Process Safety Audit - duplicate

• Conducted on

  Date

• Prepared by

• Location
  Address

Site Safety

• What are the recurrent natural disasters in the region of the plant site?

  Select Flood Storms Thunderstorms None

  • Flood
  • Storms
  • Thunderstorms
  • None

• What is the scale of impact of Flooding on process safety of your plant? (On a scale of 1 to 10)

• Is there a proper drainage system to direct water away from the facility?

  Yes

  No

• What is the scale of impact of Storms on process safety of your plant? (On a scale of 1 to 10)

• Is the facility free of any unsafe structures that might fail during a storm?

  Yes

  No

• What is the scale of impact of Thunderstorms on process safety of your plant? (On a scale of 1 to 10)

• Have you properly equipped lightning arresters within the facility?<br>(GUIDE: Rolling sphere method for the placement of arresters to provide protection to all the zones at risk)

  Yes

  No

• Do other factories/activities near the site can trigger an emergency situation?

  Yes

  No

• Is the risk identified and assessed?

  Yes

  No

• Have you considered these risks when designing the plant layout?<br>(GUIDE: Have you considered the location of other plants and wind direction when locating your flammable chemical storage, control rooms and main office building?)

  Yes

  No

• Have you Prepared emergency response plans to react if above situations take place?

  Yes

  No

Material handling & Storage

• Have you identified unsafe amounts of hazardous material at your workplace as specified under local mandates ?

  Yes

  No

• Have you considered using less hazardous alternatives?

  Yes

  No

• Does the storage of hazardous substances is within the limits specified under local mandates?

  Yes

  No

• Have you provided special storage conditions for the substances that require ones?

  Yes

  No

• Are Material Safety Data Sheets (MSDS) available for all substances present?

  Yes

  No

• Are all the containers labeled correctly?

  Yes

  No

• Have you provided Standard Operating Procedures (SOPs) for handling of all harmful substances?

  Yes

  No

• Are all the employees provided with proper training & awareness on handling & storage of harmful substance?

  Yes

  No

• Do you continually monitor and supervise the storage and handling of chemicals?

  Yes

  No

• Do you have an emergency response plan in place in case of a spillage or leakage?

  Yes

  No

• Have you provided necessary Personal Protective Equipment (PPE) to the workers?

  Yes

  No

• Have you equipped the facility with Emergency Showers and Eye Washing equipment?

  Yes

  No

Maintenance

• Does your Maintenance process involve handling hazardous chemicals that has the possibility of being exposed to workers and environment during maintenance?

  Yes

  No

• Is the Maintenance Related to electric equipment?

  Yes

  No

• Do you always electrically isolate the equipment at the start of maintenance?

  Yes

  No

• Noise/Vibration created during maintenance?

  Yes

  No

• What are the actions you have taken to address the sound/vibration levels?

  Select Providing earplugs to maintenance workers Maintenance work scheduling to avoid sensitive times None

  • Providing earplugs to maintenance workers
  • Maintenance work scheduling to avoid sensitive times
  • None

• Is the Maintenance Related to entering into confined spaces?

  Yes

  No

• What are the safety actions you follow while entering into a confined space?

  Select Issue an entry permit Isolate the space from hazards Use LOTO system Ventilate the space Evaluate the space before entering Carry a breathing apparatus Place an attendant at the entry side None

  • Issue an entry permit
  • Isolate the space from hazards
  • Use LOTO system
  • Ventilate the space
  • Evaluate the space before entering
  • Carry a breathing apparatus
  • Place an attendant at the entry side
  • None

• Do you always isolate the section in the process which is under maintenance?<br>

  Yes

  No

• Do you use Lock Out & Tag Out (LOTO) system during maintenance activity?

  Yes

  No

• Do you issue a Permit To Work to employees to perform both routine and non-routine maintenance activities?

  Yes

  No

• Do you provide workers with necessary instructions to perform the task beforehand?

  Yes

  No

• Do you always communicate the maintenance schedule to other workers in the plant?

  Yes

  No

• Have you provided proper training to maintenance workers?

  Yes

  No

• Are maintenance activities being supervised?

  Yes

  No

Fire Safety

• Are the work areas where fire hazards are present, free from open flames ?

  Yes

  No

• The exhausts from engine powered equipment are in reasonable distance from explosive material?

  Yes

  No

• Are there any hazardous or flammable vapor sources near combustion equipment?

  Yes

  No

• Any action has been taken to substitute flammable raw materials and chemical and with a non-flammable or less flammable raw material and chemical?

  Yes

  No

• The storage of materials within the work structure is setup in a way that minimizes the spread of fire within a given structure?

  Yes

  No

• Is there enough space between heat-producing objects?<br>(GUIDE: lightbulbs, heating units)

  Yes

  No

• Garbage is removed daily or more frequently?

  Yes

  No

• Aisles and floors free of oil and other flammable spills?

  Yes

  No

• Ventilation systems implemented and working properly?

  Yes

  No

• Proper fire/heat/smoke detectors have been installed?

  Yes

  No

• Is welding, grinding, or metal cutting being conducted with a hot-work permit?

  Yes

  No

• Is there a fire and evacuation plan in place for each building and visible for all to see in general area?

  Yes

  No

• Are there any evacuation signs/diagrams/labeling with the required information?

  Yes

  No

• Are evacuation routes clear of obstructions?

  Yes

  No

• Are the fire/smoke doors unobstructed and undamaged?

  Yes

  No

• Has evacuation practice been conducted annually?

  Yes

  No

• Is there a Fire Detection and Alarm System?

  Yes

  No

• Is the Fire Detection and Alarm System operating with no isolation or fault indicating?

  Yes

  No

• Work sites equipped with firefighting material at all times?

  Yes

  No

• Firefighting material located in prominent, easily noticeable area?

  Yes

  No

• Firefighting equipment is inspected per local mandates?

  Yes

  No

• Are fire extinguishers chosen for the type of fire most likely in that area?

  Yes

  No

• Are all extinguishers fully charged and operable?

  Yes

  No

• Are special purpose extinguishers clearly marked?

  Yes

  No

• Power supply for fire pumps works under any situation?<br>(GUIDE: is power given directly from the main supply)

  Yes

  No

• Is there an accurately functioning Sprinkler system in place?

  Yes

  No

• Fire drills are conducted frequently?

  Yes

  No

• Is there a designated fire team composed of employees of the company?<br>(GUIDE: A fire team made of employees responsible for each department/area in the plant)

  Yes

  No

General Electrical Safety

• Are there warning signs displayed near high voltage distribution boards?

  Yes

  No

• Required components of a distribution board are available and are in functional state?

  Yes

  No

• Are the distribution boards accessible in case of an emergency?

  Yes

  No

• Distribution boards are maintained cleanly?

  Yes

  No

• Indicator lamps are available in distribution boards?

  Yes

  No

• Have you placed rubber carpets near the distribution boards?<br>(GUIDE: So the person who works with the distribution board is standing on the rubber carpet)

  Yes

  No

• Is new colour code for conductors practiced? <br>(GUIDE: Brown (L1), Black (L2), Gray (L3), Blue (N))

  Yes

  No

• Ingress protection is within the required level?

  Yes

  No

• What are the tests you have carried out for the relevant installations and obtained results within the IEC standards?

  Select Insulation resistance test Loop impedance test RCD (Residual Current Device) test Electrode to earth resistance test Earth resistivity test None

  • Insulation resistance test
  • Loop impedance test
  • RCD (Residual Current Device) test
  • Electrode to earth resistance test
  • Earth resistivity test
  • None

• Panel services carried out at most every six months?

  Yes

  No

Incident report & Review

• Have you encouraged the employees to report accidents and near misses?

  Yes

  No

• Do you keep records on the accidents and near misses?

  Yes

  No

• Have you identified the root causes and taken necessary measures to prevent the incidents?

  Yes

  No

• Do you communicate the incident reports among all the stakeholders?

  Yes

  No

• Do you review the feasibility of the preventive measures taken?

  Yes

  No

First Aid & Medical Facilities

• Do you have a medical center equipped to provide medication to the victims of accidents?

  Yes

  No

• Do you have designated personnel with necessary medical proficiency to treat the victims?

  Yes

  No

• Have you provided First Aid kits to each area of the premises?

  Yes

  No

• Is every First Aid kit accessible to any employee?

  Yes

  No

• Have you provided the employees with necessary First Aid training?

  Yes

  No