Site Safety

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

  • 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?

  • 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?

  • 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?
    (GUIDE: Rolling sphere method for the placement of arresters to provide protection to all the zones at risk)

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

  • Is the risk identified and assessed?

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

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

Material handling & Storage

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

  • Have you considered using less hazardous alternatives?

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

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

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

  • Are all the containers labeled correctly?

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

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

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

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

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

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


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

  • Is the Maintenance Related to electric equipment?

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

  • Noise/Vibration created during maintenance?

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

  • Is the Maintenance Related to entering into confined spaces?

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

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

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

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

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

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

  • Have you provided proper training to maintenance workers?

  • Are maintenance activities being supervised?

Fire Safety

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

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

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

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

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

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

  • Garbage is removed daily or more frequently?

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

  • Ventilation systems implemented and working properly?

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

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

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

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

  • Are evacuation routes clear of obstructions?

  • Are the fire/smoke doors unobstructed and undamaged?

  • Has evacuation practice been conducted annually?

  • Is there a Fire Detection and Alarm System?

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

  • Work sites equipped with firefighting material at all times?

  • Firefighting material located in prominent, easily noticeable area?

  • Firefighting equipment is inspected per local mandates?

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

  • Are all extinguishers fully charged and operable?

  • Are special purpose extinguishers clearly marked?

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

  • Is there an accurately functioning Sprinkler system in place?

  • Fire drills are conducted frequently?

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

General Electrical Safety

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

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

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

  • Distribution boards are maintained cleanly?

  • Indicator lamps are available in distribution boards?

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

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

  • Ingress protection is within the required level?

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

  • Panel services carried out at most every six months?

Incident report & Review

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

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

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

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

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

First Aid & Medical Facilities

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

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

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

  • Is every First Aid kit accessible to any employee?

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

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