Is 14489:2018 Occupational Health and Safety Audit — Code of Practice

CHECK SHEET

C-1 OH & S MANAGEMENT

SL Content
1 Does the organization have OH & S policy?
2 Who has signed the OH & S policy?
3 Whether the OH & S policy is per guidelines of the statutory provisions?
4 When was the OH & S policy declared and adopted?
5 Whether the OH & S policy reviewed periodically?
6 Whether the OH & S policy is available in local language and made known to all?
7 What was the last date of updation?
8 Does the policy find a place in the annual report?
C-2.1 Safety Department

9 Does the factory have a safety department and what is strength of safety department?
10 Whether the strength and qualifications of Safety Officers are as per the statutes?
11 Does the head of safety department report to the Chief Executive?
12 How often are the safety officers retrained in the latest techniques of total safety
management? What is the frequency of retraining?
13 What additional duties the safety officer is required to do?
14 What is the power of safety officer vis-a-vis unsafe condition or unsafe act?
C-2.2 Safety Committee(s)

15 Does the factory has a safety committee(s)? What are the types, structures and terms
of reference of the committees?
16 Is the constitution of the safety committee(s) as per the statute?
17 How are the members of safety committee(s) selected? (elected / nominated)
18 How often are the meetings of safety committee(s) held?
19 Are the recommendations of the committees(s) implemented?
20 Are the minutes of the safety committee(s) meetings circulated among the members?
21 Are the minutes forwarded to the trade union(s) and chief executive and occupier?
22 Whether the management and trade union play their active roles in supporting and
accepting the committee(s) recommendations?
23 How are the safety committee(s) members apprised of the latest development in
safety, health and environment?

C-2.3 Safety Budget

24 What is the annual safety budget?

25 How much percentage is this budget of the total turnover of the company?
26 How much budget has been utilized till date?
27 Is the safety budget adequate?
28 How is the safety budget arrived at?
29 What is the pattern of expenditure for the last five years?
30 What are the approved sanctions for the expenditure in this budget?
31 Does this budget get reflected in the annual report of the company?
C-3 SAFETY MANUAL

32 What is the periodicity of updation / review of safety manual?

33 Does the safety manual adequately address all the hazards in the plant?
24 Are the employee made aware of safety rules / instruction mentioned in the safety
manual?
C-4 STANDARD OPERATING PROCEDURES (SOP)

25 Are written Standard / safe operating procedures available for all operations and
processes?
26 Whether the written Standard / safe operating procedures are displayed or made
available and explained in the local language to the workers?
27 c) Whether concerned section and safety department prepares standard / safe
operating procedure jointly?
28 d) Are standard / safe operating procedures reviewed and updated?
29 e) Have the workers been informed of the consequences of failure to observe the
standard / safe operating procedures?
C-5 PLANT MODIFICATION PROCEDURES

30 What is the system for effecting any change in the existing plant, equipment or
process?
31 Whether the P & I diagrams and other related documents are updated accordingly?
32 Whether hazard assessment done before implementation of modification?
C-6 WORK PERMIT SYSTEM

33 What types of work permits exist in the factory?

34 Are the necessary forms detailing required safety precautions have been prepared and
used for each type of work-permit?
35 Is the responsibility assigned to authorized person for issuing of safety work permit?
36 Is the copy of safe work permit sent to safety officer before execution of the job?
37 Is validity period specified in the safety work permit?
38 Are the records of work permit available and maintained in proper order?

C- 6.1 Control Measures for Work at Height

39 Is adequate safe access provided to all places

40 Are all such access in good condition?
41 Are all scaffolds are properly designed and erected?
42 Are scaffolds inspected every day before work begins?
43 Are ladders securely clamped or lashed in place?
44 Are planks in good condition?
45 Are scaffold walkaways, platforms, runs or stairs free of debris, grease, any
unnecessary obstruction and projecting nails?
46 Are the scaffolds higher than 20 m.? If yes, is a netting or intermediate railing
provided between toe-boards and hand railings?
47 Are folding stepladders properly used?
48 Are ladders set up at the proper slope of about 1:4?
49 Do workers use hand lines to lift tools or materials?
50 Are proper ladders used around electrical hazards?
51 On sloping roofs, are crawling boards, lifelines, safety belts and edge protection
provided where needed?
52 Whether the weak spots, skylights, or deteriorated asbestos-cement boards through
which a worker might fall while working in the roof has been identified and safety
net provided appropriately?
53 Are the workers being medically examined for their fitness to work at height?

C-6.2 Work in Confined Space

54 Is there any system for selection of contractors?

55 Are there any guidelines on contractor’s safety and training?
56 Whether contract document includes necessary safety and welfare clauses as per
statutes?
57 Is there any programme to ensure use of PPE by contractors personnel?
58 Do the contractors have their own safety organization?
59 Are the contractors reporting all accidents and injuries?
60 Are contractor workers trained to observe safety at work place?
61 Whether contractor workers are engaged in process / operations? If yes, are they
aware of safe operating procedures?

C-8 PLANT DESIGN AND LAYOUT

62 Whether hazardous operations in the plant are segregated?

63 Whether occupational health & safety aspects are considered during the design?
64 Are all the equipment provided with adequate space for working, maintenance etc.?
65 Are the storage tanks provided with enough space / clearance between them?

66 Whether the plant layout has taken care of the movement of fire fighting equipment
and emergency exits?

C-9 MEDICAL MANAGEMENT OF ACCIDENTS

67 Are medical facilities available with trained first aid staff and equipment in round the
clock shift for all including contractors?
68 Is the ambulance van available for round the clock basis with the dedicated driver?
69 Is there any mutual aid scheme available with the nearest hospitals to manage and
treat injuries during emergency?
70 Are the workers / contractor workers aware of emergency medical facilities?

C-10 MANAGEMENT OF EMERGENCIES (NATURAL / MAN-MADE)

71 Does the system exist to detect and control these Emergencies?

72 Are the employees aware of the measures to be taken during emergencies?

C-11 EMPLOYEES SELECTION AND PLACEMENT

73 Whether norms are available for selection of different category of employees?

74 Whether pre-employment medical examination is being conducted for employees?
75 Is there any procedure to evaluate safety awareness and record of the employees
 during their promotion?

C-12 SAFETY CULTURE

C-12.1 Attitudes of Managers

76 Do the managers follow the plant safety rules at all times?

77 What are their attitudes towards safety reviews and audits?
78 What is the response of management to safety violation?
79 Whether safety related decisions are taken in consultation with the workers?
80 What is the attitude of the managers towards non use of personal protective
equipment?
C-12.2 Attitudes of Workers

81 Whether workers are aware of the consequences of their wrong actions?

82 Are laid down safe working procedures followed strictly?
83 What is the attitude of the workers towards their own mistake, which can prejudice
safety?
84 Do the workers report near miss incidents and suggest safety Improvements?
85 Are the workers aware of the system of rewards and sanctions relating to safety
matters?
86 What is the attitude of workers towards use of personal protective Equipment?

C-13 STATUTORY LICENSES, APPROVALS AND RECORDS

87 Whether all the safety related Acts / Rules (with latest amendments) applicable to
your organization identified, informed to all employees and complied?
88 Whether the licences have been validated?

C-14 MOTIVATIONAL AND PROMOTIONAL MEASURES FOR OH & S

89 Does the factory have occupational health and safety suggestion scheme?
90 Are occupational health and safety contests organized in the factory?
91 Does the factory participate in National Awards?
92 Has the factory been awarded during last five years?
93 Does the organization publish safety bulletin / newsletters?
94 Whether the safety bulletins are widely distributed?
95 How is the occupational health and safety information including accident statistics
disseminated in the factory? (Bulletin boards, Newsletter etc.)
96 What are the activities conducted during National Safety day / week? What is the
percentage of Workers participating in the various safety promotional activities?

C-15 HAZARD IDENTIFICATION AND JOB SAFETY ANALYSIS

97 Was an initial process hazard analysis (PHA) completed?

98 What are the stages of PHA? Whether a dedicated group is identified for PHA?
99 Was the PHA appropriate for the complexity of the process and identify, evaluate,
and control the hazards involved in the process?
100 Does the hazard evaluation use one or more of the following PHA methodologies:
What-If Anysis, Process Checklist, Hazard and Operability Study (HAZOP), Failure
Mode and Effects Criticality Analysis (FMECA), Fault Tree Analysis (FTA) or any
other appropriate equivalent methodology?
101 Does PHA assures addressing issues of inherent safety features with respect to
 material and their properties?
102 Does the PHA address the hazard identification, incidents history, consequences of
failures (engineering and administrative controls), human factors, consequent
analysis with respect to possible safety and health effects of failure of controls?
103 What are the stages of PHA? Whether a dedicated group is identified for PHA?
104 Does the system exists to promptly address findings and Recommendations of
PHA?
105 Are the PHA’s updated and revalidated at least every five years by a qualified team
to assure that the PHA is consistent with the current process?
106 Whether the activities requiring Job Safety Analysis have been identified?
107 Whether the identified jobs for Hazard Identification have been carried out by
trained and experienced persons?
108 Whether the checklists have been prepared on each Job Safety Analysis and are
being used while carrying out the job?

C-16 PRODUCT SAFETY

109 Whether hazards arising from use of the products are identified?
110 Whether material safety data sheet prepared for the products?
111 Are all the products labelled and packed appropriately?
112 Whether safety instructions are given along with products?
113 Whether policy exists for recall of products?

C-17 SAFETY TRAINING

114 Whether training needs have been identified?

115 Is there any programme of induction training, its duration and topics covered?
116 Whether the assessment of the trainees has been carried out?
117 What are the infra-structural facilities available for training?
118 Whether training is conducted by qualified person?
119 Whether trainers are being re-trained from time to time?
120 Whether proper records of training program conducted are maintained?
121 How training programs are evaluated?
122 Whether schedule for training on occupational health and safety is available and
maintained?
123 Are all the employees periodically trained / retrained and what is the frequency of
such training?
124 Are the retraining needs identified whenever a new process / products and change in
existing process introduced?
125 Whether training covers top management?
126 How many hours of safety training is given to different employees?

C-18 CHANGE MANAGEMENT

C-18.1 Management of Change

127 Are there written procedures for managing change to process chemicals, technology,
equipment and procedures and changes to facilities that affect the plant process /
system operation?
128 Do the procedures assure that the technical basis for the proposed change addressed
prior to any change?
129 Do the procedures assure that the impact of the change on safety and health
addressed prior to any change?
130 Do the procedures assure that modifications to operating procedures are addressed
prior to any change?
131 Do the procedures assure that the necessary time period for the change is addressed
prior to any change?
132 Do the procedures assure that the authorization requirements for the proposed change
are addressed prior to any change?
133 Are employees involved in operating a process, and maintenance and contract
employees whose job tasks will be affected by change informed of, and trained in,
the change prior to the start-up of process or affected part of process / operations?
134 Is the safety information is reviewed and updated on changes?
135 Are the operating procedures or practices updated?

C-18.2 Mechanical Integrity

136 Does the mechanical integrity program include for all mechanical equipment
including pressure vessels and storage tanks, piping and components, relief devices
and vent systems, emergency shutdown systems, pumps, control systems?
137 Are there written procedures to maintain the on-going integrity of process
equipment?
138 Whether training been provided to each employee involved in maintaining the on-
going integrity of process equipment?
139 Are inspections and tests performed on each item of process equipment included in
the program?
140 Does the inspection and test frequencies meet the manufacturer’s recommendation
and good engineering practice?
141 Are inspections and tests performed more frequently if determined necessary by
operating experience?
142 Are deficiencies in equipment that are outside limits corrected before further use so
as to assure safe operation?
143 In the construction of new plants and equipment, whether quality assurance
programme is implemented to ensure that equipment fabricated is suitable for the
process?
144 Are appropriate checks and inspections made during equipment installation stage?
145 Are the suitability of maintenance materials, spare parts and equipment ensured
during maintenance?
C-19 PHYSICAL HAZARD

C-19.1 Housekeeping

146 Are all the passages, floors and the stairways in

good condition?
147 Is glass door taped or otherwise marked to make it visible to workers?
148 Do you have the system to deal with the spillage?
149 Do you have sufficient disposable bins clearly marked and whether these are suitably
located? Are containers of refuse (waste) and trash emptied at the end of every day or
soon after they are full? Are the containers or bins regularly cleaned?
150 Are drip trays positioned wherever necessary?
151 Do you have adequate localized extraction and scrubbing facilities for dust, fumes
 and gases? Please specify.
152 Whether walkways are clearly marked and free from obstruction
153 Do you have any inter-departmental competition for good housekeeping?
154 Has your organization elaborated good housekeeping practices and standards and
made them known to the employees?
155 Are there any working conditions, which make the floors slippery? If so, what
measures are taken to make them safe?
156 Does the company have adequate measures to suppress polluting dust arising out of
materials stored on the roadside?

C-19.2 Machine and General Area Guarding

157 Whether machinery and equipment which can cause physical injuries to operator
have been identified?
158 Are all moving parts and point of operation of machinery adequately guarded?
159 Are all fixed guards securely bolted in position and in good condition?
160 Are all interlock guards for prevention of physical injury in good condition?
160 Are all emergency stop buttons effective and clearly labeled?
162 Are the operators for machines having moving parts aware of the danger of working
with loose clothing?
163 Are the openings where there is free fall hazard covered or fenced securely?

C-19.3 Material Handling

164 Are adequate equipment available for handling materials?

165 Are the workers aware of the hazards associated with material being handled?
166 Where manual handling is necessary, are the workers been trained? Do they practice
this? Are workers warned for lifting of excessive weight? (Maximum weight of
material for adult male and female are 55 Kg and 30 Kg respectively)
167 Is the register maintained to record particulars of examination of all lifting machines,
tools and tackles?
168 Is the register maintained to record particulars of examination of all lifting machines,
tools and tackles?
169 Are all the statutory examinations and tests carried out and certified by competent
person(s)?
170 Are the operators of crane, lifts, hoists and other mechanized operations adequately
qualified?
171 Is the safe working load clearly marked?
172 Has the person employed to operate crane, forklift, or to give signals to crane been
medically examined for eyesight and colour vision?
173 Is the frequency of eyesight and colour vision examination as per the latest rules?

C-19.4 Electrical Safeguarding

174 Are licensed electricians available for electrical work?

175 Whether area classification for electrical equipment has been carried out?
176 Do the electrical fittings conform to area classification for electrical equipment?
177 Is a ground fault current interrupter system (ELCB) in use?
178 Are there any make shift connection bare wires or damaged cables?
179 Is there a system of ensuring periodical inspection of hand tools, extension boards
 used for electrical work?
180 Do the workers use proper types of PPE during the working on live line?
181 Is the separate work permit issued for working on high voltage line?
182 Whether the process(s) and equipment that generate and accumulate static charge
have been identified?
183 Whether all such equipment including pipelines for flammable materials are properly
bonded and earthed?
184 Whether earth pit resistance is measured and the record maintained?
185 Whether lightning arrestor has been installed and is adequate?

C-19.5 Safety in Storage and Warehousing

186 Whether the Material Safety Data Sheet for all chemicals is available?
187 Are the chemicals stored as per their hazardous properties including the
incompatibility?
188 Are all containers clearly, indelibly labelled? Are all chemicals stored as per safety
regulations?
189 Whether all racks and steel cages have sufficient load bearing capacity?
190 Is adequate natural ventilation provided to storeroom? Is there any emergency exit?
191 Whether adequate fire fighting arrangement existing in flammable chemical storage?
192 Whether methodology for handling spillages of hazardous chemical available along
with the equipment required handling the spillage?
193 Whether aisles are marked and emergency exits displayed?

C-19.6 Hazard Assessment for New Equipment

194 What is the system for effecting any change in the existing plant, equipment?
195 Is there system for evaluating hazards from new equipment?
196 Whether the P and I diagrams and other related documents are updated accordingly?
197 Is any Job Hazard Analysis (JHA) carried out after installation of new equipment?

C-19.7 Hazards from Radiation Sources

198 Whether licences have been obtained for storage / handling of radioactive material?
199 Whether approved Radiological Safety Officer appointed?
200 Whether appropriate PPEs are used against radiation hazards?
201 Is the flooring of the radioactive material handling area amenable for proper
decontamination?
202 Is the storage room of radiation source as per the licence condition?
203 Are all persons working in the facility have radiation safety training?
204 Is the operators handling devices using radioactive materials qualified and possess
the necessary certificate?
205 Is the periodical radiation monitoring carried out?
206 Are the records of inventory of radioactive material maintained in the standard
format and submitted to the competent authority as per the period specified?
207 Are emergency handling tools available?
208 Are the personnel monitoring badges (TLD, Pocket dosimeter etc.) assigned and
worn by each radiation worker?
209 Are the radiation symbol and red light displayed as required?
C-20 CHEMICAL HAZARD

C-20.1 Transportation of Hazardous Substances

210 What potentially hazardous materials are transported to or from the site (including
wastes)
211 What mode of transport are used? 1) Road,2) Rail, and 3) Pipelines
1) Road
i) Does the company employ licenced vehicle of its own / outside sources?
ii) Are the loading / unloading procedures in place and safety precautions displayed?
iii) Is there a provision to check the healthiness of road tanker with respect to
explosives rules?
iv) Are loaded tankers or trucks parked in a specific area on-site?
v) Do all truck and tanker drivers carry transport emergency (TREM) card or
instruction booklet?
vi) Do all truck and tanker drivers get training in handling emergencies during
transport?
vii) Are all the tankers marked for proper Hazchem code?
212 2)Rail
i) What hazardous materials are transported by rail?
ii) Does the company have a direct siding on site?
iii) Are tankers or other wagons used in transportation
213 3) Pipelines
i) What materials are transported to and from the site by pipelines?
ii) Are the pipelines underground or over ground?
iii) Are corrosion protection measures employed in pipelines?
iv) Whether intermediate booster pumps are used?
v) What is the maximum, minimum and average transfer rates?
vi) Are the pipelines extended in the public domain?
vii) Are the pipelines dedicated for each type of chemicals?
viii) Are the pipelines fitted with safety equipment such as leak detectors,
automatic shut-off valves etc.?
ix) What is the frequency and method of testing of the pipeline?
x) Is there written procedure for tackling leakages in pipeline?

C-20.2 Handling of Hazardous Substances

214 What are the hazardous substance handled in the factory?

215 Whether quantity of hazardous substances is above the threshold limit specified in
the Manufacture, Storage and Handling of Hazardous Substances
Rule, 1989? If yes, then required documentation is available as per the rule.
216 Whether written procedure for handling the hazardous substance is available and
operators are trained for handling such substances including actions required in case
of leakages and spillages?

217 Are the employees aware of the hazards arising from hazardous substances and safety
precautions to be taken during handling of these?

C-20.3 Material Safety Data Sheets (MSDS)

218 Are the material safety data sheets available for all the chemicals handled, used and
manufactured in the factory? INCLUDING IN LOCAL LANGUAGE
219 Whether the latest MSDS are displayed at strategic locations?

C-20.4 Spill Control Measures

220 Whether spill control procedure is available?

221 Whether spill collection pit / sump is available at the workplace?
222 Whether methodology for recovery / disposal of collected material has been
established?

C-20.5 Storage of Hazardous Substances

223 Whether storage vessels are identified with the capacity as required under MSIHC,
Rules 1989.
224 What are the storage pressure and temperature?
225 Whether vessels are above ground / underground?
226 If any of the tanks storing flammable material, whether electrical equipment and
fittings are as per electrical area classification?
227 Is the bunded area takes into account the total quantity of the largest tank?
228 Whether the bund perimeter takes into consideration of trajectory of leak from tank?
229 Are the vessels properly bonded and earthed and whether periodically checked and
record maintained?
230 Are the vessels fitted with remotely controlled isolation valves?
231 Are vessels provided with emergency vent, relief valve, bursting disc, level
indicator, pressure gauge, overflow line?
232 Where do such vents discharge?
233 Are the vessels provided with alarms for high level, high temperature and high
pressure?
234 Are standby empty tanks or any other alternate systems provided for emptying /
transfer in case of emergencies?
235 What are the provisions made for fire fighting /tackling emergency situations around
the storage vessels?
236 Has any consequence analysis for loss of containment been carried out?
237 Whether the vessels are tested as per statute?
238 Whether log sheets are filled up on daily basis for recording the parameters of these
vessels?
239 Whether monitors for detection of leakage of flammable / toxic material installed?
240 Whether the chemicals stored are as per their compatibility?

C-20.6 Gas Cylinders

241 What are the various gas cylinders used in the plant?
242 Are valid licenses available for storing all these cylinders?
243 Are the cylinders stored and segregated as per their compatibility?
244 What are the measures taken for combating any emergency in the cylinders storage
area?
245 Whether integrity test certificates are obtained from the suppliers of the cylinders
246 Are the cylinders chained and secured properly along with the valve caps and proper
identification colour code?
247 Are the cylinders protected from heat or sun and rain?
248 Whether monitors for detection of leakage of flammable / toxic gas installed?

C-20.7 Labeling and Colour Coding

249 Are all the containers, vessels and storage tanks labeled for its content and capacity?
250 Whether the pipelines are colour coded as per IS 2379?
251 Is any plant specific colour code followed?
252 Whether the colour codes are displayed conspicuously in the working areas?

C-20.8 Hazardous Waste Management

253 Is identification done for various types of hazardous wastes?

254 Are these quantities less than those specified by the Hazardous Wastes (Management
& Handling) Rules, 1989 ?
255 What are their disposal modes?
256 What are the systems / measures adopted for controlling air / water / land pollution?
257 Whether the solid waste like combustibles, plastic, metals etc. segregated?

C-21 FIRE AND EXPLOSION HAZARD

C-21.1 Organisational Set-up for Fire Fighting

258 What is the total strength of fire station and fire crew?
259 How many fire crews are available in each shift?
260 Is there fire squad identified in each shift?
261 Standing fire order is available with latest revision
262 How is the communication with fire station?
263 Does fire safety inspections carried out?
264 Does emergency procedure available for leakage or combustion of flammables?
265 What measures are available to control the fire load in the plant area?
266 Whether technical knowledge and skills of the manager and staff responsible for
overall fire safety of the plant is adequate?
267 How many major and minor incidents / fires were there in the factory during the last
five years? Give department / plant wise.
268 Have all the fires / incidents been investigated and corrective actions taken? Give
break-up.
269 Resources: Adequacy of protective clothing (coat, trouser, gloves, boots and helmets)
270 Resources: Availability of SCBA for fire fighting operations and spare cylinders (at
least 2 for each SCBA);
271 Resources :Adequacy of hose, nozzles, ladders, lighting equipment and pumps;
272 Resources : Communication facility at fire station, walkie talkie sets during fire
 fighting.

C-21.2 Built in Safety in Civil Design and Construction

273 Whether the two safe means of escape available? Are they in separate directions?
274 Is emergency exits provided to the building handling flammables?
275 Whether emergency lights are provided?
276 Whether fire / smoke detectors are installed in fire prone areas?
277 Whether fire call points are provided in different areas?
278 Whether Fire hydrants are provided near the buildings?
279 Is ventilation system in plant handling flammables is adequate to prevent formation
of flammable mixtures?
280 Is adequate separation is provided between combustible / flammable materials and
other material to restrict the fire growth?
281 Access routes for fire fighting operations is available for areas having high fire load
282 Whether building changes interferes with fire detection and / or fire suppression
systems?
283 Whether building changes cause unreasonable fire loading / openings in the fire rated
walls?

C-21.3 Built in Safety in Electric Circuits and Equipment

284 Are the electrical equipment in areas where flammables mixture is likely to be
present of flame-proof type?
285 Are lightning arrestors are provided to the buildings / structures storing flammable
materials?
286 Whether adequate bonding and grounding of electrical equipment / pipelines
provided?

C-21.4 Explosive Substances

287 Whether necessary license / approval taken from concerned statutory bodies?
288 Whether systems for explosion suppression, high speed fire detection with deluge,
sprinklers, explosion venting etc. are provided?
289 Whether explosion resistant walls or barricades are provided around explosive
storage?
290 Whether explosive substance storage areas are restricted for entry?
291 Whether only trained persons are handling explosive substances?
292 Whether explosive substances are stored and transported in approved containers
only?
293 Whether electrical fixtures in areas handling explosives are explosion proof type?
294 Whether adequate measures are taken to prevent any sources of ignition where
explosive substances are handled?

C-21.5 Fire Safety in Handling Flammable and Explosive materials

295 Whether emergency procedure is available for control of leakage?
296 Whether emergency measures are displayed locally in case of accidental spillage /
leakage?
297 Whether facility is provided for safe drainage of combustible or flammable liquids in
case of leakages?
298 Whether highly flammable liquids are stored under inert atmosphere?
299 Whether flammable storage tanks are provided with flame arrestors?
300 Whether suitable PPEs are provided?

C-21.6 Fire Detection and Alarm System

301 What type of fire detection and alarm system provided?

302 Whether all fire prone areas of the plant are covered with fire detection system?
303 Whether fire detection equipment and smoke alarms in good operating condition?
304 Whether the numbers of fire call points are adequate and free from obstruction?
305 Whether regular inspection / maintenance / testing of fire detection and alarm system
carried out and records maintained
306 Whether any atmospheric monitoring is carried out for explosive mixture of gases or
vapours?
307 Whether emergency power supplies are provided to fire detection and fire alarm
system?
308 Whether smoke detectors are located considering ventilation pattern?
309 Whether annunciation of fire is local or in the control room or in both places?
310 Whether fire panel is constantly attended?

C-21.7 Passive and Active Fire Protection System

311 What are the passive fire protection measures available? (barriers, doors, dampers
etc.)
312 Are the areas requiring fire barriers identified?
313 Whether the fire barrier provided is of adequate ratings?
314 Whether ventilation ducts in flammable areas have been provided with isolation
dampers of suitable fire rating?
315 Whether sprinklers / deluge are installed wherever necessary?
316 Whether regular inspection / maintenance / testing of fire protection system carried
out and records maintained?

C-21.8 Fixed Fire Extinguishing System

317 What are the sources of firewater and whether they are dedicated to the fire
extinguishing system?
318 Whether the capacity of dedicated water reservoir is adequate to supply to hydrants
for minimum 2 hours?
319 Whether un-interrupted power supply is provided to the firewater pumps?
320 Whether the extinguishing medium selected is appropriate to the class of fire (water,
gaseous, foam, dry powder)?
321 Whether fire hydrants layout is available?
323 Whether additional (over minimum requirement) fire hoses, nozzles are available?
324 Whether the hydrants lines are kept pressurized?
325 Whether regular inspection / maintenance / testing of fixed fire extinguishing systems
carried out and records maintained?

C-21.9 Portable Fire Extinguishing System

326 Whether suitable type and numbers of fire extinguishers provided?
327 Whether the fire extinguishers are located at conspicuous position and easily
accessible? Are they fully charged and tagged?
328 Whether fire extinguishers periodically inspected, tested, refilled and records
maintained?
329 Whether defective / unchecked fire extinguishers present at site?
330 Whether additional fire extinguishers are available?

C-21.10 Fire Fighting Equipment and Facilities

331 Whether fire tenders (water / foam) are available?

332 Whether the fire-fighting system and equipment approved, tested and maintained as
per relevant standard?
333 Whether the SCBA / fire suit provided to fire fighting team for immediate action?
334 What is system for maintenance / recharge of SCBA?
335 Is proper access available for fire fighting equipment?
336 Whether fire hose cabinets are in good condition, easily visible, and accessible?
337 Whether drill tower is available? Are fire personnel carrying out regular fire drill?
338 What is the communication facility at fire station? Is it adequate?

C-21.11 Fire Drill

339 Whether mock fire drills are conducted? What is the frequency of drills?
340 Whether fire drills are also performed in night shift
341 Whether feedback of fire drill is documented?
342 What is the system of mutual-aid scheme?

C-21.12 Fire Fighting Training

343 Whether there is a system of providing fire fighting training to plant personnel
344 What is the frequency and duration of such training? Whether training records are
maintained?
345 Whether fire squads are identified for different areas for first-aid fire fighting and
rescue, and suitably trained?
346 Are all personnel conversant with the fire prevention and protection measures?
347 Whether the fire staff are sent for refresher / advanced training courses?

C-21.13 Static Electricity and Lightning

348 Whether all vessels and pipes are provided with suitable bonding and grounding?
349 Whether arrangement has been made for grounding the tanker containing flammable
liquid during loading / unloading?
350 Whether spark resistant tools are provided?
351 Whether lightning protection is provided and is adequate?
352 Whether antistatic clothing, hand gloves and footwear are provided?
C-21.14 Pressure Relief System

353 Whether the listing of all ‘pressure plants’ [as defined under Factories Act] has been
done?

C-22 INDUSTRIAL HYGIENE / OCCUPATIONAL HEALTH

C-22.1 Ventilation, Illumination, Noise, Vibration, Heat stress and Non-ionizing Radiations

354 Whether any ventilation study has been carried out?

355 Whether natural ventilation is adequate or not?
356 Whether dust / fumes / hot air is generated in the process?
357 Is there any exhaust ventilation system in any section of the plant?
358 Is periodic / preventive maintenance of ventilation system carried out and record is
maintained?
359 Does any ventilation system re-circulate the exhausted air in work areas?
360 Is the work environment assessed and monitored for chemical and physical hazards?
361 Whether PPE are provided to workers exposed to dust / fumes and gases?
362 Whether illumination study has been carried out for the assessment of illumination
level?
363 Is there any system of periodical cleaning and replacing the light fittings / lamps in
order to ensure that they give the intended illumination levels?
364 Are the workers subject to periodic optometry tests and records maintained?
365 Are emergency lighting available at first aid center.
366 Whether any noise study conducted?
367 Are there any machines / processes generating high-noise?
368 Whether engineering and administrative controls been implemented to reduce noise
exposure below the permissible limits?
369 Is there a system of subjecting all those employees to periodic audiometric test who
work in high level noise areas?
370 Whether the workers are made aware of the ill effects of high noise?
371 Whether ear muffs / plugs are provided and used?
372 Are there equipment which contribute excess level of vibrations and whether they
are identified?
373 Whether any vibration study has been carried out?
374 Are the measures taken to combat vibration to acceptable levels?
375 What is the frequency for measurements of vibration?
376 Are there sources from equipment increasing the heat load in work places?
378 Whether evaluation of heat stress is carried out?
379 Whether natural ventilation is adequate to minimize the heat stress in work
environment?
380 Whether natural ventilation is adequate to minimize the heat stress in work
environment?
381 Do workers know the symptoms of heat cramps / heatstroke or frost bite /
hypothermia?
382 Are the personal protective equipment suitable forreducing the effects of heat stress
 available?
383 Does the work involve likely exposure to non-ionising radiations (ultraviolet,
infrared, radiofrequency, microwaves, lasers, etc.)
384 Whether risk assessments have been done for all work areas involving presence of
non-ionising radiations?
385 Are the work areas displayed with relevant safety signs?
386 Are the employees aware about the hazards of non-ionising radiations?
387 Does written procedures exists for working in non-ionising radiations?
388 Is the work environment monitored periodically for physical hazards and control
measures initiated whenever deviation from permissible values is
observed?
389 Whether suitable personal protective equipment are provided to workers exposed to
non-ionising radiations?

C-22.2 Work Place Monitoring for Hazardous Chemicals

390 Whether the dust, fumes, smoke aerosols and mist are monitored as per statute and
records maintained?
391 What are the types of detectors used for monitoring concentration of hazardous
chemicals?
392 Is any alarm system installed for any leakage of hazardous chemicals?
393 Are antidotes available for toxic chemicals?
394 Are control measures initiated whenever deviation from permissible values is
observed?

C-22.3 First Aid Facilities and Occupational Health Centre (OHC)

395 Are adequate numbers of first aid boxes provided? Give location details?
396 b) Are qualified / trained first aiders available in each shift?
397 c) How many qualified / trained first aiders are available at each plant / department?
398 How many persons are trained / given refreshers training in first aid in a year?
400 Whether occupational health center is provided?
401 Does OHC conform to the provisions of the existing statutes?
402 Are the Medical Attendants / Doctors available in each shift?
403 What facilities are available for transportation of the injured to hospital?
404 Are the names of the trained first aiders displayed?
405 Are the name of nearest hospitals and its telephone number available in OHC?
406 Does the plant have any special preventive medicine program?
408 Is ambulance posted in proper place and is it available whenever required?
409 Are sufficient numbers of anti-dotes available in case of any emergency?
410 Are fire safety measures provided in first aid centre?
411 Are emergency lighting arrangements available at first aid centre?

C-22.4 Periodic Medical Examination

412 Whether the periodical medical examination of employees, required under relevant
statute is carried out?
413 Whether it is ensured that contractors employee are medically examined during pre-
employment as well as during the course of employment?
414 During the periodical medical examination of the workers, are they examined as per
the hazardous process in which they work? (First schedule of The Factories Act,
1948)
415 Are the records of all such examination maintained?

C-22.5 Personal Protective Equipment and Emergency Equipment

416 Whether list of required PPE for each hazardous activity is available
417 Whether feedback from workers obtained during selection of PPE?
418 Have the workers been trained in proper use of PPE including BA sets?
419 What is the system of procurement, inspection, issue, maintenance and replacement
of PPE?
420 What are the arrangements for safe custody and storage of PPE?
421 Whether qualitative and quantitative fit-check for respirators is ensured prior to use?
422 Are the contractor’s workers provided with the required PPE?
423 Do the PPE conform to any standard?
424 Are sufficient eye wash fountains and safety showers available?
425 Whether appropriate respiratory protective devices are available in accordance to the
hazard potential?
426 Are the staff members trained in the right uses of respiratory protective devices?

C-22.6 Occupational Diseases

427 Whether pre-employment medical check-up data available?

428 During the medical check-up, is any person found having occupational diseases
mentioned in 3 schedule of The Factories Act, 1948?
rd

429 Whether the medical practitioner informed the Chief Inspector of Factories about the
occurrence of the occupational disease?

C-23 ACCIDENT / INCIDENT REPORTING, INVESTIGATION AND ANALYSIS

C-23.1 Accident Reporting and Database Management

430 What is the procedure for accident / incident / dangerous occurrence reporting?
431 Whether the accident data for the last five years for reportable and non-reportable
accidents are available?

C-23.2 Accident Investigation

432 Are all the accidents investigated?

433 Whether accident investigation procedure is documented?
434 Whether accident investigation reports are submitted to top management?
435 How are the findings from accident investigation reports communicated to workers?

C-23.3 Analysis of Accidents

436 Whether accident analysis is done as per IS 3786?

437 Whether root causes of accidents are analysed?
438 Is the accident statistics effectively utilized? If yes, how?
439 What nature of injuries occurred during the last five years?

C-23.4 Implementation of Recommendations

440 How does the management ensure implementation of the recommendations to avoid
recurrence of accidents and incidents?

C-23.5 Reporting and Investigation of Near-miss Incidents

441 Are all near-miss incidents reported and investigated?
442 Is there any system of classifying and analysing the near-miss incidents?

C-24 EMERGENCY PREPAREDNESS

C-24.1 Site Specific Details

443 Are the site area maps (including layout, access roads and assembly points) available
in control room / emergency control centre?

C-24.2 Duties and Responsibilities of Key Personnel

444 Is the hierarchy of emergency response personnel right from site emergency
controller downward, and alternative officials identified?
445 Are the duties and responsibilities assigned to the designated officials during
emergency, both during and outside normal working hours clearly identified and
understood by them?

C-24.3 Identification of Emergencies and Accident Scenario

446 Are the possible accident scenarios leading to emergency identified and known to the
operating personnel?
447 Are approved emergency preparedness plans (onsite and off-site) in place?

C-24.4 Declaration and Termination of Emergency

448 Is the list of designated officials who are to be communicated about declaration and
termination of emergency available in the control room /
emergency control centre?
449 Are the methods of communication (siren, public address system etc.) for declaration
and termination of an emergency known to all the workers?

C-24.5 Resources-evacuation / Transport

450 Are the following resources (equipment, personnel and procedures) required to
handle emergency available?
1) Communications,
2) Public announcement systems
3) Monitoring of hazardous releases into the environment,
 4) Emergency shelters at the facility,
5) Emergency exits with proper illumination, with uninterrupted power supply ,
6) Direction for emergency exit / escape route marked in haulage / Alleyways,
7) Transport for evacuation of plant personnel,
8) Medical care including administration of antidotes, and
9) Security / maintenance of law and order.

C-24.6 Communication Facilities

451 Does the emergency control centre have direct communication links with the fire
station and the plant control room?
452 Are there adequate alarm points from which an emergency alarm can be raised?
453 Is there infrastructure available for ensuring backup electric power supply for
communication links where required

C-24.7 Medical Care

454 Is the procedure for emergency medical care available?

455 Whether the system has been tested at regular frequency through mock drill /
exercises for its adequacy?
456 Does the system of periodic replacement of antidotes and medicines required in
emergency exist?

C-24.8 Updation of Emergency Plan

457 Is the emergency plan updated based on the feedback from the periodic drills /
exercises?
458 Are the contact details of all concerned officials kept updated in the emergency plan?

C-24.9 Periodic Drills / Exercises

459 Are mock-exercises conducted at stipulated intervals?

460 Are the scenarios varied in the mock-exercises to ensure that all possible factors
including meteorological conditions, affected plant personnel covered?
461 Whether emergency preparedness Plans have been tested and reviewed at regular
frequency through mock drill for its adequacy

C-24.10 Training of Plant Personnel

462 Are the plant personnel trained in handling emergency equipment?

C-24.11 Public Awareness Programmes

463 Are public awareness programs conducted for the people around the site regarding
the actions to be taken in case of off-site emergency?

C-24.12 Mutual-aid Programme

464 Are the types of accidents where external organizations would be involved in
remedial actions identified? Are their responsibilities defined?
465 Is the plant responsible for rendering mutual aid assistance to any other external
organizations? Does this assistance effect the plant’s emergency
preparedness?
466 Whether the communication channels for mutual assistance identified and known
with and between two organizations?

C-24.13 Emergency Control Centre

467 Is the emergency control center located beyond the effective distances of identified
emergency scenarios?
468 If the emergency control center is located within the effect distance, is it suitably
protected that it will be available in case of emergency?

C-25 SAFETY INSPECTION

C-25.1 Inspection Programme

469 Are checklists available for inspections? availability of checklists for

a) Handling, Storage and Transportation of hazardous chemicals;
b) Electrical hazards;
c) Fire safety;
d) Hand and portable power tools;
e) Machine hazards;
f) Lifting equipment;
g) Ladders and scaffolding;
h) Environmental Monitoring;
j) Civil structure;
k) House keeping;
m) Emergency equipment; and
n) Gas cylinder and other pressure vessels used / available in the organization.

C-25.2 Safety Related Deficiency (SRD) Report

470 Are SRDs generated based on the area wise checklists?

471 What is the procedure for resolving the SRDs?
472 Whether the procedure exists for notification and root cause analysis of non-
conformities and action taken on them?

C-25.3 Safety Inspection Records

473 Are the safety inspection records maintained?

C-25.4 Methodology and Inspection Team

474 Is there written procedure for safety inspection?
475 Whether safety inspection is carried out by a designated team?
476 What is the frequency of safety inspections?
477 Whether an inspection report is generated?

C-25.5 Compliance of Recommendations

478 To whom the recommendations are submitted

479 Are recommendations of safety inspections complied in time?
480 Is compliance of recommendations sent to top management?
481 Is compliance of recommendations reviewed by safety committee?
482 Does top management follows-up the compliance?