12 Are the vessels find with remotely Yes
controlled valves?
Are vessels provided with emergency Yes as applicable
vent, relief valve, bursting disc, level
13
indicator, and pressure gauge
overflow line?
Where do suchvents discharge? CS2 tank vent discharge at open
14 atmosphere

Are the vessels provided with alarms Yes

15 for high level, high temperature and
high pressure?

37
 Are stand by empty tanks provided Yes
for firefighting /in case of
16 emergencies?

What are the provisions made for Fire hydrants , portable fire
firefighting / tackling emergency extinguishers, sand buckets, monitors,
17 situation around the storage vessels? etc.

What periodical testing is carried out Details available with concern

18 on the vessels to find out the department
integrity of the vessels?
Whether these tests are certified by Yes
19
the approved competent person?

38
 28. ON- SITE GAS CYLINDERS STORAGE AREA

What are the various gases used in O2 , CO2, N2, NH3

1.
the plant?
What are the storage facilities? Separate storage
2.
What are the measures taken for Adequate measures provided (fire
3 combating any emergency in the hydrants, fire extinguishers)
cylinders storage area?
Are valid licenses available for Not required
4
storing all these cylinders?
Whether integrity test certificates Yes, available with supplier
5 are obtained from the suppliers of
the cylinders?

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 29. COMMUNICATION SYSTEM ADOPTED IN PLANT

Is public address system available Yes

1.
in all plant areas?
Are public address system provided Battery operated PA system available
2.
with uninterrupted power supply?
Whether public address system is Yes
3 checked periodically for its proper
functioning?
Is there any hot line provided to fire No
4
station?
What is the means of Internal phones, mobile, siren
5 communicating emergency in the
plant?

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 30. TRANSPORTATION

What potentially hazardous materials are Yes, the security check at the main gate
1. transported to or from the site (Including ensures the same
waste)?
What modes of transport are used: Road
(1) Road?
2. (2) Rail?
(3) Pipelines?

3 ROAD
Does the company employ licensed Yes, outside source
vehicles of its own/outside sources?
Are loading /unloading procedures on-site Yes
and safety precautions displayed?
Are loaded tankers or trucks parked in a Yes
specific area on-site?
Do all truck ad tanker drivers carry TREM Yes
card or instruction booklet?
Do all truck and tanker drivers get training Yes
in handling emergencies during transport?
RAIL
What hazardous materials are transported NA
by rail?
Does the company have a direct sliding on NA
site?
Are tankers or others wagons used in NA
transportation?
PIPELINES NA
What materials are transported to and NA
from the site pipelines?
Are the pipelines underground or over NA
ground?
Are corrosion protection measure NA
employed in pipelines?
Whether intermediate booster pumps are NA
used?
What are the maximum, minimum and NA
average transfer rates?
Are the pipelines extended in the public NA
domain?
Are the public dedicated for each type of NA

41
 chemicals?
Are the pipelines fitted with safety NA
equipment such as leak detectors,
automatic shut- off valves, etc?
What is the frequency and method of NA
testing of the pipelines?
Is there written procedure for tackling NA
leakages in pipelines?

42
 OBSERVATIONS AT A GLANCE

No Observation Compliance
1 Near pallet storage area one civil Civil support maintenance to be done
support is found damaged. regularly as per the GFR.
2 Forklift should have reverse horn Forklift should be provided with reverse horn
with light arrangement to avoid with light arrangement to avoid incident
incident during night hours in plant during night hours in plant areas per the GFR.
area.
Testing date to be updated on Testing status to be provided to the Forklifts
forklifts. to avoid missed out inspection as per GFR.
spark arrestor to be provided in Forklift working in sulpur storage area should
forklift , as forklifts are working in be provided with spark arrester. As it may
Sulphur area it may lead to fire lead to ignition to sulphur and may catch fire.
Forklift should not be parked Designated area to be provided to forklift for
inside FG storage area and to be parking during rest period .
park in identified area only
3 Quarantine area board to be Sulphur wastage material are to be identified
display outside U-1/2. and display board to be provided as per GFR.
4 Purifier ladder should have Vertical Ladder should be provided with
handrail and zebra marking handrail and marked with zebra mark to
avoid incident during work in night as per
GFR.
5 Protective angels to be provide in Protective angels should be provide in FG
FG storage around pillars, storage around pillars, electrical panels where
electrical panels where forklift forklift movement is there to avoid damage
movement is there to avoid from forklift.
damage from forklift.
6 MH hoist identification to be MH hoist should identified as hoist and for
provided as a hoist and for goods goods only instead of lift.
only instead of lift.
7 Rubber vibration absorber pads not Rubber vibration absorber pads should be
provide between connecting beam provided between connecting beam of plant
of plant and godown to avoid and godown to avoid shifting of vibration
shifting of vibration from plant to
from plant to godown  civil structure.
godown  civil structure.
8 FHB-56/U4 is blocked with FHB-56/U4 should always be clear for easy

43
 packed material evacuation during emergency.
9 Gents & Ladies toilet found with Ladies toilet should be provided with separate
common entry in QC. entry from urinal/gents toilet in QC as per
GFR.
10 Safety valves inspection is not Safety valves inspection should be done by
done by competent person once in competent person once in year .
year 2020.
11 Noise monitoring report is evident Noise monitoring is to be done for both day
for day time, but it is not available time and night time as per GFR.
for night time.

Signature of Auditor Signature of Auditee

44