Essar Refinery Integrated Management System

MASTER CHECK LIST FOR APR 2012- MAR 2013

Plant: S & D Dept. /Section: S & D (Tank Farm)

Sr. Doc. No. Description Frequency Remark Responsibility

No.
1 Inspection of Locked Open/Closed Valves Half Yearly To be start from 1st Alpesh Patel
week of Sept 2012
2 Inspection of Guards Moving Machinery Half yearly To be start from 1st Abhishek Tiwari
week of Sept 2012
3 CHECKLIST FOR SAFTEY HARDWARE Monthly To be start from 1st Sandip Patel
week of Sept 2012
4 Inspection of Stairs/Fixed Ladders Half Yearly To be start from 1st Saurabh Gawali
week of Sept 2012
5 TOOL BOX TALK REPORT Weekly To be start from 1st Bhavik Mehta
week of Sept 2012
6 IN SERVICE INSPECTION CHECK LIST FOR Monthly To be start from 1st All field Officers
TANKS week of Sept 2012 of Tank farm

7 INSPECTION OF SAFETY SHOWER Monthly To be start from 1st Indu Mishra

week of Sept 2012
8 HOUSE KEEPING CHECKLIST Monthly To be start from 1st All Field Officers
week of Sept 2012 of Tank Farm
9 Inspection of BA/Escape Sets Quarterly To be start from 1st Krunal Jagani
week of Sept 2012
10 INSPECTION OF MCP (MANUAL CALL POINT) Quarterly To be start from 1st Nirav Vyas
week of Sept 2012
11 CHECKLIST FOR FIRE HYDRANT INSPECTION Quarterly To be start from 1st Laxman
week of Sept 2012 BhanuShali
12 WATER & FOAM TOWER MONITOR Quarterly To be start from 1st Laxman
week of Sept 2012 BhanuShali
Maintained By: - Name: - Designation: - Sign: - Date:-

Reviewed By: - Name: - Designation: - Sign: - Date:-

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Inspection of Locked Open/Closed Valves

Plant: S & D Dept. /Section: S & D (Tank Farm)

Frequency: Half Yearly Date:-

SN Location/Area Description /Identification of Normal Position Actual Position Seal is Intact Remarks
Valve
Locked Locked Open Close Yes No
open closed
1
2
3
4
5
6
7
8
9
10
11
12

Maintained By: - Name: - Designation: - Sign: - Date:-

Reviewed By: - Name: - Designation: - Sign: - Date:-

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Inspection of Guards Moving Machinery

(Coupling, Belt Pulley, Roller etc.).
Plant: S & D Dept. /Section: S & D/ Tank farm
Frequency: Half yearly Date: ________________

SN Check Points/ Details of Moving Machinery with Deficiency Deficiency No. Corrective
Deficiency SN Moving Area/ Description Action Taken
Machinery Location
Tag No.
1. No Identification Nos. & 1
Description/not clearly painted/ 2
needs repainting.
3
2. Not fixed Properly.(Tied with
metallic wire, No/with Less bolts 4
etc.) 5
3. Guard 6
4. broken/deformed/corroded.
7
Incomplete Guard. (Excess
opening/ gap to normal reach to 8
moving parts) 9
5. No /missing guard. 10
6. Any other (please specify).

Inspected By: - Name: - Designation: - Sign: - Date:-

Reviewed By: - Name: - Designation: - Sign: - Date:-

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CHECKLIST FOR SAFTEY HARDWARE

Plant: S & D Dept. /Section: S & D/ Tank farm
Frequency: Monthly Date: _______________ _

Deficiency List List of fire hydrant with Deficiency

Sr. Equipment Location Deficiency Corrective Action Taken
No No. No.
.
A WIND SOCK
1. Wind sock cage NOT moving freely
2. Wind sock NOT showing right direction
3. Wind sock cloth found damaged / open
stitched / colour faded
4. Wind sock base loose bolts / open
5. bolts
6. Wind sock visibility in night hours
7. NOT clear
Telescopic stand bent position
Any other, specify ( )
B EMERGENCY ASSEMBLY POINT
1. Condition of Emergency assembly
point easily visible from all sides, in
sound condition, without dull paint /
2 picture
Surrounding area - easily accessible
3. and unobstructed from all sides
Ways to Emergency Assembly point
identified and displayed / paint with in
plant?
C PORTABLE GAS DETECTOR
1. Is the gas detector not working
2. properly?
Are all attachments to the gas detector

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viz. pump and tubing handy and in non
3. working condition?
4. Battery charging not working.
5. Display screen not clear and intact
6. Function of any button not working
7. properly
8. Sampling Pump body damage /
defect
Sampling pump not working
satisfactory
Any other, specify ( )

Inspected By: - Name: - Designation: - Sign: - Date:-

Reviewed By: - Name: - Designation: - Sign: - Date:-

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Inspection of Stairs/Fixed Ladders

Plant: S & D Dept. /Section: S & D/Tank Farm
Frequency: Half Yearly Date: -

Deficiency List Details of Stairs/Fixed Ladders with Deficiency

Sr Area Stairs/ Location/ Deficienc Corrective Action
No. Ladder Description y Taken
Sr. No. No.
1. Cracked/Damaged steps.

2. Rusted or corroded spots

3. Loose, worn or damaged rungs

or side rails
4. Damaged or corroded part of
cage.
5. Corroded bolts & rivet heads
on inside of metal stack.
6. Damaged or corroded hand
rails or brackets on platforms.
7. Weekend or damaged run on
brick or concrete slab
8. Base of ladder obstructed.

9. Loose, corroded or damaged

support

Inspected By: - Name: - Designation: - Sign: - Date:-

Reviewed By: - Name: - Designation: - Sign: - Date:-

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TOOL BOX TALK REPORT

Plant: S & D Dept. /Section: S & D/Tank Farm
Frequency: Weekly Date: -

SN Main Points Explained Names of the persons present Remarks

1 Importance of PPES

2 Emergency Numbers

3 Fire Fighting System (Hydrant , Monitor)

4 Usage of Safety Shower

5 House Keeping in Area

6 Importance of Safety during Hot & Cold

work

7 Fire and Gas Detection (MCP)

8 Spillage

9 Assembly Point Importance

Tool Box talk given by: - Name: - Designation: - Sign: - Date:-

Reviewed By: - Name: - Designation: - Sign: - Date:-

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IN SERVICE INSPECTION CHECK LIST FOR TANKS

Plant: S & D Dept. /Section: S & D/Tank Farm
Frequency: Monthly Date: -

Capacity (KL): Dia (Mt): Height (Mt): Type of Tank:

SN Particulars Observation

1.0 Foundation. Check levelness.

1.1 Concrete Ring -check for broken concrete, crakes, drain opening for
bottom leak
1.2 Asphalt-check for tank settling, look for areas where leaching of oil left rock
filler exposed.
1.3 Site drainage check operating condition of drains.

1.4 Housekeeping- inspects area for vegetation, flammable material build up.

2.0 Shell- inspect for paint failure ,pitting corrosion

Sealing between bottoms to foundation.
2.1 Shell internal-inspect for Grooving, corrosion, pitting and coating failure.

2.2 Wind girder-Inspect for corrosion at, tack welded junction, support to shell.

3.0 Man ways Nozzle-inspect for cracks, dimpling of shell plate around nozzle,
flange leak.
3.1 Tank piping and manifold-Inspect piping, flange for, leak, anchored
piping, sample connections, check weld on shell mounted davit clips above
6 dia pipe.

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3.2 Mixer Inspect for proper mounting, leak and power cable.

4.0 Roofs Deck plate external corrosion-inspect for paint failure, pitting, hole
product on roof.
4.1 Roof deck- inspect for standing water, sagging etc.

4.2 Roof insulation-inspect for crack & leak.

4.3 Primary seal fabric inspect for deterioration, opening in seals, inspect
secondary seal for buckling,
5.0 Sample hatch- inspect sample hatch cover, its sealing, check marking of
reference height & reinforcing pad,
5.1 Gauge well-inspect size of slots, thinning, &Roof guide.

5.2 ATG-Check the hatch for corrosion and missing bolts.

5.3 Roof mounted vents in IFR Tank- check condition of screen, locking and
pivots pin.
5.4 Emergency Roof Drain- check for water level.

5.5 Roof leg-Check for their position, condition of neoprene cover.

5.6 Vacuum breaker Report type, check cleanliness of mesh.

5.7 Rim Vent- Check condition of screen on Rim Vent cover.

5.8 Pontoon inspection hatch-Check pontoon for leakage by opening hatch

cover, check for LEL, Inspect lock down device.
6.0 Handrails Inspect for pitting, hole, paint failure, attachment welds, inspect
handrail between rolling ladder and gauging platform.
6.1 Platform Frame-inspect frame for corrosion and paint failure, inspect
attachment of frame to support and supports to tank for corrosion and weld
failure.
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6.2 Deck plate and grating Inspect deck plate for corrosion, Paint failure,
inspect grating for corrosion and tie down clip.
6.3 Stairway stringer-inspect spiral stair way stringer for corrosion paint
failure, weld failure, attachment of stairway treads to stringer, stairway
support to shell weld and reinforcing pad.
6.4 Rolling ladder-inspect rolling ladder stringer for corrosion, check condition
of ladder fixing rungs, check for wear and corrosion where rolling ladder
attached to gauging platform, inspect moving parts, inspect rolling ladder
wheel for freedom of movements, ensure 18 of unworn track & inspect
alignment of rolling ladder with roof track.
7.0 Piping Inspect piping for shoes off support, bottom out springs, support
corrosion, loose brackets & side plates and rollers.
7.1 Insulation check for damage, penetration, missing jacketing, bulging &
banding broken and missing.
8.0 Dyke check for vegetation build up, trash, inspect for cracks, inspect for
settlements, and ensure all out going pipes are properly sealed.

Abbreviation 1. Leaching - Permeate or penetrate gradually 2. Dimpling A slight depression 3.Davit clip structure
used to lower things. 4, Tread step, 5 Stringer long beam. 6, Rung one step of ladder 7.Bracket projected support.

Inspected By: - Name: - Designation: - Sign: - Date:-

Reviewed By: - Name: - Designation: - Sign: - Date:-

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INSPECTION OF SAFETY SHOWER

Plant: S & D Dept. /Section: S & D/Tank Farm
Frequency: Monthly Date: -

Sr Description location Observation Action

No
1 Water pressure

2 Shower head.

3 Eye wash fountain ball

4 Pedal valve

5 Pull Rod

6 Housekeeping in surrounding area

7 Other if any specify

Inspected By: - Name: - Designation: - Sign: - Date:-

Reviewed By: - Name: - Designation: - Sign: - Date:-

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HOUSE KEEPING CHECKLIST

Plant: S & D Dept. /Section: S & D/Tank Farm
Frequency: Monthly Date: -

S.No Check Points Observations Corrective Action

. Taken
Plant operations area :
1 Floor clean, no pools/spillage of condensate/ oil/chemicals/water etc.
2 Platform/Grating ok
3 Tag Nos. painted as per standard on equip./machines
4 Plant area free of superfluous material
5 Escape routes marked
6 Access to fire extinguishers/MCP/Emergency exit etc. unobstructed
7 Scrape and refuse bins provided & cleaned.
8 Temporary floor opening without barricading caution/sign boards "Do
not enter without permit".
9 Drains and vents are plugged/capped/blinded

10 Is insulation in good condition

11 Guards- Machine/Railing/Ladders/platforms ok

12 Colour Coding and Sign Boards

13 Colour coding of pipelines done & displayed conspicuously

14 Adequate Nos. of caution /hazard boards & displayed conspicuously

-appropriateness of display locations
15 Tanks identification as per standards

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16 Road
17 Swept , No dust , No debris ,Road in good condition

18 Drains :
19 Plant drains having proper cover and surrounding area of OWS pit
clean. Pits not over flowing
20 Storm water channels -free from hydrocarbon and debris. No
vegetation growth. Pass ways over channels.
21 Fire Equipments(FH/FM/Hose Boxes/Deluge/ Extinguishers)

22 Identification Nos. painted properly & in good condition

23 Extinguishers & hose boxes at their proper location

24 Route Not obstructed

25 Hydrants/Monitors/Deluge not leaking

26 Dyke/tanks
27 Water logging/ spillage

28 Material stored/lying inside the dyke

29 Damaged dyke wall/gap at the entry point of pipes or at joints
30 Loose material lying on tank top
31 Growth of wild vegetation

Inspected By: - Name: - Designation: - Sign: - Date:-

Reviewed By: - Name: - Designation: - Sign: - Date:-

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Inspection of BA/Escape Sets

Plant: S & D Dept. /Section: S & D/Tank Farm
Frequency: Quarterly Date: -

Deficiency List S. No. Equipment Location Deficiency No. Corrective

No. Action Taken
1. Cylinders empty or pressure < 150 bars.
2. Set is not clean.
3. Facemask is dirty.
4. Hose pipe is leaking.
5. Hose pipe is deteriorated.
6. Hose connection/fittings are leaking.
7. Neck strap is in bad condition/damaged
8. Cylinder bag is in bad condition/damaged
9. Valve pin is missing.
10. No/damaged box for set.
11. Pressure gauge condition.
12. Working of whistle.
13. Condition of body harness and buckle.
14. Any other (please specify)

Inspected By: - Name: - Designation: - Sign: - Date:-

Reviewed By: - Name: - Designation: - Sign: - Date:-

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INSPECTION OF MCP (MANUAL CALL POINT)

Plant: S & D Dept. /Section: S & D/Tank Farm
Frequency: Quarterly Date: -

Deficiency List Details of MCPs with Deficiency

Sr. Equipme Type Location Deficien Corrective Action Taken
No nt cy
. No. No.
1. Sign board/painting faded.

2. Broken glass

3. Cable condition (not

clamped/deteriorated

4. Alarm indication at Control Room.

5. Alarm indication at Fire Station.

6. Siren status in field (if provided)

7. Sounding of siren (Not OK)

8. No accessible (obstructed)

9. Any other, specify ( )

Inspected By: - Name: - Designation: - Sign: - Date:-

Reviewed By: - Name: - Designation: - Sign: - Date:-

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CHECKLIST FOR FIRE HYDRANT INSPECTION

Plant: S & D Dept. /Section: S & D/Tank Farm
Frequency: Quarterly ` Date: -

Deficiency List List of fire hydrant with Deficiency

Sr. Equipment Location Deficiency Corrective Action Taken
No No. No.
.
1. Painting
2. Hydrant number not
legible/painted
3. Isolation Valve condition
4. Any part broken/damaged
5. Leaking valve
6. Manual Operation not
satisfactory Condition
(damaged/jammed).
7. Operating valve is obstructed
(not easily accessible).
8. Lugs damage
9. Rubber washer damage
10. Spindale/wheel damage
11. Coupling not proper
12. Blank cap missing
13. Any other, specify ( )

Inspected By: - Name: - Designation: - Sign: - Date:-

Reviewed By: - Name: - Designation: - Sign: - Date:-

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WATER & FOAM TOWER MONITOR

Plant: S & D Dept. /Section: S & D/Tank Farm
Frequency: Quarterly ` Date: -

Sr. No. Location Tag No. Deficiency no Corrective Action Taken

Deficiency List

1 Physical condition

2 Approach to Foam
Inlet Breeching
Connection
3 Appearance/paint
condition
4 Local Operation of
valves
5 Foam/Water line
condition
6 Foam accessories
condition
7 Remarks if any or
any other deficiency

Inspected By: - Name: - Designation: - Sign: - Date:-

Reviewed By: - Name: - Designation: - Sign: - Date:-

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