safety audit n

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SAFETY AUDIT

INTRODUCTION

Safety audit is a well recognised tool to improve the effectiveness of safety programme and loss preventionmeasures by carrying out systematic and critical appraisal of potential safety hazards involving personnel,

plants and equipments.

For a structured and systematic safety audit of any plant/ facility, check lists are the most important

prerequisite. Check lists should cover all the operational areas, maor equipments, operating/ maintenance

procedures, safety practices, fire prevention/ protection systems etc. !bservations/ recommendations ofsafety audit team should be presented in the form of a formal report and action plan for corrective measures

should be prepared and subsequently monitored for implementation

"dentification of vulnerable areas and specific potential hazards, is one of the prime function of loss

prevention in oil industry. Safety audit is an important tool in undertaking this function.

OBJECTIVES OF SAFETY AUDITS

#hile the basic aim of safety audits is to identify the areas of weaknesses and strengths, safety audits are undertaken

to meet different specific obectives viz.$

%. &o identify any design deficiencies and also any weaknesses which might have cropped up during

modifications / additions of facilities.

'. &o ensure that fire protection facilities and safety systems are well

maintained.

(. &o ensure that operating / maintenance procedures, work practices are as per those stipulated in the

manuals and standards, which might have degraded with time.

). &o check on security, training, preparedness for handling emergencies and disaster management etc.

&o check the compliance of statutory regulations, standards, codes, etc.

*. +s a social obective to cater to public opinion and concern for safe environment. &his also

improves public relation of the organization.

SCOPE OF SAFETY AUDITS

%. + Safety +udit subects various areas of a companys activities to a systematic critical e-aminationwith the obective of minimizing loss.

'. &his includes all the components of the system viz. management policy, attitudes, training, design

rocess, 0echanical, 1lectrical, etc.2 aspect, layout and construction of the plant, operating "nspection 3

0aintenance procedures, emergency plans, personal protection standards, accident records.



TYPES OF SAFETY AUDITS

&wo types of Safety +udits are proposed to be carried out as below4

"nternal Safety +udit

1-ternal Safety +udit

+udit conducted by "nternal +udit teams of the organisation is categorized as "nternal Safety +udit.

1-ternal Safety +udits will be carried out by outside teams consisting of technical e-perts from other organizations

in oil industry, professional bodies and statutory authorities under the overall coordination of !"S5.

METHODOLOGY OF INTERNAL SAFETY AUDITS

%. Frequency of safety audit4

&he +udit should be covered minimum once in a year however any maor modifications or addition can beaudited once in three years

'. 6rouping for +udit4

&he area should be clearly identified and logically grouped. For 7efinery "nstallation, the groupings aregiven below4

6roup " 8 +ll 96 Storage, Filling and 5ispatch Facilities

6roup "" 8 +ll 5ispatch Facilities like &ank &ruck loading, :itumen Filling and 5ispatch Facilities

6roup """ 8 !il 0ovement and Storage !03S26roup "; 8 rocess <nits

6roup ; 8 ower 3 <tilities, 1lectrical Substations and 1&

6roup ;" 8 0iscellaneous Such as #ork shop, ware house, laboratory, :uildings etc

6roup ;"" 8 Fire Fighting Facilities, 9ayout etc

FORMATION OF MULTI-DISCIPLINARY AUDIT TEAMS:

&he "nternal +udits should be carried out through multidisciplinary audits teams. &he composition of the

"nternal Safety +udit may vary depending on the 6roup and areas to be audited, however, persons2concerned should have necessary e-perience and background to undertake in$depth audit in a particular

discipline. + team of ) to = e-perienced officers from various disciplines viz. rocess / roduction,

0aintenance /"nspection, 1lectrical, "nstrumentation, Fire 3 Safety and with the activity involvement of

concerned lant / +rea 0anager is suggested. !ne of the team members should be nominated as the leader of theaudit team. "n multi$unit organizations, the team members could also be drawn from the >ead !ffice / Corporate

!ffice and other operating <nits under its control.

DURATION OF AUDIT

5epending on the nature of audit and type / comple-ity of the installations in the selected group, the duration of

internal safety +udit can be fi-ed. &his may vary from ' to ? working days for facilities under each group.

USE OF SAFETY AUDIT CHECK LISTS



Check lists are the most useful tool for undertaking systematic Safety +udit. 1ven for a skilled and well

qualified engineer a good check list would be necessary as a guide. 9ike a code of practice, a Check 9ist is a means

of pooling the knowledge and hard won e-perience and ensures that no important aspect is overlooked or forgotten.

Such check lists help maintaining uniformity and speeding up the audits.

PREPARATION BEFORE SITE VISITS FOR INTERNAL SAFETY AUDITS:

:efore the safety +udit team visits any particular facility for carrying out Safety +udit, it would be essential to

study all relevant documents as below to get complete picture 4

%2 9ayouts'2 3 "5s

(2 !perating 0anuals

)2 0aintenance / "nspection 0anuals

=2 Fire and Safety 0anuals, etc.

5epending upon the nature of audit more emphasis can be given to study specific documents. +ll the audit team

members should study these documents in advance to know the details of the installation.

BRIEFING:

:efore beginning of each audit, all concerned persons of the area/installation be briefed by the team leader about the

purpose of the audit. @o impression should be left that audit will throw bad light on them.

SITE INSPECTIONS4

0ost of the information could be gathered through site inspection using ready$made check lists. &he

auditors should enter their observations under the remarks column and not simply state AyesA / AnoA.

#herever necessary, observations should be recorded in separate sheet. "nspection should be carried out

accompanied by "nstallation / lant 0anager or the assigned officials.

DISCUSSIONS:

Further information can also be gathered through discussions formal 3 informal2, with site personnel and

"nstallation / lant 0anager, who is in$charge of the area or other site officers. &he audit team should interact with

persons from various disciplines such as roduction, 0aintenance, 1lectrical, "nstrumentation, etc.. Formaldiscussions could be in the form of brief periodical sessions while informal discussions could be over a cup of

tea with personnel working in the area.

STUDY OF DOCUMENTS:

"n addition to the documents which are already studied before inspection of the facilities, other documents,

such as !perating "nstructions, Standing !rders, 9og :ooks, 9og sheets, +ccident 7ecords, 0inutes of SafetyCommittee 0eetings etc. may also be studied as required.

PREPARATION OF AUDIT REPORTS

&he work of the "nternal Safety +udit item should be presented in the form of a Safety +udit 7eport for

each group which should contain observations 3 recommendations and also in brief the modalities

adopted in conducting audit and the names of the audit team members.



:efore finalizing the report, the Safety +udit &eam can give a presentation as feedback to the !perating /

0anagement personnel of the +rea / "nstallation. +dditions or deletions could be made in the draft report based

on the discussions and comments received during the presentation. &his approach is always constructive and does

not undermine technical competence of the audit team.

FOLLOW UP OF AUDIT REPORTS

6enerally, the "nternal Safety +udit 7eports are submitted to the concerned authority who appoints the audit teamfor undertaking needful follow up actions. !nly the appointing authority should e-ercise udgment in reecting

any of the recommendations. &he appointing authority shall be of senior management level 6eneral 0anager and

above2.

&he cru- of the safety audits lie in removing the weakness identified during the audit. Sometimes audit reports

identify only the problem / weakness, but not the solution.

"n such cases, it would be necessary to undertake a detailed study of the specific area and to identify the

rectification measures. #herever the necessary in$house e-pertise is not available for detailed studies, help ofconsultants / professional bodies should be sought for.

IMPLEMENTATION OF RECOMMENDATIONS

&he final and most important phase is the implementation of recommendations. + senior person should be

nominated for coordinating implementation of all accepted recommendation under a time bound program. Seniormanagement should review the progress of implementation of recommendations periodically through

0anagement Safety Committee meetings and other review meetings.



LIQUIFIED PETROLEUM GAS

9iquefied etroleum 6as 962 is a mi-ture of light hydrocarbons primarily C( 3 C) derived from petroleum,

which is gaseous at ambient temperature and atmospheric pressure, is liquefied at ambient temperature with

application of moderate pressure. 96 due to its inherent properties is susceptible to fire, e-plosion and other

hazards. Such hazards can have an impact on the property, equipment, plant personnel and public.9iquefied etroleum 6as 962 handling, bottling and distribution throw maor challenges due to its inherent

properties. 0aor incidents i.e fires/e-plosions in 96 facilities in world have underlined the need for total in depth

review of design, procedures, maintenance, fire fighting and safety aspects in 96 handling.

&he oil and gas industry over the years have learnt lessons from fires and e-plosions and have been updating andstandardising design, operations, bottling and distribution of 96.

Some of !e "m#o$%& #$o#e$"e' of LPG %$e %' (e)o* 4

%2 96 at atmospheric pressure and temperature is a gas which is %.= to '.B times heavier than air. "t is

readily liquefied under moderate pressures. &he density of the liquid is appro-imately half that of water and

ranges from B.='= to B.=B D %= oC.

'2 &he pressure inside a 96 storage vessel/ cylinder is equal to the vapour pressure corresponding to thetemperature of 96 in the storage vessel. &he restriction on vapour pressure is stipulated by "S$)=?*.

(2 96 has an e-plosive range of %.E to .=E volume of gas in air. &his is considerably narrower than other common gaseous fuels. &his gives an indication of hazard of 96 vapour accumulated in low lying area in

the eventuality of the leakage or spillage.

)2 #ater, being insoluble in 96, if present in 96 can cause rust and corrosion and freeze$up of valves,drain valves, e-cess$flow check valves, cylinder valves and regulators thereby affecting their functioning

and at times can lead to leakage of 96.

=2 96 liquid has low viscosity of around B.( CS D )= oC and can leak when other petroleum productsnormally cannot, thus demand a very high integrity in the pressurised system to avoid leakage.

*2 96 even though slightly to-ic, is not poisonous in vapour phase, but can, however, suffocate when in

large concentrations due to the fact that it displaces o-ygen. "n view of this the vapour poses mildanesthetic properties.

?2 96 is colourless both in liquid and vapour phase. 5uring leakage the vaporization of liquid cools the

atmosphere and condenses the water vapour contained in them to form a whitish fog which may make it possible to see an escape of 96.

2 &he coefficient of e-pansion is around B.BB'(? per oC. +t liquid full condition any further e-pansion of

the liquid, the container pressure will rise by appro-. %) to %= kg./sq.cm. for each degree centigrade.

2 96 has only a very faint smell, therefore, ethyl mercaptan is normally used as stenching agent for

identifying the leakage as per "S4 )=?*.

%B2 &he auto$ignition temperature of 96 ranges from )%B to =BoC.



STATUTORY RULES + REGULATIONS

&he 96 installation 3 various facilities are covered under many regulations and require specific approval / license

from concerned statutory authorities. &he various regulations applicable to 96 installation facilities are as below4

6as Cylinders 7ules, %% under "ndian 1-plosives +ct,%)2

Static 3 0obile ressure ;essels unfired2 7ules$%% <nder "ndian 1-plosives +ct %)2.

&he Factories +ct, %).

"ndian 1lectricity 7ules

&he Standards of #eight 3 0easures 7ules $ %? <nder #eight 3 0easures +ct $ %?*.

&he Standards of #eight 3 0easures ackaged Commodities 7ules$%??2

9iquefied etroleum 6as 7egulation of supply and distribution !rder $ %(2.

&he 0otor ;ehicles +ct $ %.

1nvironmental 7egulations 4

#ater revention 3 Control of ollution2 +ct, %?).

&he 1nvironment rotection2 +ct 8 %*

0anufacture, storage 3 import of >azardous chemicals 7ules $ %.

6uidelines for 1nvironmental clearance of new proects $ %%.

"n addition to the above statutory regulations, there are various recommended guidelines emerging out of the various

Committees set up by the 6ovt. of "ndia from time to time for streamlining/ improving the safety standards of 96

:ottling/ 5istribution4

%. ;asudevan Committee $ %( 0inistry of 1nergy 5epartment of etroleum2.

'. 1-pert Committee 7eview of Safety and !perating rocedures in 96 facilities $ %*, 0inistry of etroleum 3

@atural 6as 5epartment of etroleum2

(. Sudha Goshi Committee for better services to 96 users $ %? 0inistry of etroleum 3 @atural 6as2.



STORAGE AND HANDLING OF BULK LPG

61@17+9

&his section deals with the safe practices and provisions applying to unloading of bulk 96 and storage of bulk 96

at installations. &here should be strict compliance w.r.t selection, deployment of proper skilled manpower foreffective operation and maintenance.

,, BULK HANDLING FOR MOVEMENT BY ROAD

&he tank truck for road movement shall be designed, constructed and tested in accordance with the Static and

0obile ressure ;essels <nfired2 7ules, %% and !"S5$S&5$%=.

SAFETY PRECAUTIONS

Following precaution should be taken due to associated hazards during transfer of 96 to or from a tank truck.

a2 @o source of ignition must be allowed in the area where product transfer operations are carried out.

b2 Fire e-tinguishers shall be placed near the tank trucks during transfer operations.

c2 &he first operation after positioning the truck should be to provide proper earthing. 1arthing shall be

disconnected ust before the release of the truck.

d2 :efore removing plugs or caps, always crack open to allow for release of trapped 96 and further to ensurethat the valves are effectively sealing.

e2 >oses shall be handled with care and inspected periodically as per !"S5$S&5$%(=.

f2 #hile disconnecting hoses/arm, connections shall be loosened only slightly at first to allow release of

trapped pressure, if any.

g2 5o not e-pose hands, face or clothing to liquid 96. +lways use personal protective equipment whilemaking or breaking the connections to avoid cold burns.

h2 &he master switch shall be put off immediately after parking the truck in position. @o electrical switch on

the truck shall be turned A onA or A offA during the transfer operation.

i2 @o repairs shall be made on the truck while it is in the loading area.

2 +vailability of wheel chokes.

k2 @ew tank trucks vessels or vessels received after repair shall be purged as per laid down procedure.

l2 "n case, the receiving vessel is having a pressure of less than % Hg/sq.cm.g, it shall not be filled. Suchvessel shall be taken for filling only after detailed safety checks.

m2 ;enting and purging of 96 during transfer operation shall not be carried out in open atmosphere. "t shall

be piped to a suitable flare system. #here such facility does not e-ist, vent pipes shall be provided to carrythe vented product to a safe distance and released at a height not less than %.= m above the eves of the

structure.



PROCEDURES FOR OPERATION

9!+5"@6 !17+&"!@S

• Check for following in a tank truck as per statutory regulations before accepting it for filling4

•

rovision of two safety valves, level gauge, 1-cess flow check and control valve on liquid and vapourlines, pressure gauge, temperature gauge on the vessel / bullet.

• Fire screen between cabin and vessel is provided. For this purpose, cabins with metallic back cover without

any opening will be considered as fire screen.

• rovision of ' nos. of %B Hgs. 5C Fire 1-tinguishers.

• Fitment of Spark arrestors of approved quality.

• @o leakage in e-haust silencer pipe e-ists.

• 0anufacturers name plate with date of testing is fitted on the vessel.

• ;alid 1-plosive 9icence and 7&! certificate is available.

• +pproved drawings of vessel are available.

• :lind flanges/caps are provided on vessel.

• +vailability of 1arthing cable.

• :onding between vessel and chassis and between flanges is satisfactory.

• 1arthing / bonding point is available.

• &hird party inspection/test certificates for vessel/fittings are available.

• 9iquid / vapour line valves are in good condition.

• 0ove truck to the loading bay/weigh bridge and record the weight of the empty tank truck.

• lace the truck on loading bay and place choke blocks at front and rear wheels. Heep the truck in neutral

mode with hand brakes A!@A.

• Stop the engine and switch off all electrical equipment.

• +ll persons should leave the drivers cabin.

• 0ake earthing connections of the vehicle at specified point to the fi-ed grounding system.

• Connect liquid and vapour lines suitably with the loading point. Crack open valves on loading 3 vapour

return lines and inspect hoses 3 connections for leakage. 9oading should start only when the system isleak free.

• Start the loading pump.



• &he quantity loaded into the truck can be determined by $

• 9iquid level

• #eighment

• ositive displacement meter

• 0ass flow meter

• &he quantity of 96 filled shall not e-ceed the 79# of the tank truck.

• 9iquid level may be determined by roto$gauge or fi-ed liquid level gauge. ercentage volume to be filled

shall not e-ceed = E at ==!C i.e. the allowable filling limit as per C0; 7ules.

• #here weigh bridge is used, it is necessary to determine the density of the product being loaded to avoid

e-cess filling in terms of volume. &he weigh bridge shall be periodically calibrated and stamped by#eights 3 0easures +uthorities.

• #hen the filling operation is in progress, the pressure within the tank truck vessel shall be observed to

ensure that it does not approach the start$to$discharge pressure of the relief valve. Filling rate may beregulated as required.

• &he couplings may then be removed and plugs/caps replaced on the tank truck valves. 7e$check tightness

with soap solution.

• <nloading !perations

• !perations described under "tem % through * in para ?.%.'a2 should be carried out.

•

9iquid line and vapour line of the tank truck shall be connected to the respective hoses fi-ed to theunloading point.

• &est the connections for leaks by slightly opening the valves for pressurising. #hen satisfied, valves on the

tank truck and the receiving vessel shall be opened.

• Start the 96 compressor. ;apours will be sucked from the receiving vessel and will be discharged into the

vapour space of the tank truck vessel creating pressure differential thereby pushing the liquid from the

tank truck vessel to the receiving vessel.

• Care should be e-ercised to see that the pressure created within the delivering vessel does not reach or

e-ceed the set pressure of the relief valve.

• +n authorised person of the company shall supervise the transfer operation and respond immediately in theevent of an emergency.

• +fter the liquid has been e-pelled, the vapour recovery operation may be started. Care should be taken not

to bring down the pressure of the delivering vessel below %.= Hg/cm'g.



BULK HANDLING FOR MOVEMENT BY RAIL

96 is moved in &ank #agons by the 7ailways. &hese wagons are designed by 75S! and are fitted with various

devices as shown in F"./$e-VII

&he loading facilities are similar as for tank truck loading while unloading of 96 from tank wagons shall be done

with the help of compressor. &he compressor is used to create a differential pressure between the receiving and

discharging vessels by withdrawing vapors from the receiving vessel and forcing it at high pressure into thedischarging vessel thereby establishing a smooth flow. &he content of tank wagons can be ascertained by weighment

on weigh bridge before and after emptying or, alternatively, mass flow meters can be used.

Checklist for bulk 96 tank wagons at unloading locations is given at +nne-ure ? 8"".

SAFETY PRECAUTIONS

5o not allow the locomotive to come on the weigh bridge unless its capacity is designed to take the locomotive load.

Sufficient number of dummy wagons may be used to avoid electric loco coming closer to the gantry. 0aintain the

distance of %= m from first fill point.

&he first operation after positioning the wagon shall be to provide for proper earthing. 1arthing shall be

disconnected ust before the release of the wagon.

For connecting and disconnecting hoses, only non$sparking tools shall be used.

+fter the wagons are placed on weigh bridge and before the loco is detached, the hand brakes on each and every

wagon shall be applied.

9ike$wise, before the wagons are moved from the weigh bridge, release brakes on all the wagons.

5o not use footwear with protruding nails.

1nsure that the lower portion of flapper bridge at wagon side is fitted with rubber or wooden padding.

1nsure that electrical continuity of the system is intact.

1nsure that all fittings on the wagons are checked physically.

>oses shall be tested as per !"S5$S&5$%(= and records maintained.

&he loading/unloading operation shall be carried out under close supervision of authorised person.

5uring unloading operation, after the liquid transfer is over, the wagon pressure shall not be reduced below %.=

Hg/sq.cm.g2.

DEGASSING OF SICK+LEAKY TANK WAGONS

7ecommended rocedure"n the degassing system recommended for 96 wagons, vacuum cycle purging technique should be followed as

outlined below 4

a2 ;essel should be evacuated repeatedly by a vacuum pump.

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b2 ;apour should be discharged through high rise vent, keeping the steam on.

c2 0a-imum possible vapours should be sucked out in first step depending on the capacity of vacuum pump/compressor. +s per 75S!, vessel can sustain the full vacuum also.

d2 :etween the two vacuum cycles, nitrogen/inert gas should be used for breaking the vacuum.

e2 $ Cycle should be repeated till the 96 concentration is found below the end point of 96 for

butane, it is )E by volume when purging is done by nitrogen2. eriodically, samples should be drawn from

suitable location and analysed for 96 concentration.

f2 Finally the vessel should be flushed with air to displace the nitrogen. :arrel should be tested finally with

e-plosive meter to ensure that hydrocarbon concentration is below %BE of 919.

STORAGE OF BULK LPG

recautions for storage of 96 in bulk 4

+. 9iquid level in the vessel shall not e-ceed the permissible limits. Filling shall not e-ceed safe permissible

filling ratio.

:. ;essel shall be inspected daily for any 96 leakage and corrective action taken.

C. +ll gauges, viz. >igh level alarm, measuring gauges, pressure gauges, temperature gauges should be kept

in operating condition at all times and be checked daily.

SAMPLING AND DRAINING

SAMPLING

a2 Sampling is primarily required at supply locations i.e. 7efineries, 6as rocessing lants, "mport &erminals,etc. Sampling of 96 for different analytical tests shall be carried out in accordance with "S4%)). 5uring

handling of 96 samples, the following safety precautions shall be followed 4

b2 Special sampling bombs shall be used for 96 sampling. +rrangement of rupture disc or any other suitablesafety relief device shall be incorporated in the sampling bomb.

c2 Sampling bombs shall be inspected periodically and tested hydrostatically at regular intervals. 7ecord of

such inspection/test shall be maintained.

d2 Sample bombs shall be earthed effectively before and during discharge of sample.

e2 96 samples shall be collected only in open/ventilated areas and the person taking the sample shall standon the windward side.

f2 &he sampler shall wear protective goggles, hand gloves, shoes etc. while taking samples.

g2 Samples, after collection, shall be properly labeled and kept at designated place.

h2 Sampling of 96 should preferably be done in bombs with provision of pre$charge at one end. &his will

not only eliminate the possibility of undesirable presence of air in the bomb, which may become a safetyhazard, but also minimises flashing of sample during collection, thereby providing a truly representative

sample.



DRAINING

a. Storage vessel should be drained regularly for its water content, sediments, caustic contents etc.

5raining operation should be carried out under the supervision of an authorised person.

b. For draining of water from 96 vessels , following procedure shall be followed 4

c. &he valve nearer to the vessel shall be opened first and closed. &hen, draining shall be carried out

by gradually opening the valve farther from the vessel. &he operation shall be repeated till 96release starts.

d. "t shall be ensured that the drain outlet is at a safe distance from the vessel so that accidental

ignition of any escaping vapour would not e-pose the vessel to flame impingement.

e. "t is important not to attempt removal of the entire quantity of water as considerable liquid 96

may escape in the process. +t the first sign of appearance of 96, the operation shall be stopped.

1scape of 96 may lead to formation of ice block at the valve seat, preventing closure of valve.

&his will result in escape of uncontrolled vapour to the atmosphere causing a very serious hazard.

f. &he valve shall be operated slowly to avoid ice formation.

FIRE PROTECTION FACILITIES

F"7S& +"5 F"71 F"6>&"@6 1I<"01@&

PORTABLE FIRE E0TINGUISHERS

ortable fire e-tinguishers shall be located at convenient locations and shall at all times be readily accessible andclearly visible.

&he ma-imum running distance to locate an e-tinguisher in working areas shall not e-ceed %= meters.

&he top surface of the e-tinguisher shall not be more than %.= meter high.

&he fire e-tinguishers shall be provided at various locations as under 4

A$e% Po$%()e F"$e E1"&./"'!e$

96 Storage ;essel 1ach2 ' @os. %B kg 5C e-tinguisher

.

96 cylinder sheds ' @os. %B kg 5C e-tinguishers per 'BB Sq.0.+rea.

96 ump houses ' @os.%B kg. 5C e-tinguisher per =B Sq.m. +rea.

&ank &ruck loading/ gantries % @o. %B kg.5C 1-tinguisher in each bay.

&ank #agon loading/ unloading gantries % @o. %Bkg 5C 1-tinguisher for every %=/'B meters

of gantry. !ther ump >ouses ' @os. %B kg 5C e-tinguishers



!ffice/Canteen/ Stores ' J %B kg 5C e-tinguishers in each building

WHEELED+ MOBILE FIRE FIGHTING EQUIPMENT

% 0obile ?= Hg 5C fire e-tinguisher shall be provided in filling shed, 96 storage vessels/ 96 ump >ousearea, &ank truck loading/ unloading gantry area 3 tank wagon loading/ unloading gantry area.

&he 5ry chemical powder used in the e-tinguishers shall be otassium/ <rea based or Sodium :icarbonate as per

!"S5$65@$%%=. @itrogen/ Carbon 5io-ide shall be used as e-pelling gas.+ trolley containing first aid fire protective accessories shall be readily available in the 96 plant.

HOSES2 NO33LES AND ACCESSOREIS

7einforced rubber lined hoses *(mm2 conforming to "S 4 *(* type + or :2 shall be provided.

&he hoses shall be of %= 0eters standard length and shall be provided with 6un metal/ +luminium alloy male 3female couplings of instantaneous pattern.

0inimum of two or '=E spare >oses shall be stored in the 96 plant.

"n addition to the nozzles provided in the hose bo-es there shall be at least ' @os. spare nozzles in each category viz.

Get @ozzles with branch pipes, Fog @ozzles, universal @ozzles, water curtain @ozzles, Spray @ozzles and &ripple

purpose nozzles in the plant.

&he following accessories/ first aid items shall be provided in the plant 4

%. Fire hoses ' nos. for each

>ose :o-

'. Safety helmets % for each person min. %B nos.2

(. >ose :o- +t each hydrant point.

). Stretcher with 0in. ' @os.

:lankets.

=. First aid :o- 0in. ' nos.

*. 7ubber hand gloves 0in. ' pairs :"S approved2

for electrical

purpose.

?. 9ow temperature ) pairs

rubber hand gloves

for 96 emergency

as per !"S5$65@$%%=

. 9ow tem. protective 0in. ' sets

clothing for 96 emergency.

%B. Fire pro-imity suit 0in. % @o.

%%. 7esuscitator 0in. ' @o.



%'. 7ed/6reen Flags +s required

%(. Self contained 0in. % @o.

breathing apparatus with one spare cyl.

Cap. (B minutes2

%). #ater el blankets 0in. ' nos.

%=. ortable 6as detectors min. '.

/ 1-plosimeter

&he above are guidelines and minimum requirements of each item and can be increased depending upon the scale ofoperations, statutory/ mandatory requirement of local bodies/ State 6overnments or any other e-pert body.

EMERGENCY CONTROL + ALARM SYSTEM

FIRE ALARM SYSTEM

0anual call points near to filling shed, storage area, tank truck/ wagon gantry, pump house, etc. shall be provided

and clearly marked in the installation. !peration of these points shall raise audio visual alarm in control room.

1lectricity operated Fire Siren shall be audible to the farthest distance in the plant % H.0. from the periphery of the

plant2.

0anually operated fire sirens shall be provided at strategic places.

For fire condition the siren shall be wailing sound for minimum K' minutes and for all clear signal it shall be straight

run siren for ' minutes.

For 5isaster condition the wailing sound given shall be repeated thrice with a minimum %B seconds gap.

COMMUNICATION SYSTEM

Communication system like telephone/ + or paging or walkie$talkie shall be provided.

"n the hazardous areas, flame$proof / intrinsically safe telephones shall be provided.

#herever possible >ot line connection between City Fire :rigade/ near by maor "ndustries shall be provided.

lant shall have a K 0utual +id arrangement with near by industries.

SPECIAL FIRE PROTECTION

&he most hazardous situation in 96 vessel is the possibility of :911;1. &his usually takes place when

the vessel is subected to e-ternal fire.

&he unwetted vapor space2 portion of the shell gets overheated and fails even at the operating pressure. +ssuch, it is important that metal temperature in the vapour space is protected from overheating by some

measures. assive measures like fire proofing/ insulation or fire retardant coating will provide protection inthe initial period of fire which is very crucial. &his will give some breathing time for activating other fire

fighting measures like starting of pumps, organising people, opening of valves etc. &his will also take care

of automation failure wherever it is provided.

&he fireproofing of 96 storage vessel should be decided based on the risk analysis keeping in view local

considerations, availability of water and societal risk.



&he fireproofing of 96 storage vessel shall be decided based on the fire safety analysis keeping in view

local considerations, population density, availability of water, societal risk and fire protection measures

provided.

Fire proofing provided on the vessel and supporting legs shall be adequate to protect the shell material from

overheating and consequent failure. &he minimum rating for fire proofing shall be as under 4

%. 96 storage vessel 3 connected % hr.

lines up to the fire safe 7!;s

'.Supporting legs of all above ' hr.

Fire proofing is not required for diagonal bracing, including tie rods, or redundant members that are not

necessary for supporting the static loads.

:efore fire$proofing application, protected metal surfaces shall be prepared through such means as sand$

blasting and corrosion$protective primers. articular attention shall be given to the top unction of the fire$

proofing with the protected metal to prevent water ingress. !"S5$S&5$%*) on AFire proofingA shall bereferred for details on fire proofing.

Fire water line to each sphere should be so routed that it is not e-posed to direct fire. &his is to protect it

from failure in the initial period when water flow has not commenced. "t is recommended that riser should be located away from bottom 7!;. &he horizontal run of the Fire #ater line may be buried if fire

engulfment cannot be avoided otherwise. Fire proofing shall include connected 96 lines and pipe

supports within %= 0 of a storage vessel or in the drainage paths.

INSPECTION AND TESTING

&he fire protection equipment shall be kept in good operating condition all the time.

&he fire fighting system shall be periodically tested for proper functioning and logged for record and corrective

actions. "n addition to routine daily checks/ maintenance the following periodic inspection/ testing shall be ensured.

FIRE WATER PUMPS

1very ump shall be in test run for at least %B minimum twice in a week at the rated conditions.

!nce in a month each pump shall be checked and tested and the shut$off pressure observed and logged. +lso the

pump performance shall be ascertained.

&he Gockey pump operation shall be checked periodically. Frequent start/ stop condition of Gockey pump indicatesthat there are water leaks in the system.

FIRE WATER SPRINKLER SYSTEM

+ll deluge valves and sprinkler system shall be operated and checked once in a quarter for correct remote operation

performance of each nozzle and effectiveness of system in total.

&esting of sprinkler system in the sheds shall be carried out by closing the outlet of the deluge valve for correct

remote operation once in a quarter.

&he strainers provided in the Fire water sprinkler system shall be cleaned once in a quarter and records maintained.



TYPE OF SAFETY AUDIT AND PERIODICITY:

"n view of the high hazard potential of 96, safety audits at frequent intervals by the teams/ personnel of variouslevels are advocated. :road check lists for different recommended safety audits are given. &hese check lists can be

further supplemented and modified suitably to meet the specific requirements of individual plant. 7ecommended

minimum safety audits at different levels, their frequencies and broad check lists to be used are indicated below4$

5aily audit essentially shall cover the compliance of recommended operating procedures/ safety practices. 7eports

of audit shall be reviewed by the lant 0anager on daily basis and corrective action is undertaken on priority

wherever required.

------------------------------------------------------------------------------------------------

SNo T4#e of S%fe4 B4 F$e5/e&64

A/7"

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%. "nspection Safety 96 lant 5aily+udit of 96 "nstallation Safety !fficer

'. 1lectrical audit of +uthorised +nnual96 "nstallation electrical 1ngineer

(. 5etailed safety audit 0ulti disciplinary +nnual

of 96 "nstallation team of region/ >I

). "nspection and ersonnel from +nnual0aintenance audit of "nspection/ 0aintenance

96 "nstallation

=. 1-ternal safety audit !"S5

!f 96 "nstallation

6!e68 )"' of e1e$&%) '%fe4 %/7":

a. Safety !rganisation

b. Security System

c. Fire prevention/ protection system

d. reparedness to handle any emergency $$5isaster control plan and mock drills.

e. Skill level and training needs for >75.

f. !perating manual/ instructions, display of 5os/ 5onts etc.



ELECTRICAL AUDIT OF LPG BOTTLING PLANT

9!C+&"!@ LLLLLLLLLLLLL 5ated LLLLLLLLLLLL

+<5"&/ "@S1C&"!@ :M LLLLLLLLLLLLLLLLLLLLLL

$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$

S.@o. "&10 51SC7"&"!@ +<5"&!7S 710+7HS% ' (

$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$

ELECTRICAL SUBSTATION+ SWITCH ROOM

+$B% "s painted line diagram of power/ lighting distribution provided.

+$B' "s the equipment easily accessible for operation, inspection 3 maintenance.

+$B( 0CC anel condition 4

5oors okay and closed

5ust/soot/ cobwebs not e-isted

9ugs e-isting at each cable, termination not loose.

;isual condition of switch contact fuse etc. !.H.

Control wiring condition satisfactory.

Gumper condition between bus and distribution okay.

6rounding !H

+larm/ trip circuit working.

+$B) 9ive parts of equipment made inaccessible by barriers/ shrouds.

+$B= @o temporary electrical connection e-isting.

+$B* Condition of cable duct

Cables are on rack

Cable deck clear

Sealing of duct

Cable identification tags.



$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$

S.@o. "&10 51SC7"&"!@ +<5"&!7S 710+7HS

% ' ($$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$

+$B? 7ubber mats with "S" mark2 e-isting are enough in number.

+$B rotective relays set at recommended values.

+$B +ll fuses are of proper type and rating as specified in single line diagram.

+$%B Fire e-tinguishers are of proper type and are in working condition.

+$%% 9ighting condition !H fi-tures/ tubes/ wtiches etc.2

+$%' 1mergency lighting system in order.

+$%( +ll energised equipment provided with caution boards.

+$%) Condition of transformer 4

6rounding !H

@o oil leak

Silica gel !H

!il level !H

&erminal bo- earthing !H

!il/winding temp. !H

eriodic oil quality test conducted.

+$%= #hether location/type of transformer in conformity with area classification drawings.

+$%* >ousekeeping is good.

MOTORS IN PUMP HOUSE+ COMPRESSOR

ROOM+ FILLING 9 STORAGE SHED ETC

:$B% "s double independent earthing connection for all motors provided.

:$B' "s grounding wire !H not loose2.

:$B( a2 "s terminal bo- and gland !H

Flame$proofness maintained and not tampered.

1-isting cable termination are proper



:$B) a2 "s push button earthed properly and flame proof condition not tampered.

b2 6eneral condition of push button good.

:$B= 6round resistance at motor/ push button measured and found okay.

:$B* @o motor abnormality

;ibration/ bearing condition, faulty guard, fan condition,

e-cessive noise, high body temperature.

:$B? 1-isting preventive maintenance schedule !H.

:$B a2 1arthing resistance test schedules/ records satisfactory.

1arthing pit condition !H

:$B i2 Carousel machine frame to filling gun earthing continuity maintained.

ii2 Carousel machine frame to central column earthing continuity !H.

:$%B Conveyor system bonding and earthing maintained.

:$%% First$aid chart for treating electrical shocks displayed prominently in 0CC room.

UNIT LIGHTING

C$B% +ll lighting fi-ture flame proof as per area classification.

C$B' #hether flame proof condition of fi-tures ensured N

C$B( #hether proper earthing of fi-ture provided N

C$B) Condition of wiring good.

C$B= 5oes water enter and accumulate in fi-ture distribution bo-es etc N

C$B* #hether lighting 5:, switches, 0C: well maintained N

C$B? +ny other unsafe point observed.

MAST LIGHTS AREA LIGHTING;

5$B% #hether grounding of mast !H N

5$B' Condition of unction bo-es, switch board, fuses etc. !H

5$B( +pproach to electrical installation and ladder good and safe.

5$B) Condition of flood lights 4

"s gasket present N

"s glass cover in good condition N



"s control gear condition !H

$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$

S.@o. "&10 51SC7"&"!@ +<5"&!7S 710+7HS

% ' (

$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$

5$B= "s earthing electrode of mast !H and its

connection with mast proper N

TANKAGE AREA2 PIPELINES2 LOADING+

UNLOADING GANTRY

1$B% +re 96 pipelines provided with flange earth umper connectionfor electrical continuityN

1$B' +re earthing provision on 96 storage vessel well maintained N

1$B( Condition of grounding electrode !H

1$B) Continuity of location, hoses maintained.

1$B= 6rounding resistance at inlet of grounding connection checked/ date for vessels etc.2

1$B* Connection of earth$bonding of railway track !H.



ELECTRICAL SAFETY AUDIT

LOCATION4 96 storage / / 96 bulk filling / cylinder filling areas/ >e-ane loading

+<5"&15 +S 17 !"S5 8S&5$%)).

ELECTRICAL OBSERVATIONS:

a. 1lectrical Gunction bo-, rainhood cover corroded in he-ane loading area.

b. >e-ane filling hose not bonded.

c. &he unwanted loose electrical cable found lying near 96 :FS$ 9 'B in between sphere compound wall

and bulk loading point.

d. "solated Gunction bo- and cables to be removed near " /C SS$?+ $0CC$%$F($(.

e. Cable dressing is to be done in east of bulk loading point.

f. 1lectric cable going through water culvet 6C;$(.

g. :ase support found damaged in 96 lamp post ?%*$9$B(.

h. 7ainhood cover missing in the two unction bo-es on the north of sphere ?%.

i. 7ainhood cover found in loose condition in unction bo- near 'B$06 ?% :.

. :ase support found damaged in lamp post 96 ?%$ 9$B.

k. 7ainhood covers missing in unction bo- 'B 06 ?%$+.

l. Supply cable tray corroded and not properly dressed in unction bo- ?% + / ?% :.

m. 1lectrical cable trench is to be properly covered in north of 'B 06$('$+.



LOCATION4 *.* 067,S<:S&+&"!@ ?+/?:3*.

+<5"&15 +S 17 !"S5 8S&5$%))

ELECTRICAL OBSERVATIONS:

&he unction bo- found in open condition in "!C9 Co$ordination office wall facing on the road OP.

1arthing found disconnected in motor 'B 60$(? :@$#a-.$+&9F

<< MGR

&he lighting cable not routed properly zigzag condition2 on pump bay !F *.* 067.

Gunction bo- found in open condition on '($9$B.

1arthing found disconnected on '( 6$% :.

Gunction bo- found open condition and rainhood corroded near '( 6$B'$+.

9ighting unction bo- was found with temporary cover on '( 9$B.

&wo motors left abandoned south of '($6 '': and terminal cables found e-posed.

Start and Stop switch came out of its position in '( 6 '':.

0otor body not earthed in '( 6 ='C,5.

SUBSTATION =A+=B9<

ainted line diagram of power 3 lighting distribution not provided as per

!"S5 8S&5$%)) in all the above substations.

1lectric cable came out of the rack opposite to SS$?: along the road OP.

9ighting cable from SS$?+ was routed above ground level upto materials building compound wall.

1arthing pit covers totally damaged in front of SS$?+,: and also in open condition.

9ighting switch bo- open condition inside SS$?:.

Flooring 7ubber mat not available in front of 0CC$( and 95: on SS$?+.

7oof e-posed above 0CC$' and tarpaulins kept on the panel in SS$?+.

Cable supply board covers missing in 9ogicstat isolation transformer on SS$?+.

Supply cable on redundant motor lying on the floor for quite long distance near

'B$6 (%'.



Cables found inside water culvert F C;$%( and adacent one opposite to 7!;$B($'B along the road OP.

1-cess cables are lying near the culvert FC;$%' along road 8.

7edundant panel boards and tube light fittings dumped in the technician room of SS$*.

0any anel boards is in off and doors found in open condition in SS$*.

+s per !"S5$S&5$%)) ,Shall not be kept open2

Switches are provided in panel boards (.),).',).= instead of isolators in SS$*.

7oof e-posed above panel boards and tarpaulins provided in SS$*.

&he used cable wires kept below the stairs at the south entrance of SS$*.

Cable trench at the south entrance of SS$* is not covered.



RECOMMENDATIONS:

%2 &he unwanted loose electrical cable should be properly disposed.'2 "solated Gunction bo- and cables to be removed

(2 roper bonding must be done in he-ane filling area.

)2 :ase support must be strong..

=2 7ainhood must be covered in unction bo-.*2 Care must be taken to avoid corrosion in unction bo-, rainhood, electric cables

?2 Supply cable tray must be properly dressed.

2 1arthing connection must be done properly.

safety audit n

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