ABOUT THE PLANT

Name of the Insured Company

Full Postal Address of the Insured Property

(including Pin code)

Date of Risk Inspection

Name & Designation of the Executives of
Insured / Intermediary present during the
visit
EHS Head Name and Designation

FEATURES OF THE INSURED PROPERTY

Risk Occupancy & Risk Code:

Year of Establishment:
Year of Commencement of operations:
Number of Employees (incl. contract):
Raw materials used:
Finished Products:
Production capacity:
Annual Turnover:
Major customers (with locations):
Number of shifts & timings:
Total plant area
(plot area & built-up area):
No. of gates:
Compound wall around the unit:
Approach Road:
(Condition; width; Fire tender access)
Types of vehicles plying within the
premises:
Internal roads:
(Black topped and 6m wide?)
Nearest Public Fire Brigade:
(Location and approx response time)
Plans for present / future expansion or
mergers:
Applicable Statutory / Regulatory
approvals related to EHS and its
validity
Name of the security agency & total no
of security persons & no of security
guard in day / night
 Details of the neighbouring property and its occupancy

Direction Occupancy Distance Segregation Remarks

North
South
East
West

LIST OF THE BLOCKS

It is a Multi-block building having various blocks and having Class II construction. Section wise occupancy and
construction is as under:

FLOOR WISE OCCUPANCY - MULTIPLE BLOCKS

Building Construction Details Fire & Safety Details
Distance
Block from
Sr. Description No of Height Age Nearest Fire Detection Fire Protection
No. / Occupancy Wall Roof Floors (m) (Years) Block System System
Fire Alarm
Smoke detector/
1 heat detector/ fire extinguishers,
gas detector fire hydrant /
/CCTV sprinkler
Fire Alarm
Smoke detector/
2 heat detector/ fire extinguishers,
gas detector fire hydrant /
/CCTV sprinkler
Fire Alarm
Smoke detector/
3 heat detector/ fire extinguishers,
gas detector fire hydrant /
/CCTV sprinkler
Fire Alarm
Smoke detector/
4 heat detector/ fire extinguishers,
gas detector fire hydrant /
/CCTV sprinkler
Fire Alarm
Smoke detector/
5 heat detector/ fire extinguishers,
gas detector fire hydrant /
/CCTV sprinkler
PROCESS DESCRIPTION

Plant is engaged in the manufacturing of …………... Details process flow chart of FG is as under:

Process Flow Chart -

STORAGE PRACTICE - GENERAL STORAGES

Number of storage areas (warehouses, stores etc.
for RM, FG, Fuels and Consumables)
Nature or Type of stocks stored, Quantity and how it
is packed 
Housekeeping in storage areas
Method of storage - % of stocks stored on pallets
and floor
Comment on the safe storage practices (Refer IS
3594)
Any allied activities happening in storage area (e.g.
packing, shrink wrapping, etc.)
Open Storage: If materials are stored in open, give
details of nature of materials stored, describe about
the storage practices, stacks height and distance
from compound wall / nearby buildings.
Book Keeping and Valuation – Whether the stock
details & quantity stored are computerized and hard
& soft copies are kept available in other place other
than the insured premises

STORAGE - HAZARDOUS MATERIAL AND CHEMICALS

List of Hazardous materials and chemicals stored

with quantity
Method of storage (Tanks-U/g, A/g; Barrels;
Cylinders; etc.)
Availability of applicable statutory approvals (e.g.
Explosive License; Fire NOC, etc.)
Comment on the safe storage and handling practices
as per the applicable rules / standards (e.g.
Petroleum Acts / Rules; Gas Cylinders Rules; OISD
std; Applicable IS / NFPA standards, etc.)
 DETAILS OF UTILITIES

TRANSFORMER
Sr. No. KVA Make Oil Capacity (Litres) Oil Pit Available
1
2
Is there Baffle wall provided between the transformers
Is the transformers are 6 Meter away from the rest of the property

DG SETS
Sr. No. KVA Qty. Make Year of Installation
1
2
3
Dedicated underground Diesel Tank Capacity in KL
Flame proof light is installed in diesel storage yard

Cooling Tower
Sr. No. Capacity Qty. Make & Model Serial No.
1
2

Air Compressor
Sr. No. Capacity Qty. Make & Model Serial No.
1
2

Chiller Plant
Sr. No. Capacity Qty. Make & Model Serial No.
1
2

Boiler
Sr. No. Capacity Qty. Make & Model Year of Installation
1
2

Turbine
Sr. No. Capacity Qty. Make & Model Year of Installation
1
2

ETP/STP Plant
Sr. No. Capacity Qty. Make & Model Year of Installation
1
2
FIRE DETECTION AND PREVENTION SYSTEMS

 Portable Fire Extinguishers:

a. Total Numbers of fire Extinguishers: -
b. Validity Of Fire Extinguishers: -
c. Whether All Fire Extinguishers are Installed at their dedicated place –

 Fire Hydrant System:

Name Make Qty. Discharge (LPM) Pressure (Kg/cm2)

Hydrant
Jockey
DG Driven
No. of Hydrant Points
Dedicated Fire Water Underground Tank Capacity in KL
Overhead/ Above Ground Water Tank Capacity in KL
Whether Hydrant System is in Auto & Pressurized mode

DETECTION, ALARM, SPECIAL TYPE AND SAFETY SYSTEMS:

Name Availability
(Yes / No) Place / position of the system
Smoke Detector
Gas Detector
Fire Alarm
Sand Bucket
CCTV
CO2 flooding & gas
suppression system
Sprinkler
 SAFETY PRACTICES
Parameter Description Remarks

Safety Policy Is there occupational health & safety policy

Policy displayed at strategic locations and copies supplied
to those concerned
Safety dept Is there a safety department?
Safety Manual Is there a manual indicating the definition, categories of
risk, risk acceptance levels, safe operating procedures
Emergency Plan Is there an emergency plan?
Are the roles of key personnel indicated in the plan?
Emergency control center and assembly points identified?
Emergency lights – Provision / Identification / Power supply
Emergency escape route?
Identification of facilities to be used in case of emergencies.
Mutual aid Is there a written agreement with the neighboring
agreement industrial units?
Emergency Mock Periodicity of drills
Drills
Employee Participation covering all shifts
Presence of external observer
Implementation of mock drill report recommendations
Safety Committee Safety committees at department level and apex level

Periodicity of meeting.
Are remedial measures to be recorded & implemented?
Are follow up measures taken?
Safety Inspections Are safety inspections carried out by safety organization
members periodically?
Is a Checklist available?
Are deficiencies in safety systems are brought to the notice
of the departmental head and implemented?
Is external Safety audit carried out?
Safety awards Received from international safety agencies (past 2 years)?
Safety Studies Any specialized safety studies (e.g. HAZOP, QRA, other PHA
studies, PSM, JSA / HIRA, etc.) are carried out in the facility?
(If yes, list down the studies done below)
Status of Implementation of such study recommendations
ISO Certifications
Housekeeping Is there accumulation of unwanted combustibles
Is disposal of combustible waste carried out from the shop
floor at periodic intervals
Is 5 S system of housekeeping followed?
 Parameter Description Remarks

Accident record & Is there a system for recording the accidents and conduct
Investigation subsequent investigations & analysis
Implementing Is there a system in place to monitor and implement
recommendations various recommendations arising out of Safety Audits /
Inspections / Investigations / other safety studies, etc?
Safety Training Is there an annual training calendar for safety?
Number of safety training man days per employee
Are Training programs by external agencies organized on
Fire fighting, First aid, use of Personal protection?
Work Permit Implementation of Hot work / Work at height / Electrical
system isolation / Vessel Entry etc.
Number of hot work permits issued per week?
Material Safety Are there Material safety data sheets for all hazardous
Data Sheets chemicals and copies available with the user departments
Acceptance Tests Is there a system of carrying out Factory Acceptance Test
and Machinery Acceptance Test for new equipments during
major expansions (e.g. involving >10% capital expenditure)?
Behaviour Based Is there a BBS program implemented in the facility?
Safety (BBS)
BBS observations completed, feedback given to employees
and BBS checklist filled as per weekly / monthly plan?
“At-Risk” behaviors recorded and analyzed monthly?
Corrective actions by barrier removal team implemented?
Management of Is there a formal MoC procedure in place to ensure that
Change (MoC) changes(e.g. process, technology, equipment, procedures, key personnel or any
change to facilities) are properly reviewed and approved by
persons with the required expertise prior to
implementation? (to eliminate workplace hazards that could lead to
injuries, equipment damage, production losses, reputational impact or
environmental impact)

Records of MoC in the facility maintained? If yes, mention

the number of MoC issued per year.
Accountability for proper change implementation defined?
Does the MoC procedure cover Temporary change reviews
with duration and review if an extension is required?
Other safety features
Are ‘No smoking’ instructions displayed on strategic fire prone areas
Visitors/ Vehicle drivers checked for carrying smoking materials & match sticks
Are Pressure relieving devices are available and tested as per statutes
Is Cylinder storage done with adequate ventilation under protected area,
complying with the requirements as per Gas Cylinders Rules?
Electrical installation
Does the electrical installations meet the requirement of National Electrical Code
Number of licensed electricians available in the facility
 Parameter Description Remarks

Are the electrical equipment maintained under AMC? If yes, list down below the
equipment’s covered under AMC along with the periodicity of AMC visits:

Is there an Electrical Preventive Maintenance program in place?

If yes, whether the PM is carried out as per plan and records maintained?
Are transformers provide with Baffle walls in between and separated from rest
of the property by 6m distance or by a fire wall?
Arrangement for collecting transformer oil in case of major accidental damage
Electrical cabling below ground OR partially below ground OR fully above ground
Is the entire wiring taken through rigid PVC or metallic conduits?
Are industrial type tube light fittings used (with choke concealed)?
Whether any Loose wiring / defective earthing visible?
Are adequate protective devices (MCB, ELCB, RCCB, HRC Fuse, FRLS cable) used?
For electrical installations more than 5 years, comment on the following:
 Condition of cable trays (are they crowded, cables stressed & bent)
 Are IR values of cables measured and recorded?
 Does the cables in MCC panels have proper bending radius?
Whether static charges can be generated in the normal operation? If Yes, are
suitable static dissipation devices provided and maintained?
Are solar panels installed in the facility?
 Locations where the panels installed
 Load on roof taken into consideration
 Shall not hamper firefighting capability
 BUSINESS INTERRUPTION RISK
Parameters Details
Operating Capacity:
a. State the current operating capacity (% of rated capacity)

b. State the annual production level or sales and applicable year

c. Could operations be shifted to another location within or outside the company?

d. If the business is seasonal, state what percentage of production is completed during the
seasonal period
Production Bottlenecks:
a. Is there a single production line?
b. Is there any critical single machine?
c. What is the replacement time?
Interdependencies

a. Are any raw, intermediate or finished materials supplied to or from another location
within the company?

b. What percentages of total production do these materials represent?

c. Are there other sources available inside or outside the company?

Contingent Business Interruption

a. Are there any single-source suppliers of raw materials?

b. Are there other sources available? If so, how long would it take for other sources to
supply raw materials?

c. Are materials sent to sources outside the company for further processing (i.e. painting,
plating, etc.)? Are there other sources available?

d. Are there a limited number of customers?

Critical Equipment

a. Is there any equipment or tools with an unusual replacement time [i.e. custom-made,
one-of-a-kind, difficult to replace, large electric motors (>500 hp), large transformers, etc.]?

b. Are spares available?

c. Is standby equipment available?
d. What is the replacement time?
Environmental Hazards

a. Any critical processes requiring pollution abatement equipment to operate (i.e. dust
collectors, electrostatic precipitators, scrubbers, regenerative thermal oxidizers, etc.)?

b. What is the replacement time?

Statutory Requirements
 a. Any Licensing / Statutory clearances required for restarting operations / manufacturing,
following an accident? If yes, give details.

b. What is the expected lead time for restarting the operations / manufacturing process?

Raw Materials & Finished Goods

a. State if they are highly susceptible to damage from smoke, heat, water dropping, etc.

Business Continuity Planning

a. Provide details on any business continuity planning
b. Is the plan written, comprehensive, and tested?
c. When was the BCP prepared?
d. When the plan was last reviewed and tested?

MACHINERY BREAKDOWN:

DETAILS OF THE CRITICAL MACHINES / HIGH VALUE MACHINES

Operating No of
Parameter Replacement days to
Sr. Name of the - Temp / Serial No. of New / Imported / Year of Value as on repair /
No. Machine Pressure Machine Old Indigenous Installation date replace
1
2
3
4
5
6
7
8
9
10
NEW
Sr.
No. Question Answer
1 Whether MBD study done by the insured?
2 Maximum Interruption in number of days that can occur in case of breakdown of critical equipment’s
3 Existing level of maintenance practices
4 Is the maintenance practices aligned as per OEM Recommendations / Industry accepted practices?

Technical expertise of maintenance team (Number of personnel; qualification; trained by OEM)

5
Repair or Replacement facilities available within the Insured’s factory or within the town / city for the
6 critical machineries?
7 Spares / standby facilities available?
8 Are there machines which cannot be repaired in India? If yes, please provide details of the same.
9 Average equipment downtime in the past 5 years?

THANKS A LOT FOR YOUR KIND COOPERATION