Safety Audit as per IS 14489

Safety Points Observation Remarks

HEALTH AND SAFETY POLICY
1 Does the organization has a health and safety policy?
(if yes, please attach one copy)
2 Do you have any corporate safety policy?
(if yes, please attach one copy)
3 Who has signed the health safety policy?
(indicates his position)
4 Whether it is prepared as per guidelines of the statutory provisions?
5 When was the safety policy declared and adopted?
6 How many times it has been updated till now?
7 Whether the policy is made know to all?
8 Whether the safety policy was scrutinized by outside expert agency?
9 What was the last date of updation?
10 Does it find a place in the annual report?

SAFETY & HEALTH ORGANIZATION

(A) Safety Department
11 Does the factory has a safety department?
12 If yes, furnish the following information:
a) Head of the safety department:
a)Name
b) Designation
c) Qualification
d) Experience
e) Status
b) Strength of the safety department including safety officers and staff.
Does the head of safety department safety officer report to the chief
13 executive?
How often are the safety officers retained in the latest techniques of total
14 safety management? What is the frequency of retraining?
15 What additional duties the safety officer is required to do?

16 what is the power of safety officer vis-à-vis unsafe condition or unsafe act?

(B) Safety Committee(s)

17 Does the factory has a safety committee(s)?
give details of their types, structures and terms of reference.
18 Is the tenure of the safety committee(s) as per the status?

19 How are the members of safety committee(s) selected ?(elected/nominated)

20 How often are the meetings of safety committee(s) held?
What are the subjects? Are the problems discussed in the meetings? (Attach
21 a copy of agenda and minutes of the last meeting)
22 How are the recommendations of the committee(s) implemented?
Are the minutes of the safety committee(s) meeting circulated among the
23 members ?
Are the minutes forwarded to the trade union(s) and chief executive and
24 occupier?
How the management and trade union play their active roles in supporting
25 and accepting the committee(s) recommendations?
How are the safety committee(s) members apprised of the latest
26 developments in safety, health and environment?

(C) Safety Budget

27 What is the annual safety budget?

28 How much percentage is this budget of the total turnover of the company.
29 How much budget has utilized till date?
30 Is the safety budget adequate?
31 How is the safety budget arrived at?
32 What is the pattern of expenditure for the last five years?
33 What are the approved sanctions for the expenditure in this budget?
34 Does this budget get reflected in the annual report of the company?

ACCIDENT REPORTING, INVESTIGATION AND ANALYSIS

Whether the accident data for the last three years for reportable and non-
35 reportable accident available?
Is there any system of classifying and analyzing the near-miss incidents and
36 accidents? Give the details.
37 Are all near-miss incidents and accidents reported and investigated?
38 For how many years are the investigation reports retained?
39 By whom the accident statistics and data are maintained?
40 How is the top management apprised of these data?
41 Is the accident statistics effectively utilized? If yes, how?
42 What nature of injuries occurred during the last three years?
How do you ensure implementation of the recommendations to avoid the
43 recurrence of the incidents and accidents?

SAFETY INSPECTIONS
What type of safety inspections are carried out and what are their
44 frequency?
45 Is there any system of internal inspection?
46 Who does the inspections?
Are the check-list prepared for these inspections? (Specify item-wise, for
47 example, housekeeping, fire protection, etc.)
 48 To whom the recommendations are submitted

SAFETY EDUCATION AND TRAINING

(A) Training
49 Is there any training department?
50 Is there any programme of induction training?

51 Mention the duration of induction training for each category of employees.

52 Whether the assessment of the trainee worker is done or not?
What infrastructural facilities with audio-visual support are available for
53 training ?
Do the programmes cover the plant safety rules, hazard communication and
any other special safety rules or procedures unique to the plant or specific
54 departments?
55 Whether the training programmes are conducted in the local language?
56 Whether visits to safety institutions/ organizations are arranged?

(B) Periodic Training / Retraining

57 Are all the employees trained and what is the frequency of such training?
Do the training programmes cover safety and health aspects and if so how
58 much (in terms of number of sessions/hours)?
Do the trained supervisors train their own employees in safety and health
59 aspects?
Is the retraining performed whenever new hazards/process changes are
60 followed/introduced?
61 How are the senior management personnel trained in safety and health?
How many employees have been trained in safety and health in the last five
62 years? Give break up with details.
63 How many man-days/hours are used in training the employees?
how do you ensure that the training is put to use by the employees trained
64 in safety and health
65 What is the training plan for the next two years ? Give details.
What documentation system has been established regarding safety and
66 health training?

(C) Safety Communication/Motivation/Promotion

67 Does the factory has safety suggestion schemes? Give details.
68 Does your factory participate in National Awards/Suggestion schemes?
69 factory been a warded during last five years?
70 Are safety contests organized in the factory?
Give details
What are the publications of your organization? Do they include information
71 on safety and health subjects?
72 Is the literature on safety and health made available to the employees?
73 How is the safety and health publicized in your factory?
a) Bulletin boards?
b) Post serious accidents?
c) New letter?
d) Others/ Specify
Does the organization celebrate safety jay/week or organize safety
74 exhibition?
75 When was the last safety day/week celebrated?

FIRST AID
76 Are adequate number of first aid boxes provided? Give location details?
77 Is there any first aid/ambulance room?
78 Are qualified/trained first aid's available in each shift?
How many qualified/trained first aide's are available at each
79 plant/department?
80 How many persons are trained refreshers training in first aid in a year?

OCCUPATIONAL HEALTH CENTRE

81 Whether occupational safety and health centre is provided or not?
82 Does it conform to the provisions of the existing legislation?
83 Are the Medical Attendants/Doctors available in each shift?
84 Is ambulance van available in each shift?
85 Any liaison with the nearest hospital(s) ? Give details.

GENERAL WORKING CONDITION

(A) Housekeeping
86 Are all the passages, floors and the stairways in good condition?
87 Do you have the system to deal with the spillage?
Do you have sufficient disposable bins clearly marked and whether these are
88 suitably located?
89 Are drip trays positioned wherever necessary?
Do you have adequate localized extraction and scrubbing facilities for dust,
90 fumes and gases? Please specify.
91 Whether walkaways are clearly marked and free from obstruction?
92 Do you have any inter-departmental competition for good housekeeping?
Has your organization collaborated good housekeeping practice and
93 standards and made them known to the employees?
Are there any working conditions which make the floors slippery ? If so, what
94 measures are taken to make them safe?
Does the company have adequate measures to suppress polluting dust
95 arising out from goad transport?
(B) Noise
96 Are there any machines/processes generating noise? Specify.
97 Was any noise study conducted ?
98 Which are the areas having high-level noise ?
Have engineering and administrative controls been implemented to reduce
99 noise exposure below the permissible limits ?
Is there a system of subjecting all those employees to periodic audiometric
100 test who work in high level noise areas ?
101 Whether the workers are made aware of the ill-effects of high noise
Whether any personal protective equipment along with car muffs/plugs are
102 provided and used

(C) Ventilation
103 Whether natural ventilation is adequate or not ?
104 Whether dust/fumes/hot air is generated in the process ? Give details.

105 Is there any exhaust dilution ventilation system in any section of the plant ?
Whether any ventilation study has been carried out in the section(s) to check
106 the record ?
Are periodic/preventive maintenance of ventilation system carried out and
107 record is maintained ?
108 Does any ventilation system recirculate the exhausted air I work areas ?
109 Is the work environment assessed and monitored ?
Whether personal protective equipment are given to workers exposed to
110 dust/fumes and gases ? Give details.

(D) Illumination
111 Was any study carried out for the assessment of illumination level ?
Is there any system of periodical cleaning and replacing the lighting
fittings/lamps in order to ensure that they give the intended illumination
112 levels ?
Are the workers subject to periodic optometry tests and records maintained ?
113 Give details

HAZARD IDENTIFICATION AND CONTROL

114 Are all the hazardous areas identified ?
What are the types of hazards (physical-noise, heat etc. and chemical - fire,
115 explosion, toxic release etc.) ?
116 What steps have been taken to prevent these hazards ? Give details.
117 Are there any safety inter-locks, alarms and trip system ? Give details.
118 Are these tested periodically ? How often ? Please specify.
Are there any ambient monitoring devices with alarms for leakage of
119 hazardous materials ? Give details.
Are safety audit or HAZOP or any other studies carried out and the
120 recommendations implemented ? Give details.
What has been the major modification done in plant/process and has the
121 approval of the competent authority concerned ?

What decision and monitoring equipment are available and used for checking
122 the environmental conditions in and around the plant ? Give details.

TECHNICAL ASPECT
Safe Operating Procedures
123 Are written safe operating procedures available for all operations ?
Whether the written safe operating procedures displayed or made available
124 and explained in the local language to the workers ?
Whether the safe operating procedures are prepared jointly by the plant and
125 safety departments ?
system is used to ensure that the existing safe operating procedures are
126 updated ? Give details.
Have the workers been informed of the consequences of failure to observe
127 the safe operating procedures ?
Are contractor workers educated and trained to observe safety at
128 workplace ?
Whether contractor's workers are permitted on process/operations ? Give
129 details.

WORK PERMIT SYSTEM

130 What necessary type of work permits exists in your factory ? Give details.
131 What are the hazardous chemicals handled ?
Are the keys kept for individual locks which are used for electrical lock outs
132 with the supervisor concerned ?

WASTE DISPOSAL SYSTEM

133 Is identification done for various types of wastes ? Give details.
Are these quantities less than those specified by the hazardous wastes.
134 (Management & Handling Rules, 1989/2008) ?
135 What are their disposal modes ?
What are the systems/measures adopted for controlling air/water/land
136 pollution ?
What is the system of effluent treatment plant and whether it is approved by
137 the competent authority ?
138 How are the treated effluent used ?

PERSONAL PROTECTIVE EQUIPMENT (PPE)

 Has a list of required PPE for each area/operation been developed and the
139 required PPE is made available to the workers ?
Are the safety department and the workers consulted in the selection of
140 PPE ?
141 Have the workers been trained in proper use of PPE ?
142 What is the system of replacement/issue of PPE ?
What are the arrangements for safe custody and storage of PPE provided to
143 the workers ?
Are the contractor's workers provided with the required PPE ? Who is
144 responsible ? Give details.
145 Are the PPE conform to any standard ? Give details.
Give the details of PPE and also specify the responsibility for their inspection
146 and maintenance ?

FIRE PROTECTION

Indicate on a plant layout the location, number (Quantity) and types of

147 portable fire extinguishers available.
Are the fire fighting system and equipment approved, tested and maintained
148 as per relevant standard ?
What is the inspection and maintenance schedule of the above
149 extinguishers ? Who performs these functions ?
Which areas of the plant are covered by fire hydrants ? Indicate the locations
of the hydrant points and how the required pressure maintained in the
150 system and ensured.
What is the capacity of dedicated water reservoir for supply to the hydrants ?
151 What is the source of water ?
152 a) How is the power supply to the fire hydrant pump ensured ?
b) What is the alternate source of supply in case of power failure ? Give
details.
Are all personnel conversant with the fire prevention and protection
153 measures ? Give details.
What percentage of plant personnel and staff and officers have been trained
154 in the use of portable fire extinguishers ? Give details.
Do you have fixed or automatic fire fighting installation(s) in any section of
155 your plant ?
156 Are the fire alarms adequate and free from obstruction ?
157 Do you have fire department ? If yes, give details.
158 What is the system for conducting mock drills? Give details.
Do you have nay mutual aid scheme with any of your neighboring industry or
159 any local organization(s) ?
160 Give details of the existing fire resistant walls and doors.
Do you have any system of colour coding for all the pipelines for hazardous
161 chemical ? Give details including marking of flow directions
Are there any safe containers for the movement of small quantities of
162 hazardous chemicals ? Give details.

163 Are all self-closing fire doors in good condition and free from obstructions ?
How many major and minor incidents/fires were there in the factory during
164 the last five years ? Give department/plant-wise.
Have all the fires/incidents been investigated and corrective actions taken ?
165 Give break up.

EMERGENCY PREPAREDNESS

166 Prepare an on-site emergency plan for your plant (attach a copy of the plan)
167 the frequency of conducting mock drills of on-site emergency plan ?
What are the number and location of emergency control centre, assembly
168 points ?
169 Whether emergency team or the key personnel identified ?
Are suitable and adequate protective and rescue equipment available ? How
170 is the emergency rescue team trained to use these equipment ?
How is the emergency communication with local bodies and other
171 organizations ensured ? Give details.
172 Is any alternate power source identified ? Give details.
173 What is the medical emergency response system ? Give details.
Are you a member of any MUTUAL AID SCHEME of your area ? If so give
174 details.
175 How many emergency alarm system(s) is/are available ? Give details.

PLANT LAYOUT AND AREA CLASSIFICATION

What is the system of classification of hazardous zones in the plant for
176 electrical installations? Please specify.
Whether periodic inspection and preventive maintenance of electrical
177 installations is done by a qualified person and record is maintained?
Whether plant layout with area classification has been displayed at
178 appropriate place(s) ?

STATIC ELECTRICITY
Whether the process(s) and equipment generate and accumulate static
179 charge have been identified ? Give details.
180 Whether all such equipment are properly bonded and earthed ?
How is electrical resistance for earthing circuits maintained ? Are periodic
181 inspections done and recorded ?
Are adequate earthing arrangements made at the terminal points where
182 hazardous chemicals are handled through pipes ?
183 Are anti-static charge devices fitted wherever necessary ?
Whether these devices are periodically checked and maintained by a
184 qualified person ?

PRESSURE VESSELS (FIRED AND UNFIRED)

Give details of the plants, piping and vessels which are operated at a
185 pressure greater than the atmospheric pressure ?
How is it ensured that the working pressure inside the pressure
vessels/pressure plants will not exceed their maximum working pressure for
186 which it is designed ?
What means of isolating the pressure vessels or means to prevent rise in
187 pressure are installed ?

What standards/codes of practice are adopted for design, fabrication,

188 operation and maintenance of the pressure vessels and records maintained ?
189 How are the pressure vessels tested ? Give details.
Is there any competent person for testing these pressure vessels ? Give
190 details.
191 How are the recorded results verified ?
192 Give details of safety devices available for these pressure vessels?
Whether log book for pressure vessel and pressure plant has been
193 maintained ?

NEW EQUIPMENT REVIEW

What is the system for effecting any change in the existing plant, equipment
194 or process ? Whether it is approved by the appropriate competent authority ?
Whether the P & I diagrams and other related documents are updated
195 accordingly ?
LIFTING MACHINES & TACKLE
196 Whether all the lifting machines are marked with their S. WL ?
197 Are all the examinations and tests documented in the prescribed form ?
Are all the examinations and tests carried out and certified by competent
198 person(s) ? Give details
Are adequate lifting tackles provided at all the places where it is required ?
199 Give details.
Are the trained operators engaged for operating the equipment ? Give
200 details.
201 What is the system of training such operators?
Are all the lifting machines and tackles maintained in good conditions and
202 record maintained ?

MOBILE EQUIPMENT AND VEHICULAR TRAFFIC

203 Are all the mobile equipment good condition ?
204 Are trained derivers engaged for fork-lift trucks ?
205
What system do you adopt to assess their standard of driving as
206 poor/fair/satisfactory/good ?
207 Are there adequate number of warning signs/signals ?
Are the hazards associated with transportation within the plant identified and
208 safety measure taken ? Give details.

ACCESS

209 Is adequate safe access provided to all places where workers need to work ?
210 Are all such access in good condition ?
211 Are portable access platforms necessary ? If yes
a) Are these sufficient ?
b) Are these regularly inspected ?
c) Are these readily available ?
d) Are these provided with toe-boards and railings ?
212 Oiling and greasing points:
a) Are these located and extended to safe place clear of moving parts ?
b) Are these easily accessible?
c) Are these liable to drip into wall ways ?
d) Whether such workers were trained and whether they are provided with
fit-tight clothings and register is maintained ?
213 Are all drain covers in good condition and fitting flush ?

MATERIAL HANDLING
214 Are there adequate storage facilities available ?
215 Are these areas clearly defined ?
216 Are all racks and steel ages in good condition ?
217 have you adequate equipment for handling materials ?

218 Do the workers know the hazards associated with manual material handling ?
219 Where manual handling is necessary, are the workers been trained ?
220 Do they practice this ?
221 Do workers follow safe procedures for storage of materials ?
222 Whether contractor workers are trained in safety ?
What is the system for handling over plan to the maintenance department
223 and receiving back ?
224 Is the system consistently applied ?
What is the system for the preventive and predictive maintenance and how
225 do you assure its effectiveness ? Give details.

TANK STORAGE VESSEL AREA

226 Whether it is pressure vessel or not.
 Give storage vessels designation (exceeding threshold quantities specified in
227 MSIHC. Rules 1989).
228 Give the names of storage materials in each of them.
229 What are the vessel sizes (capacity in tonnes) ?
What is the material of construction for each vessel and what standards
230 followed in designing / fabricating the vessel ?
231 What are the operating pressure and temperature ?

232 What are the vessels location ? (Please indicate on-site plant or plot plan)
233 Indicate whether vessels are above ground/underground.
If any of the tanks storing flammable material, whether electrical installations
234 are flameproof or not ?
235 Are these storage vessels bunded / dyked ?
236 If yes, what is the capacity of the bunds/dykes ?
Are the vessels properly bonded and earthed and whether periodically
237 checked and record maintained ?
238 How are vessels isolated in the event of a mishap ?
239 Are the vessels fitted with remotely controlled isolation valves ?
Are vessels provided with emergency vent, relief valve, bursting disc, level
240 indicator, pressure gauge, overflow line ?
241 Where do such vents discharge ?
Are the vessels provided with alarms for high level \, high temperature and
242 high pressure ?

243 Are stand by empty tanks provided for emptying in case of emergencies ?
What are the provisions made for fire fighting/tackling emergency situations
244 around the storage vessels ?
Has any consequence analysis been carried out for these vessels ? (If yes,
245 give details)
What periodical testing are carried out not the vessels to find out the
246 integrity of the vessels ?
247 Whether these tests are certified by the approved competent persons ?
Whether log sheets are filled up on daily basis for recording the parameters
248 of these vessels ?

ON-SITE GAS CYLINDERS STORAGE AREA

249 What are the various gas cylinders used in the plant ? (give details)
250 What are the storage facilities ?
What are the measures taken for combating any emergency in cylinder
251 storage area ?
252 Are valid licenses available for storing all these cylinders ?
Whether integrity test certificates are obtained from the suppliers of the
253 cylinders ?

COMMUNICATION SYSTEM ADOPTED IN PLANT

254 Are public address system available in all plant areas?
255 Are public address systems provided with uninterrupted power supply ?
Whether public address system is checked periodically for its proper
256 functioning ?
257 Is there any hot line provided to fire station ?
258 What is the means of communicating emergency in the plants ?

TRANSPORTATION
What potentially hazardous materials are transported tour from the site
259 (including wastes) ?
260 What modes of transport are used :
a) Road ?
b) Rail ?
c) Pipelines ?

ROAD
261 Does the company employ licensed vehicle of its own/outside sources ?
Are the loading / unloading procedures on site and safety precautions
262 displayed ?
263 Are loaded tankers or trucks parked in a specific area on-site ?
264 Do all truck and tanker drivers carry TREM card or instruction booklet ?
Do all truck and tanker drivers get training in handling emergencies during
265 transport ?

RAIL
266 What hazardous materials are transported by rail ?
267 Does the company have a direct siding on site ?
268 Are tankers or others wagons used in transportation ?

PIPELINES
269 What materials are transported to and from the site by pipeline ?
270 Are the pipelines underground or Overground ?
271 Are corrosion protection measures employed in pipelines ?
272 Whether intermediate booster pumps are used ?
273 What is the maximum and minimum and average transfer rates ?
274 Are the pipelines extended in the public domain?
275 Are the pipelines dedicated for each type of chemicals ?
Are the pipelines fitted with safety equipment such as leak detectors,
276 automatic shut-off valves, etc. ?
277 What is the frequency and method of testing of the pipeline ?
278 Is there written procedure for tackling leakages in pipeline ?