Project Report On Hse Management and Haz

PROJECT REPORT ONHSE MANAGEMENT
AND HAZARD IDENTIFICATION IN

PETROCHEMICAL INDUSTRIES
FOR ADVANCED DIPLOMA COURCE IN INDUSTRIAL SAFETY
2011-2012
PRAVIN M
ALI IRM RA
PROJECT REPORT ON
HSE MANAGEMENT AND HAZARD IDENTIFICATION IN PETROCHEMICAL INDUSTRIES
FOR
ADVANCED DIPLOMA COURCE IN INDUSTRIAL SAFETY
AT
XYX, (NAME HIDDEN), ADDRES, NAVI MUMBAI
SUBMITTED BY
PRAVIN NIMBA MALI
COURCSE RECOGNISED BY
MAHARASHTRA STATE BOARD OF TECHNICAL EDUACTION, MUMBAI
COURCE CONDUCTED BY
THANE BELAPUR INDUSTRIES ASSOCIATION,
TECHNICAL INSTITUTE: 408
2011 – 2012
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ACKNOW LEADGEM
ENT
At the beginning I would like to take this opportunity to express my sincere thanks and deep sense of
gratitude to all those who are directly or indirectly related towards the completion of this project
work. I take this opportunity to especially thank my institutional project guide Mr.
A. K. Gupta for his guidance in completing this project.
I am grateful to the management of XYX,(NAME HIDDEN), especially Mr. Shekhar Wani, Manager
– Business Development and Mr. D. Patil , Manager – HSE who gave me opportunity to this project
work, without their support this project would not been completed.
I would also like to thanks the management of Thane Belapur Industries Association. Particularly to
Dr. S.L. Patil Principal and Mr. Anil Chowgule and rest of the staff members to complete this project
work successfully.
Place: Navi Mumbai
Date
Pravin N. Mali
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PREFACE
The Project report is broadly based on studies into three major areas
Health
Safety
Environment
The study has been carried out with references to HSE management system and practices followed in
existing factory as well as at ongoing expansion project with special references to factory act 1948
and Contract Labour (Regulation and Abolition) Act 1970. Efforts have been made to study the
Health, Safety, and Environment practices in XYX, (NAME HIDDEN), Mumbai Plant in particular
by correlating the statuary requirement with the actual code of conduct.
Efforts have been made to touch upon hazards and control measures being followed at XYX, (NAME
HIDDEN) to overcome them with an overview of activities pertaining to XYX, (NAME HIDDEN) in
general. The subject by itself being very exhaustive in nature. Only passing references are made at
time to methods and procedures of common / universal practices.
XYX,(NAME HIDDEN), being a highly safety conscious company , many of the practices are much
ahead of the trends prevailing and some of the practices which need special attention in many
industries are practised as a natural habit and part of daily routine and code of conduct. Safety is a
part of culture in XYX, (NAME HIDDEN)
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Objective
1. To study corporate HSE practices in general and Project Specific HSE plan and work
practices
2. To study various operations carried in the factory and evaluated the risk of hazards
associated with these operations.
3. To study Emergency preparedness plan and safety procedures
4. To study and make the safety Audit list for plant
5. To study legal requirement related the safety for plant
6. To study bitumen storage and processing facility in plant
7. To give recommendations for improving the existing safety system
M et hodology
The method used for this project study is as follows –
1. Discussions with concerned officials, supervisory staff and workers

2. Study of process details and plant manuals
3. Study of the safety organisation and system of the factory in details
4. Study of accident records
5. Taking inspection and observation round of the plant site to know working
procedures, observe working condition and work practices
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INDEX
Cont ent s
ACKNOWLEADGEM ENT ..................................................................................................................... 2
PREFACE............................................................................................................................................ 3
Objective ....................................................................................................................................... 4
M ethodology ................................................................................................................................. 4
INDEX................................................................................................................................................ 5
CHAPTER – 1: COM PANY PROFILE...................................................................................................... 7
CHAPTER – 2 HSE M ANAGEM ENT SYSTEM ..................................................................................... 12
2.1 HSE Objectives: ...................................................................................................................... 12
2.2 Organization Commitment ..................................................................................................... 12
2.3 HSE Policy .............................................................................................................................. 13
2.3.1 Policy Commitment ......................................................................................................... 13
2.3.2 Based on these guiding principles.................................................................................... 14
2.4 M onitoring reviewing of IM S system ...................................................................................... 15
1. HQO: IM S management review committee M embers should be ..................................... 15
2. PLANTS: IM S management review committee M embers should be ................................. 15 2.4.3 The
agenda of M RC meetings has as below. .................................................................... 15
2.4.4 M anagement Review M eeting Output ............................................................................ 16
2.5 M anagement Orientation (Training Programs)....................................................................... 16
2.5.1 HSE orientation for new Joinee ....................................................................................... 16
2.5.2 HSE orientation for experienced employee ..................................................................... 17
2.5.3 HSE orientation for visitors.............................................................................................. 17
2.5.4 HSE orient at ion for cont ract ors....................................................................................... 17
2.6 Housekeeping Practices ......................................................................................................... 18
2.6.1 Elem ents of a good housekeeping campaign ................................................................... 18
2.6.2 XYZ, (NAM E HIDDEN) Check list for Housekeeping........................................................... 19
2.7 Work permit system .............................................................................................................. 20
2.7.1 XYZ, (NAM E HIDDEN) followed following general guidelines for work permits system ..... 20
2.7.2 HOT WORK PERM IT......................................................................................................... 21
2.7.3 CONFINED SPACE ENTRY PERM IT .................................................................................... 22
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2.7.4WORKING AT HEIGHT....................................................................................................... 23
2.7.4 WORKING ON PIPE LINE CARRYING FLAM M ABLE, CORROSIVE OR TOXIC......................... 23
2.7.6 EXCAVATION PERM IT...................................................................................................... 24
2.7.7 ELECTRICAL SAFETY......................................................................................................... 24
2.8 Personal Protective Equipm ent .............................................................................................. 26
2.8.1 St atutory requirement .................................................................................................... 26
2.8.2 M aintenance and Upkeep of PPE .................................................................................... 26
2.8.3 Training on use of PPE..................................................................................................... 26
2.8.4 Work Specific PPE ........................................................................................................... 27
2.8.5 Purchase (Regulations and St andards for procuring PPE) ................................................. 28 2.8.6
Provision of PPE to employees ........................................................................................ 30
2.9 Risk assessment at XYZ, (NAM E HIDDEN) ............................................................................... 31
2.9.1 OH& S Hazard identification shall be carried out by considering following area at XYZ, (NAM E
HIDDEN)....................................................................................................................... 31
2.9.2 On-Sit e Em ergency Preparedness & Response Plan (OSEP).............................................. 31
2.9.3 Development of On-Sit e Em ergency Preparedness & Response Plan (OSEP) .................... 32 2.9.4
Communication of the Plan and Training......................................................................... 32 2.10 Safet y
Audit ......................................................................................................................... 32 2.10.1 Benefit of
audit is .......................................................................................................... 33
2.10.2 Following are the check list followed by XYZ, (NAM E HIDDEN) for the safety audit ........ 33
2.10.2 Suggest ed Check List for Audit....................................................................................... 34
CHAPTER – 3 STUDY ON STATUARY COM PLIANCES........................................................................ 42
CHAPTER – 4 STUDY ON HAZARD IDENTIFICATION OF BITUM EN FACILITY...................................... 67
CHAPTER – 5 INCIDENT INVESTIGATION.......................................................................................... 78
CHAPTER – 6 INTERNAL AUDIT REPORT AND RECOM M ENDATIONS ............................................... 84
CHAPTER – 7 CONCLUSIONS AND RECOM M ENDATION ................................................................... 88
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CHAPTER – 1: COM PANY PROFILE
XYX, (NAME HIDDEN) is an engaged in the business of Manufacturing and Marketing of

Cationic Bitumen Emulsion, Cutback and all type of Modified bitumen. The XYZ, (name hidden)
always remained in the forefront with regard to the development of environment friendly and energy
efficient products. It believes in constant growth through all round excellence in its operations,
innovations and also alliances with internationally reputed organizations.
The impetus being given by the Govt. of India and also the Various State Governments in
developing good infrastructure, consequent to which the road construction activity is presently
witnessing significant growth. These new major road projects require high volumes of straight grade
bitumen and also various other value added bitumen products like bitumen emulsions, modified
bitumen, cutback bitumen, etc.
While the straight grade bitumen is being produced and marketed directly by HPCL from its
refineries, XYZ,(NAME HIDDEN) possess expertise in value added bituminous products like
bitumen emulsions, modified bitumen, cutback bitumen, etc.
M/s XYX, (NAME HIDDEN) was incorporated in 1995 and has successfully set up seven
manufacturing facilities till date near Mumbai, Delhi, Chennai, Vadodara, Visakhapatnam, Mangalore
and Jhansi. The XYZ, (name hidden) uses the technical know- how received from M/s -------, (world
leaders in bitumen emulsions) and the production is carried out in highly sophisticated and automated
imported plants. The superior quality products have enabled the XYZ, (name hidden) to become the
leader in bitumen emulsion and modified market, within a short span of time.
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The product range of XYZ, (NAME HIDDEN) is:
⸎ Cationic Bitumen Emulsions

⸎ Special Bitumen Emulsions
⸎ Modified Bitumen Emulsions
⸎ Modified Bitumen
⸎ Cutback Bitumen
⸎ Water proofing emulsions
⸎ Anti-Stripping Agent
⸎ Ready mix for pothole repairs
XYZ, (NAME HIDDEN) products have been very popular across the country and are being
used in almost all the states in various departments for varying applications viz., tack coat, prime coat,
surface dressing, maintenance works etc., XYZ, (name hidden) have conducted extensive trials of
“Micro surfacing” using modified bitumen emulsions successfully on national highway in Guwahati
in association with CRRI & Assam PWD. XYZ, (name hidden) have recently introduced a readymade
solution for pothole repairs. The product is emulsion based aggregate mix, designed for easy
application. XYZ, (name hidden) have also undertaken extensive trials in coordination with CRRI
successfully replacing bitumen with bitumen emulsion for BM and SDBC layers.
In the ongoing “Golden Quadrilateral” and “ North-South-East-West” corridor projects,

besides the World Bank Aided Projects in various states, XYZ,(NAME HIDDEN) products
particularly bitumen emulsions and modified bitumen are being extensively used.
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MAIN RAW MATERIALS USED
Sr. No. Raw Material
1 Bitumen
2 Emulsifiers
3 Wax
4 Calcium Chloride
5 Acid
6 Gilsonite
7 Stabilizing Agent
8 Crumb Rubber
9 Flux
10 HDPE Drums – 200 kg
11 Reconditioned MS Drums – 210Kg
12 MS drum – 150 kg
13 Anti-stripping Agent
14 Hytherm oil
15 Furnace Oil
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Applicable Laws & Regulations
Compliance Requirement Act / Rule Sec. / Rule
License / Consent / Authorization
Factories Act,1948 / State Factories Sec 8 / MFR 5,7

Factory License
Rules &8
PCB Consent & HW Sec. 26/ Sec.

P&CP, Water Act 1974/ Air Act 1981
authorization 21 / Rule 5
Sec. 7, 8 & 9/
Petroleum License Petroleum Act 1934 and Rules 2002
Rule 116, 148
Solvent, raffinate and Slop Solvent, Raffinate and Slop Order

Clause 2
registration 2007
Statutory Testing
Structural Stability Testing State Factories Rules MFR 3A
Pressure testing of thermopac

State Factories Rules MFR 73 - ZA
coils
Testing of thermic fluid State Factories Rules MFR 73 - ZA
Statutory Testing of pressure

State Factories Rules MFR 65
vessels External
Statutory Testing of pressure

State Factories Rules MFR 65
vessels Hydro
Statutory Testing of lifting Factories Act, 1948 /State Factories Sec. 29 / MFR
machines Rules 64
Statutory Testing of lifting Factories Act, 1948 /State Factories Sec. 29 / MFR
tackles Rules 64
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Examination of acid storage
State Factories Rules MFR Sch. XII
tank and pipelines.
Medical examination State Factories Rules MFR 73 - V
Testing of earthling Pits. Indian Electricity Rules, 1956
Testing of Transformer Oil Indian Electricity Rules, 1956
Filling of periodic returns
Factories Act 1948 / State Factories Sec. 110 / MFR

Factory annual returns
Rules 119
Environmental statement
Env. (Protection) Rules, 1986 Rule 14
yearly
Hazardous waste annual

Hazardous Waste (M&H) Rules Rule 9 (2)
returns
Monthly Water Cess Filling Water (P&CP) Cess Rules Rule 4
Water cess paid Water (P&CP) Cess Rules Rule 4
Quarterly returns under

Solvent, Raffinate and Slop Order
Solvent, raffinate and Slop
2007
order
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CHAPTER – 2 HSE M ANAGEM ENT SYSTEM
1. HSE Object ives:
(XYZ, (NAME HIDDEN)) is committed to attained highest standard in health, safety
and environmental performances. In this pursuit, XYZ,(NAME HIDDEN), MUMBAI plant is striving
hard to ensure no harm to employee / workers of business associates /surrounding communities, no
harm to environment and no violation of statutory rules and regulations.
Process of Achievement
Health, safety, Environment (HSE) management system incorporates a framework and key
processes which reflects the desired HSE deliverables by all employee and business associates.
Benefits of HSE
⸎ Achieving Organization Commitments

⸎ Environment protection
⸎ Adherence to legislation, law of the land
⸎ Enhancing Brand images
⸎ Increasing business avenues
⸎ Fulfilling social obligation
⸎ Fulfilling corporate obligation to stakeholders
⸎ Fulfilling corporate obligation to employee
2. Organizat ion Com m it m ent

Organizational desires and commitment are expressed in the key performances
attributes by the MANCO (Management committee) which comprises CEO, COO, CFO, operation
head, Project Head and Regional business Heads, to fulfil management expectations,
This MANCO committee develops a key result area and performances measures for all
region and all plant, which are includes in their annual business plan and balance scoring cards for all
staff.
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The expectations of management from IMS system are given below
⸎ Nil fatality at work

⸎ Nil Accidents
⸎ Adherence to the Act, Law, rules and regulations of the county
⸎ Environment protection
⸎ Pollution Prevention
⸎ Energy Conservation
⸎ Employees’ occupational Health Safety
⸎ Plant infrastructure / Equipment safety
⸎ Intensive training / Work ship / Talks for business associates
⸎ Through probe for near misses , accidents , root cause analyses, sharing
⸎ Awareness drive and implementation of HSE Policy
⸎ Security
⸎ Corporate Social Responsibility
⸎ sustainable Development
2.3 HSE Policy

Over years, the company has been following a policy which was internal audit
mechanism based. After restricting of the organization creating regions and entities, the policy was
revisited and revised. The revised policy was introduced in April 2011.
For HSE Policy of XYZ, (name hidden) see ANNEXUER – I
2.3.1 Policy Commitment

XYZ, (NAME HIDDEN) has the highest concern and commitment for protecting the
Health and safety of all employees, contractors, customers and the communities in which XYZ,
(NAME HIDDEN) operate and for conservation of the environment.
XYZ, (NAME HIDDEN) will comply with all statutory Regulation and may even go beyond these for
the benefit of environment
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XYZ, (NAME HIDDEN) consider Health Safety and Environment aspects are an integral part of
business planning and operation processes
2.3.2 Based on these guiding principles

XYZ, (NAME HIDDEN) Demonstrate commitment by
⸎ Providing and maintaining safe facility and working conditions.

⸎ Recognising that all employees have responsibility for their own safety and actions which could
affect the safety of others
⸎ Adoption of appropriate technologies to minimise the impact of our activities on the environment.
XYZ, (NAME HIDDEN) establishes clear objectives and targets to
⸎ Improve continuously for prevention of accidents and occupational illnesses and minimising
any impact of our activities of the environment
⸎ Promote learning through training and sharing of experiences and best practices including with
contractors, customers and the public, wherever required
⸎ Inculcate values and attitudes conducive to achieve excellence in Health Safety and
environment performances
XYZ, (NAME HIDDEN) Provide means to achieve mission by
⸎ Assigning clear roles and responsibilities at all level and periodically reviewing and recognising
contribution to HSE objective
⸎ Allocating adequate resources
⸎ Fostering a spirit of participation by all employees in HSE conservation efforts
⸎ creating appropriate forums for deliberations on HSE issues
XYZ, (NAME HIDDEN) monitoring performances by
⸎ Periodically auditing work process, system and practices and promptly correcting deficiencies.
⸎ Incorporation HSE performances as a parameter for assessing the overall performances of
employees, business units, contractors and business associates
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2.4 M onit oring reviewing of IM S syst em
Integrated management system has reviewed by Management Review Committee, at
least once in 6 months at Plants and once in a year at HQO by Top Management, to ensure its
continuing suitability, adequacy and effectiveness. The management review committee has
constituted, HQO and at each plant, with the following members:
1. HQO: IM S m anagement review com m it t ee M em bers should be
1. Chief Executive Officer

2. Chief Operating Officer
3. Head – Operations & HR
4. Chief Finance Officer
5. Head - Commercial
6. Head – Engineering & Projects
7. Manager – Health, Safety & Environment
8. Manager – Technical
9. Head – IT & ERP
2. PLANTS: IM S m anagem ent review com m it t ee M em bers should be
1. Regional Business Head

2. Plant Manager
3. QC Officer
4. Commercial Officer
5. Production Engineer
The aim of the MRC meeting has to arrive at decisions, taking commitments by identifying
actions, assigning responsibilities and fixing targets.
2.4.3 The agenda of M RC meetings has as below.
⸎ Actions taken on the previous review meetings

⸎ IMS Audit (both Internal and Third Party) results
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⸎ Relevant QHSE communication from external interested parties, including complaints
⸎ Improvement required based on customer feedback
⸎ Results of evaluation of compliance against applicable legal and Other requirements
⸎ Results of IMS Performance Measurement and monitoring
⸎ Achievement against IMS Objectives and targets
⸎ Status of incident investigations, Corrective actions and preventive actions
⸎ Results of employee participation and consultation
⸎ Resource adequacy and Training effectiveness
⸎ Review of suitability of Integrated Management Systems Policy and IMS Objectives.
⸎ Changing circumstances, including developments in legal and other requirements related to IMS
⸎ Recommendations for Improvement.
2.4.4 M anagem ent Review M eet ing Out put

Minutes of Management Review meetings shall record the decisions taken regarding
actions / changes required to ensure continual improvement of Integrated Management System. This
includes:
⸎ Changes to ensure improvement of processes and IMS performance

⸎ Changes to IMS Policy and IMS Objectives
⸎ Resource requirements and provisioning
⸎ Changes to any other element of Integrated Management System
⸎ Records of Management Reviews have maintained by Management representative and copies has
made available to the other members for necessary action.
5. M anagement Orientation (Training Programs)

HSE orientation schemes have been developed and available in the plant As
employee, contracts workers, visitors have to undergo safety orientation programme during which
they are informed about the likely hazards and the consequences in the premise and the safety rules
and regulations to be observed in the during their working / visit
1. HSE orient at ion for new Joinee

All new employees undergo HSE orientation programme before they are assigned with any
job/ responsibilities in the plant.
The programme includes familiarization course covering the following:
⸎ HSE Policy of the organization

⸎ Potential hazards in the plant, consequences on exposure
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⸎ safety feature for the personal i.e. PPEs, Do’s and Don’ts
⸎ Unsafe act unsafe condition and other cause for accidents
⸎ incidents identification and reporting
⸎ safe operating practices, maintenances, repairs, work permits
⸎ Housekeeping practices
⸎ Emergency preparedness
⸎ Fire Fighting arrangements and operation
⸎ Availability of operation, maintenance, safety manuals, guidelines, rules and regulations
⸎ Security features and practices
Programmes are conducted one-to-one basis for an individual employee and on

classroom style for a group of employees
2.5.2 HSE orientation for experienced employee

Experienced employees are targeted on on-going with a revision/ introduction of
rules,
regulation, procedures, and new technologies and polices. However, they undergo refresher
programmes, various internal/external workshops at least once in two years
2.5.3 HSE orient at ion for visit ors

For visitor as well as employees from other offices requiring visiting the plant, they are
required to undergo safety orientation on the day of their arrival and before entering the licensing
area. During the programme, such visitors are informing about HSE feature, various hazards control
measures available in the plant. They are given peps and escorts to move around the plant
2.5.4 HSE orient at ion for cont ract ors

Contract workers under safety orientation programmes which covers:
⸎ HSE policy of the organization and their obligation

⸎ Their working areas
⸎ facilities under operation
⸎ Potential hazards and control and measures
⸎ Do’s and Don’ts
⸎ Use of peps
⸎ Working procedures with authorization from concerned officers
⸎ Working under experienced supervisor
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⸎ Responsibility in case of an emergency
⸎ Evacuation process and emergency exist
⸎ Entry and exist pass
2.6 Housekeeping Practices

Efficient production and a good working environment are complementary. The
elimination of inefficiencies and accident hazards caused by unfavourable conditions in and about the
workplace is essential in getting the job done properly and safely. Good housekeeping involves every
phase of industrial operations and should apply throughout the entire premises, indoors and out. It is
more than mere cleanliness. It requires orderly conditions, the avoidance of congestion, and attention
to such details as an orderly layout of the whole workplace, the marking of aisles, adequate storage
arrangements, and suitable provision for cleaning and maintenance.
2.6.1 Elem ents of a good housekeeping campaign

The following are the basic elements of a good housekeeping campaign that need attention:
⸎ Aisles—Wide enough for traffic movements, marked off by floor lines from work
positions and storage areas.
⸎ Space—Sufficient room for the individual to work.
⸎ Storage—Adequate and convenient space for materials and tools.
⸎ Materials Handling—Layout planned for materials flow, with efficient methods and
equipment.
⸎ Ventilation—Good general ventilation plus local exhaust ventilation to remove air
contaminants at the source.
⸎ Floors and Walls—of construction and materials that are easy to keep clean and in good
repair.
⸎ Lighting—Well-distributed artificial light and effective use of available daylight.
⸎ Amenities—Clean, up-to-date washrooms and lockers for clothing. A clean, inviting lunch
room for employees to eat their meals.
⸎ Waste Removal—Adequate facilities to prevent congestion and disorder.
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2.6.2 XYZ, (NAM E HIDDEN) Check list for Housekeeping
XYZ, (NAME HIDDEN) prepare a checklist for good housekeeping practices
1. Buildings
a. Walls clean
b. Windows clean
c. Walls free of unnecessary hangings
d. Proper light provided
e. Platforms in good condition
f. Stairs clean and well lit. Handrails and steps of sound construction and well
maintained
2. Floors
a. Good floor surface.
b. Kept clean and free of loose material.
c. Clean in corners, behind radiators, along walls, and around pillars or columns.
d. Free of oil, grease, etc.
e. Operating floors, or work positions free of loose scrap, metal or other materials.
f. Free of unnecessary articles.
g. Bins provided for refuse.
3. Aisles
a. Free of obstructions.
b. Safe and free passage to fire-fighting equipment and fire exits. Safe
c. and free access to work positions.
d. Clearly defined.
4. Machinery and equipment
a. Clean and free of unnecessary material.
b. Free of unnecessary dripping of oil or grease.
c. Area around machines clean and free of rags, paper, etc.
d. Lockers and cupboards clean and free of unnecessary material both on top and inside.
e. Benches and seats clean and in good condition.
f. Drinking fountains clean.
g. Toilet facilities clean and well ventilated.
h. Proper guards provided and in good condition.
i. First-aid facilities and equipment fully stocked and in clean condition.
5. Stock and material
a. Properly piled and arranged
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b. Kept in storage areas.
6. Tools
a. Properly arranged in place.
b. Free of oil and grease.
c. Inspected and maintained in
good order.
d.
Tool rooms and racks in clean
7. Grounds
and orderly condition.
a. Yard and building surrounds free of refuse such as fruit peelings, scrap, wood, Iron, etc.
b. Grounds kept free of weeds and overgrown vegetation.
c. Wastes and refuse removed frequently.
7. Work permit system
IMS system of XYZ, (NAME HIDDEN) is provide the guideline and process for work permit
system
At site XYZ, (NAME HIDDEN) identified following jobs as a critical operation
⸎ Hot work
⸎ Confined space entry
⸎ Working at Height.
⸎ Working on Pipelines lines
⸎ Excavation
⸎ Electrical Maintenance
1. XYZ, (NAM E HIDDEN) followed following general guidelines for work permits system
1. A work permit has initiated by Plant Engineer / Area Owner and authorized and issued
by the Plant Manager / Regional Business Head.
2. Plant Engineer has ensure that the provision of work permit system as indicated in the
respective work permit forms / formats are strictly implemented before commencing the job.
Execution of the jobs to be started only after taking appropriate work permit and approval
from the Plant Manager / Regional Business Head.
3. Company Official (Plant Manager / Engineer) given a safety briefing to the contract workmen
and its supervisor about the hazardous involved in the job and safety measures to be taken
before commencing the work.
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4. The permit has valid for only one day and has renewed in continuation sheet after physical
inspection of site and ensuring adherence to the requirements of the permit.
5. Two copies of the permit have made- one with executing agency at site and second at the
approving authority.
6. After completion of the job, Plant Engineer / Area owner has to inspect the area for clearing
of debris / scrap material / temporary electrical connection etc. and then sign and return the
copy to file after taking signature of Plant Manager.
7. The completed permits has retained for six months period the after physical inspection of the
site by the signatory on the permit
2.7.2 HOT W ORK PERM IT

Hot work include following activity at XYZ, (NAME HIDDEN)
Hot works includes all activities which may generate enough heat to ignite flammable
Vapours / flammable material; viz Welding, gas cutting, grinding, drilling, soldering, sand blasting,
chipping, riveting, operation of power tools, burning, open flame.
Guideline for HOT Work Followed by XYZ, (NAME HIDDEN)
⸎ The Hot work Permit system has applicable to all the areas in the Plant premises / Project sites
for the jobs carried out internally or through contractors except for operation of LPG stove in
pantry, and performing Pooja in office premises.
⸎ Any hot work in the vicinity (within 15 mtr radius) wherein flammable / combustible material
is present shall only be authorized by Plant Manager /Regional Business Head after physical
inspection of the site and carefully ensuring all necessary conditions as mentioned in hot
work permit are compiled and the job can be safely carried out.
⸎ No hot jobs have carried out on or in vicinity of tanks containing flammable /
combustible material. Where the hot work is unavoidable the same has carried out only after
emptying the tank, degassing/cleaning, purging with inert gas and ensuring that the
atmosphere inside the tank is safe for carrying out the job. Fire blankets / spark shields has
used close to the job being carried out to prevent sparks flying off area. Any hot job on or in
vicinity of tanks containing flammable / combustible material shall only be authorized by
Plant Manager / Regional Business Head after physical inspection of the site and carefully
ensuring all necessary conditions as mentioned in hot work permit are compiled and the job
can be safely carried out. PM / RBH shall suspend the job any time if the conditions are
found unsafe to carry out the job.
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⸎ Plant Engineer has responsible for strict adherence to the conditions of hot work permit and
has physically present at the site wherein hot jobs are carried out on or in vicinity of tanks
containing flammable / combustible materials.
⸎ Hot Permit has issued for one hot work operation, it has non-transferable and shall expire at the
end of the day and has renewed every day after physical inspection of site and carefully
ensuring all necessary conditions as mentioned in hot work permit are compiled and the job
can be safely carried out.
⸎ The person/s including contract workmen doing hot work has made aware about the hazards
involved in the job and the precautions needs to be taken during the job as
indicted in the work permit. It has ensured that they also have basic knowledge of Fire Fighting
and use of requisite PPEs. All contract employees has given safety briefing on importance of
adherence to work permit conditions before commencing of the job and same has recorded.
Emergency management procedure of the Plant has also explained to them.
2.7.3 CONFINED SPACE ENTRY PERM IT

Confined space means any enclosed space that has limited entrance or exit,
which is not primarily designed or intended for human occupancy. (E.g. tanks, ducts, sewer,
chimney, trenches etc.)
Guideline for Confined Space Entry followed by XYZ, (NAME HIDDEN)
⸎ A permit has required for entry to all confined spaces and must be issued prior to entry of
person/s.
⸎ Plant Engineer shall take all precautions to isolate the confined space and ensure that all other
safety precautions as indicated in the permit are taken before issuing the permit.
⸎ Plant Manager has the issuing authority for all confined space permits after physical inspection
of the site conditions and ensuring that all necessary conditions mentioned in the permit are
taken and it is safe to carry out the job.
⸎ No hot work has allowed to be carried out in the confined space. Where it is unavoidable the
same has done only after taking hot work permit duly authorized by the Plant Manager.
Page | 22
2.7.4W ORKING AT HEIGHT
Purpose of this work permit is to ensure that the all employees including contract
workers are safe from any risk while working at a height.
Guideline for Working at height followed by XYZ, (NAME HIDDEN)
⸎ A permit has required for carrying out any job at height more than 10 feet where there is no
proper working platform available.
⸎ Double lined safety belt has strictly used by person working at height. All anchor points should
be checked properly before fixing the life line of safety belt. In case suitable anchor is not
available at the site arrangement should be made to provide strong anchor and then only job
should be started.
⸎ People working at height should not have a phobia for working at heights and to ensure this,
all employees required to work at a height should be interviewed to ascertain this.
⸎ Plant Manager has the issuing authority for the permit after physical inspection of the
site conditions and ensuring that all necessary conditions mentioned in the permit are taken and it
is safe to carry out the job.
2.7.4 WORKING ON PIPE LINE CARRYING FLAM M ABLE, CORROSIVE OR TOXIC

workers are safe from any risk while carrying out jobs on pipe lines carrying out flammable,
corrosive or toxic material.
Guideline for Pipeline work followed by XYZ, (NAME HIDDEN)
⸎ A permit has required for carrying out any job on pipeline carrying flammable, corrosive or
toxic material.
⸎ Plant Engineer shall take all precautions mentioned in the permit before executing the job.
⸎ Plant Manager has the issuing authority for the permit after physical inspection of the site
conditions and ensuring that all necessary conditions mentioned in the permit are
taken and it is safe to carry out the job.
⸎ Pipe line permit has initiated by Plant Engineer / Area Owner and has authorized and issued
by the Plant Manager by signing on the same.
Page | 23
2.7.6 EXCAVATION PERM IT
workers are safe from any risk while carrying out excavation job.
Guideline for Excavation work followed by XYZ, (NAME HIDDEN)
⸎ A permit has required for carrying out any excavation work only after isolation of any
underground electrical cables / telephone cables /pipelines /sewers etc., before carrying out
the job.
⸎ While road cutting can hamper the movement of the fire fighting vehicles hence if the road is
wide, preferably the road should be cut half at a time. Duration of road cut should be
restricted as far as possible.
⸎ Plant Manager has issuing authority for excavation permit after physical inspection of
the site conditions and ensuring that all necessary conditions mentioned in the permit are taken
and it is safe to carry out the job.
7. ELECTRICAL SAFETY
Following has the safe systems of work on electrical installations (fixed and portable):
⸎ With regard to all fixed electrical installations and to all portable electrical equipment there
has in place a safe system of work that shall ensure:
 Compliance with relevant legislation.
 All fixed installations are safe and tested.
 All electrical installations are maintained.
 Only safe equipment is used.
⸎ Connections shall always be suitable for the purpose for which they are being used and the use
of electrical tape alone for connections has forbidden. Cable joints shall only be through
appropriate junction boxes.
⸎ It has ensured that any protection for electrical installations and equipment are suitably rated,
sufficient and within safe working limits.
⸎ All electrical installations and equipment shall have adequate means to enable them to be
isolated from the electric supply in order to prevent danger.
⸎ Isolators / switches has easily accessible and passageways to them has kept as clear as possible
at all times.
Page | 24
⸎ Switches and fuse units has clearly labelled as to indicate the circuit or equipment controlled,
and all switches and distribution covers has kept closed at all times unless being worked on
by a competent or authorized person.
⸎ Adequate working space in terms of access and lighting has provided at all electrical equipment
on which or near which work being is carried out that may give rise to danger.
⸎ There have adequate arrangements to ensure that electrical equipment that has been made
“dead”, while work is being carried out on or near such equipment, cannot be electrically
charged. Use of tester pens for test for dead electrical has prohibited.
Multimeter, has used for LT work. For testing dead the HT, only HT tester has used. Isolation has
physically achieved through Lock out Tag out (LOTO) system, i.e. the isolator controlling
equipment is physically locked in the “off” position. Where “Lock Out” system cannot be
used then there has a procedure for ensuring that fuses are removed and held by the
authorized person carrying out the work, and appropriate tags placed.
⸎ Any work being performed on an electrical installation or equipment, except the routine work
on electrical installations in the sub-station or on power generation equipment by competent
electrical personnel has subject to the Permit-To-Work Procedure.
⸎ Only competent or authorized persons has engaged in any work on an electrical installation or
equipment and they has provided with suitable protective equipment (e.g. goggles,
electrician gloves, safety shoes with synthetic soles (having resistance not less than
103 Kilo Ohms), insulating mats in MCC rooms, insulated tools, test probes etc.).
⸎ Notices giving details of emergency resuscitation procedures in the event of electric shock has
displayed at those locations where the risk of electric shock is greater e.g. sub-stations and
MCC rooms.
⸎ In case of portable powered tools, no unattended automatic operation has allowed.
Reference:
ANNEXURE –IV: Work Permits, Hot work Permit, Confined Space Entry, Working at Height, Pipe
Line Working, Excavation, and Electrical Work
Page | 25
8. Personal Prot ect ive Equipm ent
1. St atut or y requirem ent
The Factory act and Maharashtra factory rules prescribed under
Sec 35 and rule 67: Measures for protections of eyes.
Sec 22 and sec 112: prescribe rules regarding tight fitting clothing.
The working condition mentioned in section 14, 30, 33, 35, 36, 37, 38, 87, 111 and 114 are
such that free PPE should be provided by the occupier for the protection from hazards due to dust,
fumes, gas, vapours, flying particles, glare, revolving machinery, hot or dangerous process.
For protection from excessive noise Sec 87 and rule 114
Schedule XXIV lays down suitable guideline. In every factory suitable engineering control or
administrative measures shall be taken to ensure so far as is reasonably practicable that no worker is
exposed to sound levels exceeding the maximum permissible sound exposure specified and in no case
to exposure in excess of 115 dB(A).
2.8.2 M aintenance and Upkeep of PPE

The area supervisor / Plant Engineer have ensured that the PPE are maintaining in
good and safe condition. He also ensure that any damaged PPE is immediately discarded by physical
destruction (cutting, tearing, dismantling, etc.) and replaced with a new one so that no employee
wears a PPE that becomes unworthy of providing the intended protection.
2.8.3 Training on use of PPE

All employees are going through initial training in the use of PPE.
Training for each type of PPE has given prior to exposure to any potential hazard and include:
⸎ When, where, what and why PPE is necessary and how to properly adjust, wear and use it;
⸎ The performance, end of useful life and limitations of the equipment;
⸎ How to take proper care, store, clean, and maintain the PPE in good condition;
⸎ How to dispose it safely and responsibly;
⸎ Factors affecting the degree of protection afforded;
⸎ Recognizing faults and how to report or replace faulty equipment.
Page | 26
2.8.4 Work Specific PPE
While it is essential to wear PPE and the same is be communicated to all personnel
working in the plant, the table given below presents a ready reckoner for minimum PPE
required for safely carrying out some types of routine jobs.
Work activity Recommended PPE to be used
Handling acids, bases and corrosive Safety helmet, Safety goggles, Face shield,
chemicals Rubber/PVC apron/suit, Rubber (long
gloves sleeve),
Handling toxic and irritant chemicals (both Safety helmet, Safety goggles, Face shield,
solids and liquids) Rubber/PVC apron, safety gloves,
Work on or near hot surfaces (hot objects, Leather gloves, safety helmet, safety glasses.
pipelines etc.)
Electrical work Safety shoes with insulated sole, Approved

electrician’s hand gloves and safety glasses.
Work in High noise areas Ear plugs/ canal caps, ear muffs.
Work at heights Doubled lined Safety belt, Safety harness, safety

helmet.
Welding/ gas cutting Leather gloves, safety helmet, welder’s goggles /

welder’s helmet with face shield.
Grinding operations Leather gloves, safety glasses with side protection.
Routine maintenance jobs Safety goggles, helmet
Analytical work in Quality Control Lab. Lab coat and surgical hand gloves. Apron and
safety goggles/ glasses where required.
Page | 27
2.8.5 Purchase (Regulations and St andards for procuring PPE)
XYZ, (NAME HIDDEN) use following guideline for purchase of PPES
⸎ All PPE used shall be certified either to BIS (Bureau of Indian Standards)
⸎ Specification or by international certification body such as MSHA (Mine Safety and Health
Administration – US.
Types of PPE Applicable Indian Standard
Safety Helmet IS:2925:1984
Eye Protectors IS:5983:1980
Equipment for eye & face protection during IS:1179 :1967
welding (includes welding helmets, welding IS:1179:1967/IS:5983:1980
Hand shields, welding filters, filter covers). IS:1179:1967/IS:5983:1980
Ear Protectors IS:9167:1979
Visor IS:9973:1981
Body protection (Body protection selection IS:8519:1977

guide)
IS:8990:1978
Maintenance and Care of safety clothing
Rubberized Aprons – acid & alkali resistant

IS:4501:1981
Industrial safety Face Shields IS:8521(Part: I):1977
IS:8521(Part: I):1994
Safety Shoes IS:5852:2004 / IS:11226 :1993
Leather Safety Shoes IS:5914:1970
IS:11226:1993/IS:13469:1992
IS:5677:1986
Rubber /PVC Knee Boots (Gum boots) IS:12254:1993 IS:13695:1993
Page | 28
IS:13695:1993/IS:12254:1993
Hand protectors IS:4770:1991 and IS:4770:1968
 Safety Gloves (Natural Rubber, (for electrical purpose)

Synthetic Rubber etc.)
IS:2573:1986
 Safety Clothing /Safety Gloves
( Leather ) IS:6110:1983/ IS:3322
 Hand protectors Safety Clothing (PVC
(Part: I):1987
Coated fabrics Double textured
rubberized Water proof fabrics)
Respirators
 IS:10245 (Part 1, 2,3 and 4)
 SCBA
 IS:8522:1977
 Respirators, chemical cartridge
 IS:8523:1977
 Respirators, canister type (gas masks)
 IS:9473:2002
 Filtering Half Masks to Protect Against
 IS:9623:1980
Particles
 IS:14166:1994
 Recommendations for the selection,
 IS:14170:1994
use and maintenance of respiratory
protective devices  IS:14746:1999
 Respiratory protective devices : Full  IS:15322:2003
face masks  IS:15323:2003
 Respiratory protective devices :

Mouthpiece assemblies
 Respiratory Protective Devices : Half
Masks And Quarter Masks
 Particle Filters Used in Respiratory
Protective Equipment
 Gas Filters and Combined Filters Used in
Respiratory Protective Equipment
Additionally refer to IS: 8520:1977 on guidance for selection of industrial safety Equipment for
eye, face and ear protection.
Page | 29
Some of the International Standards (to be used in the absence of National Standards) are:
Type of PPE Applicable International
Standard
Respirators ANSI Z88.2-1992
42 CFR 84
29 CFR 1910.134
Face and Eye ANSI Z87.1-1989
protection
Head protection ANSI Z89.1-1986
Footwear ANSI Z41-1991
Insulating Gloves ASTM D-120-95
General (OSHA) 29 CFR 1910.132
Where:
ANSI = American National Standards Institute; ASTM =
American Society for Testing and Materials; CFR = Code
of Federal Regulations (US)
2.8.6 Provision of PPE t o em ployees

XYZ, (NAME HIDDEN) provide the PPEs to all personnel working at the plant as per the
requirement of the job. The Plant Engineer / QC Officer ensure availability of required PPEs at the
shop-floor/ workplace. In case the PPE gets damaged or contaminated, replacement shall be issued
on recommendation of Plant Engineer /QC Officer.
Page | 30
2.9 Risk assessment at XYZ, (NAM E HIDDEN)
Petrochemical industry is an industry with high risk, both in exploration and
development of oilfields and in processing and production at plant level. It is the ultimate goal of any
HSE management is to prevent accidents by improving HSE risk management at first line
organization level.
1.OH& S Hazard identification shall be carried out by considering following area at XYZ, (NAM E
HIDDEN)
1. Routine and Non-routine activities

2. Activities of all personnel having access to the workplace (including contractors and
visitors)
3. Infrastructure, equipment and materials at the workplace (whether provided by XYZ,(NAME
HIDDEN) or others)
4. Hazards originating outside the workplace capable of adversely affecting the health and
safety of personnel under the control of XYZ, (NAME HIDDEN) within the workplace.
5. Design of work areas, processes, installations, machinery, operating procedures and work
organization, including their adaptation to human capabilities
2. On-Sit e Em ergency Preparedness & Response Plan (OSEP)
The plant shall carry out assessment of the type, scale and potential impact on man and / or
environment of potential emergencies from reasonably foreseeable incidents. The emergencies can be
a direct outcome of site operations, like fires, explosions, spills, leaks, serious injury to persons due to
collapse of structure/ building.
Review
The assessment shall be reviewed once in a year or earlier whenever a significant risk gets
introduced to the site. The On-Site Emergency Plan shall be reviewed accordingly based on the
outcome of assessment.
Page | 31
2.9.3 Development of On-Sit e Em ergency Preparedness & Response Plan (OSEP)
The basic objectives of the OSEP shall be to:
⸎ Safeguard the people during emergency.

⸎ Minimize damage to property and the environment.
⸎ Initially contain, and then control the event.
⸎ Rescue and treat the injured.
⸎ Provide accurate information to those affected.
⸎ Facilitate early restoration of activities.
⸎ Safeguard the reputation of the company.
2.9.4 Communication of the Plan and Training

The OSEP shall be communicated to all line Company Officials and Core Group members for
further sharing with all employees. The plan shall also be shared with Factories Inspectorate and any
other organization on need to know basis. Before implementing the OSEP, the “Emergency Response
Team (ERT)” shall be trained to assist in the safe and orderly evacuation of the people. Training for
each type of emergency shall be imparted so that ERT know what actions are required.
The emergency response training program shall provide for:
⸎ Initial training when the plan is developed,

⸎ When new technology is introduced,
⸎ When changes to work procedures introduce a potential emergency.
⸎ When drill exercises show that emergency responders performance must be improved.
2.10 Safet y Audit

An audit is a systematic examination to determine whether activities and related results
conform to planned arrangements and whether these arrangements are implemented effectively and
are suitable for achieving the organization’s policy and objectives.
Audit may be defined as Systematic, independent, documented process for obtaining records,
statements of fact or other relevant information and assessing them objectively to determine the
extent to which specified requirements are fulfilled.
Page | 32
2.10.1 Benefit of audit is
⸎ Assess the effectiveness of the integrated management system
⸎ Identify opportunities for improvement
⸎ Determine the conformity of the integrated management system with the specified
requirements
⸎ Meet the regulatory requirements
⸎ For the purpose of certification (registration) of the IMS System
2.10.2 Following are the check list followed by XYZ, (NAM E HIDDEN) for the safety audit
⸎ OS&H policy
⸎ Safety organization chart.
⸎ Training records on safety, fire and first aid
⸎ Record of plant safety inspections
⸎ Accidents investigation reports
⸎ Accidents and dangerous occurrences – statistics and analysis
⸎ Record of tests and examinations of equipment and structures as per statutes
⸎ Safe operating procedures for various operations
⸎ Record of work permits
⸎ Record of monitoring of flammable and explosives substances at work place
⸎ Maintenance and testing records of fire detection and firefighting equipment
⸎ Medical records of employees
⸎ Records of industrial hygiene surveys (noise, ventilation and levels, illumination levels,
airborne and toxic substances, explosive gases)
⸎ Material safety data sheets
⸎ On-site emergency plans and records of Mock Drills
⸎ Records of waste disposal
⸎ Records of effluent discharges to the environment
⸎ Housekeeping inspection records
⸎ Minutes of safety committee meetings
⸎ Approval of layouts; and other approval from statutory authorities
⸎ Records of any modifications carried out in plant or process
⸎ Maintenance procedure records
⸎ Calibration and testing records
⸎ Shut-down maintenance procedures
⸎ In-service inspection manuals, records including that of material handling
⸎ Safety budget
Page | 33
⸎ Inspection books and other statutory records
⸎ Records of previous audits
⸎ Safety in transportation of hazardous substances
2.10.2 Suggest ed Check List for Audit

There are many different disciplines and job positions with different characteristics, So Audit
checklist is very useful tool for Internal and External Auditors for examine the system. Check list
should be designed by considering the each job position with their function in organization.
Following checklist is suggested for XYZ, (NAME HIDDEN). Internal Audit
2.10.2.1 Regional Business Head.

⸎ How do you establish QHSE objectives and targets at the Plant level?
⸎ How do ensure adequate resources for implementation of IMS at the plant level.
How do you ensure that customer requirements are determined and expectations
⸎ are met?
How do you ensure awareness of the plant personnel on important customer as well
⸎ as statutory & regulatory requirements?
How do you ensure that the customer perception is being monitored w.r.t
⸎ meeting their requirements
How do you ensure that the plants are operated in safe and environmentally
⸎ responsible manner?
How do you ensure continual improvement in IMS at plant level?
⸎
2.10.2.2 M arket ing /
Sales ⸎ How to you determine the customer requirements including delivery, post-
delivery activities.
⸎ How do you determine requirements not specified by the customer but necessary
for use of the product?
⸎ How do you determine statutory and regulatory requirements related to the
products?
⸎ How do you review the requirements related to the product before commitment
to supply.
⸎ How do you ensure critical order information is 100 % complete before acceptance?
How do you communicate product requirement (including change orders) to all
⸎ appropriate levels.
Page | 34
⸎ How do you communicate with customers on product specifications, its safe and
environmental friendly use and disposal?
⸎ How frequently the customer satisfaction survey is carried out and how the inputs
are used for planning improvements
⸎ Check customer complaint records / register in SAP & its compliance status How
⸎ to you ensure that customer expectations are met.
2.10.2.3 Plant M
anager
⸎ How do you communicate IMS policy & its requirements to all employees including
contract workmen?
⸎ How do you communicate importance of meeting customer, statutory and regulatory
requirements to your plant personnel?
⸎ How do you ensure that hazards and environment impacts associated with all plant
activities are identified and significant environmental impacts / OHS risks are
adequately controlled?
⸎ How do you identify and update the legal and other requirements applicable to your
plant activities.
⸎ What are the legal and other requirements applicable to your plant? Are
⸎ all statutory licenses / consents / authorization in place?
⸎ Check following documents exists and are valid.
⸎ Factory license
⸎ PCB consent
⸎ Petroleum license
⸎ Solvent, raffinate
and slop
⸎ registration
How do you ensure that the statutory testing’s are carried out timely and
⸎ Approved
certificates plans from factory
from competent inspector
persons office
available. reflecting
Check the recent plant
for following records.
modifications / expansion
⸎ Structural stability testing as per defined frequency / after plant modifications /
expansion.
⸎ Annual Pressure testing of thermic fluid coils/ reports available and in order
⸎ Quarterly Testing of thermic fluid / reports available and in order
⸎ Annual Testing of lifting tackles / machines / reports available and in order Pressure
⸎ vessels tested as per defined frequency reports available and in order All Earthling
⸎ pits tested as per defined frequency and reports available
⸎ Acid storage and handling facility examined and reports available
⸎ Transformer oil tested reports available and in order
⸎ Are statutory returns filled in time and records available
Page | 35
⸎ Factory half yearly / annual returns
⸎ Environmental statement Hazardous
⸎ waste returns
⸎ Water cess filling & payment of cess
⸎ HSE committee meetings are held and minutes recorded. MSDS of
⸎ all hazardous materials available at the point of use.
⸎ Medical exam of employees carried out and the records available
⸎ Accident and dangerous occurrence register maintained as required under FA
⸎ Inspection book for factory inspector maintained.
⸎ Check for remarks and status of compliance
⸎ How do you set QHSE objectives and targets at plant level?
⸎ What are the significant OHS risks and environmental impacts related to plant
activities
⸎ Details of management programs initiated to minimize OHS risks and
environmental impacts.
⸎ How frequently they are reviewed for its effectiveness.
⸎ Have you determined the competence necessary for performing work affecting
product conformity or have significant environment impact or OHS risk?
⸎ How do you ensure appropriate training to all employees who activities affect
product quality or have significant impact on environment and plant safety. Check for
training records.
⸎ How do you carry out training effectiveness evaluation?
⸎ How do you do ensures participation of workmen in hazard identification, incident
investigation.
⸎ How are the new employees trained on QHSE aspects?
⸎ How do you receive and respond to external communications concerning HSE. Are
⸎ the records available?
⸎ Do you have documented operational control procedures for activities with
significant QHSE impacts?
⸎ How do you ensure the adherence to the SOPs?
⸎ How do you ensure that potential emergency situations are identified and addressed
in your plan?
⸎ Do you conduct mock drills covering all emergency scenarios? What are the learning
from mock drill and how the same are reflected in emergency preparedness plan.
How do you monitor and measure OHS performance of the plant.
⸎ Do you take any corrective and preventive actions based on the analysis data
Page | 36
⸎ Do you evaluate the compliance to legal and other requirements? Are the
records available?
⸎ Do you investigate all incidents to determine underlying OHS deficiencies in the
system (root cause), corrective actions? Are the records available?
⸎ How do you ensure that the plants are operated in a safe and environmentally
responsible manner?
⸎ Do you communicate results of investigation to all concerns?
⸎ How do you identify the actual and potential nonconformities related to QHSE and
need for corrective / preventive actions
⸎ Is environmental data displayed at board updated regularly
⸎ How do you ensure safety of contract workmen? Are they trained on plant safety
requirements and permit to work system as appropriate...? Are the training records
available?
⸎ How do you ensure that all contract workmen entering plant premises are covered
under ESIC / WCP cover?
⸎ How do you ensure that the tools and tackles brought by the contractors are in safe
condition to use?
2.10.2.4 Production –Plant Engineer & Plant M anager

⸎ Have you identified OHS hazards and environmental impacts in all the activities
including the recent one? (Check HIRA & EIA register.)
⸎ How do you carry out significance evaluation of the identified OHS hazards and
environmental impacts? Show HIRA & EIA register
⸎ Are employees aware about the activities with significant impact on Quality,
safety &environment?
⸎ Are the work instructions available at work place for working personnel
⸎ Check identification and traceability of incoming, in storage, in processes and finish
goods materials is evident.
⸎ Does the calibration maintenance plan in SAP covers all critical equipment for
QHSE performance? Check plan in SAP.
⸎ Are all these equipment calibrated as per the defined frequency? Check records
Is the acceptance and tolerance limit for each equipment defined?
⸎ Do you carry out environmental monitoring (Stack gas, ambient air, noise etc.) as per
⸎ defined frequency? Are the records available
How frequently the mock drills are carried out? Are all emergency scenarios
⸎ covered? Are records available?
Page | 37
⸎ Storage and process tanks monitored for flammable and toxic gas presence on
monthly basis?
⸎ Check adherence to permit to work system for ongoing jobs in plants
⸎ Check previous internal / external audit NC / observations and its status of
compliance
2.10.2.5 M aintenance –Plant Engineer & Plant M anager
⸎ Have you identified OHS hazards and environmental impacts in all the activities
safety and environment?
⸎ Are plant equipment and utilities which are critical from QHSE performance
identified & included in preventive maintenance plan.
⸎ Do you monitor the plant break downs in SAP? How the data is used for
improvement.
⸎ Do you inspect engineering spares after receipt and acceptance available in SAP?
Incident register – Status of Corrective and preventive action.
⸎ Check maintenance records of firefighting appliances (portable
⸎ fire extinguishers, fire pump, hydrant system, emergency siren etc.).
Check working of emergency showers / eye wash fountain
⸎ Check maintenance record of forklifts
⸎ Check maintenance records of DG set
⸎ Check maintenance records of Thermic Fluid heaters
⸎ Check records of tank cleaning and adherence to cleaning frequency Check
⸎ first aid box and training records of first aiders
⸎ compliance
2.10.2.6 Human Resource

⸎ Have carried out competence requirement for all the positions affecting the
QHSE performance.
⸎ Are training needs identified and training plan prepared.
⸎ Are trainings conducted in accordance with the training needs? Is
⸎ training effectiveness evaluation carried out?
⸎ How are the new employees trained on QHSE aspects?
Page | 38
compliance
2.10.2.7 Purchase
⸎ How do you ensure the capability of a supplier to meet organization
requirements?
⸎ Records of evaluation and revaluation of the suppliers.
⸎ What actions are taken based on the evaluation / revaluation of the supplier How do
⸎ you ensure requirements related to HSE are communicated to the contractor / service
provider?
⸎ How do you ensure that relevant safety information is received from the supplier
along new material / hazardous material?
compliance
2.10.2.8 Technical
⸎ Are designed and development activities planned and controlled.
⸎ Details of the new design and product development projects.
⸎ Records of inputs related to product development maintained.
⸎ Does the design input takes into consideration statutory and regulatory
requirements and learning from previous projects.
⸎ Does the design and development output specifies product characteristics
essential for safe and environmental friendly use of product.
⸎ Does the design review evaluate the ability to meet the design requirements Does the
⸎ review involve representatives that are affected from the product design?
Are the records of review available?
⸎ Is product validation carried out before delivery and the validation records
⸎ maintained?
Check previous internal / external audit NC / observations and its status of
⸎ compliance
2.10.2.9 Qualit y Cont rol and PM

R ⸎ Have you identified OHS hazards and environmental impacts in all the activities
Page | 39
safety and environment?
⸎ In process quality inspections carried out as per master recipe in SAP
⸎ Check non-conforming material if any is isolated and identified suitability using
placards
⸎ Details of in process product conformity detected if any and corrective actions taken.
Notification of customer complaints in SAP
⸎ Records of calibration of lab instruments Is
⸎ control copy of IMS manual available
⸎ Records of internal audits and status of corrective and preventive actions How
⸎ the documents of external origin are controlled.
⸎ List of control documents of external origin are available
⸎ Master list of plant specific IMS documents and its control
⸎ Are IMS management reviews conducted periodically? All agenda points covered?
⸎ Minutes recorded and available?
⸎ compliance
2.10.2.10 HSE & IM

S
⸎ How do you ensure that the plants are operated in a safe and environmental
friendly manner
⸎ How do you ensure compliance to HSE related legal and other requirements. How
⸎ the amendments in HSE are related statutory requirements identified and
communicated to plants.
⸎ How to you ensure promotion of safety and environment protection at work place.
How do you ensure the availability of current versions of IMS documents with all
⸎ users?
How do you ensure that the internal audits are conducted effectively? Records of
⸎ external audits and summary of internal audit NC and status of compliance
⸎ Are IMS management reviews conducted periodically? All agenda points covered?
Minutes recorded and available?
compliance
⸎
Page | 40
2.10.2.11 Engineering and Projects
⸎ How do you ensure that the environmental aspects / impacts and OHS risks in the
new projects are identified and addressed?
⸎ How do you identify and ensure that relevant statutory clearances are obtained before
the starting of the projects.
⸎ How do you ensure conformance QHSE related standards in the plant design? How
⸎ do you communicate HSE related requirements to the contractors / service providers?
How do you ensure that the contract workmen are competent / adequately trained to
⸎ carry out the jobs in a safe manner?
How do you ensure that the tools and tackles of the contactors are safe in safe
⸎ condition?
How do you ensure adherence of contractor and his workmen to the safe
⸎ operating procedures and work permit system.
⸎ compliance
References: ANNEXURE : EMERGENCY PREPAREDNESS PLAN OF XYZ, (NAME

HIDDEN) PLANT
ANNEXURE : Incident Report case study
Page | 41
CHAPTER – 3 STUDY ON STATUARY COM PLIANCES
Brief study on compliances of provisions under the factories act 1948 and the Maharashtra
factories Rules is carried out. But complete statuary study is not done at XYZ, (NAME HIDDEN).
During statuary study of XYZ, (NAME HIDDEN), MUMBAI site it is observed that
XYZ, (NAME HIDDEN) comply all requirements described in acts.
Following are some recommendation drawn for exceeding laws and improvement of HSE
performances
⸎ Increase SKO earth pits

⸎ First Aid boxes are available at two locations at security get and plant manager cabin,
but one more first aid box needs to provide at production area
⸎ Application is made for authorization to SPCB in form1 under Hazardous Wastes
(Management, Handling and Transboundary Movement) Rules, 2008.
Details observations are given in following study table
Page | 42
STUDY ON STATUARY COMPLIANCES
Review Period: March 2011 to December 2012
Company Name : XYX, (NAME HIDDEN)
Address : Mumbai
No. of Employee : 17
NO. Of Contract Workmen : 25
Area of Company : 6358Sq Meter
Products : Bituminous Product
Sr. Compliance requirement Sec. / Rule Status

No
THE FACTORIES ACT, 1948 and THE MAHARASHTRA FACTORIES RULES, 1962
1 An application for renewal of license of the factory shall be made to Section 6(1) of Factories Act,1948 Factory license valid up to
Chief Inspector of Factory in Form 3 along with the fees specified in the Rule 8 of MFR,1963: Renewal of 31.12.2012
schedule attached to Rule 5 of MFR, sixty days before it is expired. license
2 Notice of change of Occupier in Form 2. Notice of change of Occupier Available
Page | 43
No
3 Notice of change of Factory Manager shall be in Form No.5 Section 7(1) of Factories Act,1948 Rule Factory manager was change
15 of MFR,1963: Notice of change of in Nov 2009 and Notice was
manager given to the factory inspector
4 Stability Certificate is to be obtained from a competent person once in 5 Section 6(1) of Factories Act,1948 Rule Available Stability certificate
years or after extension, alteration, repairs or addition of any work of 3A of MFR,1963: Certificate of Stability carried on 26/07/2010
engineering construction or replacement or addition of machinery, plant,
etc., in form no. 1A. The same shall be submitted to Chief Inspector of
Factory.
5 The factory shall have effective arrangements to provide sufficient Rule 39 : Drinking water 1 KL separate tank was
supply of wholesome drinking water (minimum 5 litres per person per provide for drinking water and
day). the drinking water are
supplying through water
purifier and filter
6 Every moving part of a prime mover and every fly wheel connected to a Section 21 of Factories Act,1948: Safe guards are provided to all
prime mover, every dangerous part of any machinery shall be securely fenced Fencing of Machinery motor, pumps and production
by safe guards of substantial construction which shall be constantly machinery having movable
maintained and kept in position while the parts of machinery they are fencing parts
are in motion or in use.
Page | 44
No
7 Every lifting machine, ropes and lifting tackles shall be of good Section 21 of Factories Act,1948: Form No. 12 is available and
mechanical construction, sound material and adequate strength. It shall be Fencing of Machinery capacity and testing date are
properly maintained and shall be thoroughly examined by a competent person display on every lifting
at least once in every period of twelve months, record to be maintained in machine and tackles are
Form – 12.
8 Marking of safe working pressure and the date of last examination shall Section 31(2), Section 112 of Factories Form No. 13 is available , All
be marked on every pressure vessel or pressure plant. Periodic examination Act,1948 pressure equipment’s are tagged
to be carried out as Hydro test once in 4 years, External examination once Rule 65 of MFR,1963: Safety measures with safe working pressure, date
in six months. Internal Examination once in a year. Record is to be for Pressure Plant Vessels operated of examination and due date of
maintained in a register in form no. 13. under pressure over atmospheric examination
pressure
9 When any person has to work at height from where he is likely to fall, Section 32 of Factories Act,1948 : Work permit system is
provision shall be provided by fencing or otherwise to ensure safety of the Floors, Stairs and means of access established in the plant and all
person working. safety appliances are available
with plant like safe ladders,
safety belts and related PPEs
Page | 45
No
10 All practicable measures shall be taken to prevent outbreak of fire and Section 38 of Factories Act, 1948 : 1. Fire hydrant loop is
its spread. There shall be provided a) Safe means of escape for all persons Protection in case of fireSection 70 of provided to entire plant. 2. CO2
in cases of fire. b) the necessary equipment and facilities for extinguishing MFR, 1963 flooding system is provided to
fire processing tank 3. Fire mist guns
and adequate fire extinguishers
are available at various points in
the plant for easy associability of
plant
11 On site Emergency Plan for the factory is to be prepared. All workers Section 41B of Factories Act: On site emergency plan are
are to be made aware of Onsite Emergency Plan. Compulsory disclosure of information place in site. Training and
by the occupier awareness program on OSEP
are provided
12 Maintain accurate and up-to-date health records / Medical records of Section 41C of Factories Act: Specific Last health check-up for
the workers. Pre-employment medical examination and regular medical Responsibility of the occupier in employee was done on 24 Oct
examination of workers employed in a hazardous process shall be carried out relation to hazardous Processes And 2011 and contract workmen
once in a period of 12 months. applicable rules under MFR health check-up was done on 12
Nov 2012
Page | 46
No
13 A Safety Committee consisting of equal numbers of representatives of Section 41G of Factories Act: Workers Safety committee exits in
management and workers is to be constituted. participation in Safety management. plant and it compress with
Section 73-J of MFR, 1963. manager, engineers and quality
persons , commercial officers
and general workmen
14 Annual Return to be filed in following manner. Section 110 of Factories Act,1948 All records are available
1.Average number of workers employed daily and normal hours worked per Rule 119(1) of MFR, 1963: Annual Muster roll are available
week. Returns
2. Leave with wages.
3. Number of discharged or dismissed workers.
4. Wages in lieu of leave.
5. Compensatory holidays.
6. Canteens in the case of factories.
7. Shelters, rest rooms and lunch –rooms.
8. Accident Statistics.
9.Such other matter or items as may be prescribed in Form 27. To be maintained
in Form no. 29 by factory manager and shall be preserved for a period of 3
years from the date of last entry in it.
Page | 47
No
15 Provision of Protective equipment shall be made while working in HCl Section 87 of Factories Act,1948 Rule All required PPE are
storage and handling areas. 114, Schedule XII (3) of MFR, 1963- provided
Handling and manipulation of corrosive
substances
16 Provision and maintenance of Fire Extinguishers shall be made. Section 87 of Factories Act,1948 Rule Fire extinguishers are timely
114, Schedule XII (3) of MFR, 1963- change before expiry and
Handling and manipulation of corrosive record same and maintain
substances
17 Vessels used for storing corrosive substances having a storage capacity Section 87 of Factories Act,1948 Rule 1 Kl HCl stored in plant in
of 20 litres or more and pipelines, valves and fitting used for storing or 114, Schedule XII (3) of MFR, 1963- HDPE tank and all pipeline of
carrying corrosive substances should be examined thoroughly every year. A Handling and manipulation of corrosive HCl transfer is also a HDPE
register is to be maintained of such examinations. substances piping. All this system are
examined periodically and
records are maintained
18 A cautionary notice shall be affixed prominently close to the place where Section 87 of Factories Act,1948 Rule Display is available
any of the operation involving HCl is carried out. 114, Schedule XII (3) of MFR, 1963-
Handling and manipulation of corrosive
substances
Page | 48
No
19 Any accident or dangerous occurrence whether causing any bodily injury Section 87 of Factories Act,1948 Rule No such accident happened
or disability or not, the notice in Form -24 and Form 24 A respectively shall 115 of MFR, 1963: Notification of in plant premises in this
be sent to authorities (Inspector, Administrative Medical Officer- ESIS, accidents (or dangerous occurrence) review period
District Magistrate, Nearest Police Station, and the nearest relatives of the
injured or deceased persons) within specified time.
20 Register of Accidents and Dangerous Occurrences (form 30) Section 112 of Factories Act,1948 Incident record (FM/11)
Rule 123 of MFR, 1963: Register of available in IMS manual
accidents and dangerous occurrences
21 To maintain Inspection Book which is to be produced before Inspector or Section 112 of Factories Act,1948 Maintained & available
certifying Surgeon whenever required (Form 31) Rule 124 of MFR, 1963: Maintenance of
Inspection book
PETROLEUM ACT, 1934 AND PETROLEUM RULES 2002
22 Class B –If the quantity in the possession at any one place does not Section 7 SKO storage license no.
exceed 2500 list and none of it is contained in a receptacle exceeding 1000 No license needed for transport or storage
list in capacity. of limited quantities of petroleum class B
Page | 49
No
23 Class C – If the quantity in the possession does not exceed 45000 list. Section 8 No license needed for import, NA
transport or storage of limited quantities
24 All due precautions shall be taken at all times to prevent escape of Rule 9: SKO tanks are underground
petroleum into drain, sewer, harbour, river or watercourse or over any Prevention of escape of petroleum and safety precautions are
public road or railway line. place like static energy
neutralization, daily check of
tank
25 No person shall smoke and no matches, fires, lights or articles or Rule 11 Smoking is strictly prohibited
substances capable of causing ignition shall allow at any time. Prohibition of smoking, fires, lights etc. in plant premises, Such
displays are available in
plant, Security check these
things for every person and
vehicle at the time of
entering in premises
26 (1) No electric apparatus shall be allowed in a zone 0. Rule 106 Fixed electric apparatus For SKO handling flame
(2) Zone 1 – Flame proof type or intrinsically safe or approved by CCOE proof pump and motor are
(3) Zone 2 – Non sparking apparatus. available
Page | 50
No
27 (1) All equipment, structure, plant and other non-carrying metallic parts of Rule 108 Two earth pits are available
major electric apparatus or any major metallic object in any place where Earthling and Bonding for SKO tank. Unloading
petroleum is refined, blended, stored, loaded or unloaded shall be efficiently points, pipeline of SKO and
earthed – motor are earthed properly
(a)A ohms in case of electric system and equipment or a valve that ensure
the operation of the protective device in the electrical circuit
(b)10 ohms in case of all non-current-carrying metallic parts of major
electric apparatus
(2)All joints in pipeline, valve, plants, storage tanks and associated tank or
vessel /facilities shall be made electrically continuous by bonding.
(3)A piping which is not in electrical contract with the associated tank / vessel
shall be efficiently connected to such tank or vessel by flexible conductor
and earthed.
Page | 51
No
MANUFACTURE, STORAGE AND IMPORT OF HAZARDOUS CHEMICAL (AMENDMENT) RULES, 2000
28 Major Accident hazards are to be identified. Prevent such major accidents MSIHC Rules,2000 Rule 4:General Major Accident hazards are
and to limit their consequences to persons and environment Provide to the Responsibility of the occupier during identified and OSEP are
persons working on the site with the information, training and equipment Industrial Activity available like that
including antidotes necessary to ensure safety.
29 On-site emergency plan shall be prepared and kept up-to-date. MSIHC Rules,2000 On site emergency plan is
Rule 12: Preparation of On-site up to date last
Emergency Plan by the Occupier
GAS CYLINDERS RULES, 2004
30 No person shall smoke Rule 14 Smoking is not allowed in

No article or substances of flammable nature or liable to spontaneous Prohibition of smoking, fires, Lights and plant. Flammable martial
ignition in proximity dangerous substances not allowed or allow with
No match box, fuses, mobile phone or any other appliances which can some specified condition.
produce spark or ignition I.e. for issuing permit for
such work.
31 Adequately supported during handling Rule 18 NA

Conveyors, trolley and cradles of adequate strength to be used when Handling and use
moving the cylinder
Page | 52
No
Not be allowed to fall on each other or subjected to undue shock

Sliding, dropping or playing with cylinder is prohibited
Cylinders to be kept in up-right position and to be secured
32 Cylinder shall be stored in cool, dry, well ventilated place under cover, Rule 21 NA
away from boiler, open flame, steam pipes or any potential source of heat and Storage of cylinders
such place of storage shall be easily accessible.
33 No License needed for filling and possession in certain cases Rule 44 Only LPG Cylinders(two
LPG – not exceed 100kg at a time 15Kg and one 2kg )
Flammable but non-toxic – 25 cylinders or 200 kg gas, whichever is less Non-
Flammable and non-toxic – 200 cylinders
Toxic gas – 5 cylinders
Acetylene (dissolved) – 50 cylinders
Page | 53
No
THE WORKMEN’S COMPENSATION ACT, 1923 (AMENDMENT 2000)

THE WORKMEN’S COMPENSATION RULES, 1924
34 Employer shall be liable to pay compensation, if personal injury is caused

to a workman by accident arising out of and in the course of his employment.
However the employer is not responsible for in the following conditions;
1)In respect of any injury which does not result in the total or partial
disablement of the workman for a period exceeding 3 days;
2)In respect of any injury, not resulting in death, caused by an accident which
is directly attributable to:
Section 3: Employer’s liability for Employee insurance are
A.The workman having been at the time thereof under the influence of drink
compensation available and Hazards are
or drugs, or
identified in HIRA register
B.The wilful disobedience of the workman to an order expressly given, or to a
and risk analysis was done.
rule expressly framed, for the purpose of securing the safety of workmen, or
According to risk category
C.The wilful removal or disregard by the workman of any safety guard or other
precaution and arrangement
device which he knew to have been provided for the purpose of
are provided in plant
Page | 54
No
securing the safety of workmen.

D. Contract of an occupational disease in any employment
Wherein the total duration of employment is less than 6 months.
35 The amount of compensation to be paid shall be as defined in Section 4 Section 4: Amount of compensation Compensation policy for HR
of the Act. are available
36 If any accident occurs which results in death /serious bodily injury to Section 10-B : Report of Fatal Accidents No accidents in review
workman, the employer must within 7 days of the incident send a report to and Serious Bodily Injuries period
Commissioner for Workmen’s Compensation (or authority appointed by State
Government) giving the circumstances attending the death or serious bodily
injury.
37 When a workman is injured while employed by a contractor, the principal Section 12 : Contracting ESIC of all contract
employer is liable to pay compensation to him, but he is entitled to be workmen are available
indemnified by the contractor.
Page | 55
No
THE CONTRACT LABOUR (REGULATION & ABOLITION) ACT, 1970

THE CONTRACT LABOUR (REGULATION & ABOLITION) RULES, 1971
38 All the contractors (employing more than 20 employees) working in such Rule 21 (1) Labour licences are
establishment shall have a valid labour license issued by the available
Commissioner of Labour, State Government.
39 All the contractors employing contract labour should provide their workers Welfare & Health of Contract Labour All facility provided by Plant
I) Rest Rooms in case contract labours are required to halt at night. (principal employer)
ii) Sufficient supply of drinking water.
iii)Washing Facility.iv) First-Aid facility
If any of these facilities are not provided by the contractor, it is the liability of
the principal employer to provide them. Principal employer may recover the
expenses incurred by him from the contractor
40 Every principal Employer shall maintain in respect of each registered Rule 74: Registers and Records and FORM XII are available and
establishment a register of contractors in Form XII. Collection of Statistics maintained
Page | 56
No
THE ELECTRICITY ACT, 2003 AND THE INDIAN ELECTRICITY RULES, 1956
41 No electrical installation work, including additions, alterations, repairs and [Rule 29 to 35] Competent electrician are
adjustments to existing installations, except such replacement of lamps, fans, recruited in plant and
fuses, switches, low voltage domestic appliances and fittings as in no way alters electrical work permit
its capacity or character, shall be carried out upon the premises of or on behalf system are placed in the
of any consumer, supplier, owner or occupier for the purpose of supply to such plant
consumer, supplier, owner or occupier except by an electrical contractor
licensed in this behalf by the State Government and under the direct supervision
of a person holding a certificate of competency and by a person holding a
permit issued or recognized by the State Government.
42 Every person working on electric supply line or apparatus shall be [Rule 36(1)] All PPE are provided
provided with tools and devices such as gloves, rubber shoes, safety belts,
ladders, earthling devices, helmets, line testers and the like for protecting
him from mechanical and electrical injury.
43 All such tools and devices shall be maintained in sound and efficient [Rule 36(1)] All tools are maintain
conditions.
Page | 57
No
44 Fire buckets filled with clean dry sand and fire extinguishers suitable for [Rule 43 (1)] Available
dealing with electric fires shall be provided, conspicuously marked and kept in
all generating stations, enclosed substation and switch station in convenient
situation and they shall be tested for satisfactory operation at least once a year
and record of such tests maintained.
45 First aid boxes or cupboards shall be provided and maintained in every [Rule 43(2)] First aid boxes are provided
generating station, enclosed substation and enclosed switch station so as to be
readily accessible during all working hours.
46 Instruction in English or Hindi and local language shall be made available [Rule 44(1)] Available
for restoration of persons suffering from electric shock affixed by the owner of
every generating station, enclosed substation, enclosed switch station and
every factory as defined in clause (m) of section 2 of the Factories act 1948
(63 of 1848) in which electricity is used.
47 There shall be a clear space of not less than 1 meter in width provided in [Rule 51(1) (c)(i)] Space is available
front of the switchboard.
48 If there are any attachments or bare connections at the back of the [Rule 51(1) (c)(ii)] Space is available
switchboard, the space behind the switchboard shall be less than 20 cm
Page | 58
No
or more than 75 cm in width, measured from the farthest outstanding part

of any attachment or conductor.
49 If the space behind the switchboard exceeds 75 cm in width, there shall [Rule 51(1) (c)(iii)] Space is available
be a passageway from either end of the switchboard clear to a height of
1.8 meters.
50 The frame of every generator, stationary motor, portable motor and the [Rule 61(2)] Transformer and generator
metallic part (not intended as conductors) of all transformers and any other are earthed
apparatus used for regulating and controlling energy and all medium voltage
energy consuming apparatus shall be earthed by two separate and distinct
connections with earth.
51 All the plug sockets of three-pin type and third pin shall be permanently [Rule 61(2)] Arrangement provided
and efficiently earthed.
52 All earthling systems shall be capable of carrying the prospective earth [Rule 61(4)(a)] All earthling systems are
fault current to the general mass of earth. capable
53 All earthling systems shall be mechanically strong and shall withstand [Rule 61(4)(c)] All earthling systems are
corrosion and retain electrical continuity during the life of installation. capable
Page | 59
No
54 All earthling systems shall be tested to ensure efficient earthling and shall [Rule 61(4)(c), 61(5)] 25 earth pitas are available
be tested for resistance on dry day during the dry season not less than once and testing was done on
every two years.
15 - 11 - 2012 and same is
55 The records of such testing and results thereof shall be kept for a period [Rule 61(6)] displayed on the every earth
of two years after the day of testing. They shall made available to the pit with resistant
Inspector or any other officer appointed to assist the Inspector when

required.
56 ELCB (earth leakage protective device) shall be provided for every [Rule 61 A] Available
installation above 5 KW (except overhead supply lines which are having
protecting devices which are effectively bonded to the neutral of supply
transformers.
Air (Prevention & Control of Pollution) Act, 1981 amended 1987 &
Rules, 1982
57 Renovation of consent Expired on 31/12/2012
58 Comply the all condition for consent operate All parameters within a
range
Page | 60
No
Water (Prevention & Control of Pollution) Act, 1974, Amended 1988

& Rules, 1975
59 Renovation of consent Expired on 31/12/2012
60 Comply the all condition for consent operate All parameters are in limit
Specified water
consumption : 32 m3
Actual water
consumption :
24.96 m3
Water (Prevention & Control of pollution) Cess Act, 1977, amended 1992, Cess Rules 1978 & Water (Prevention & Control of Pollution)
Cess (Amendment) Act, 2003
61 submit returns of water consumption to MPCB Validity period up to

31/10/2012
62 Submit water cess as per assessment order. Cess is submitted per month
Page | 61
No
63 Water Consumption limit All parameters are in limit

Specified water consumption
: 32 m3 Actual water
consumption :
24.96 m3
Environment (Protection) Act, 1986, amended 1991 & Rules, 1986

amended 2006
64 Prevent discharges or emissions of environmental pollutants in excess of Stacks of thermic heater

the prescribed standards. and fire pump and DG are
checked in 10- 08- 2012 and
same report is available
65 Submit Environment Statement on or before 30th Sep to the MPCB for the Submitted
financial year ending 31st Mar every year
66 Noise level of DG set should be within the limit Noise level of DG set is 79
dB
Hazardous Wastes (Management, Handling and Transboundary Movement) Rules, 2008
67 Make application for authorization to the SPCB in Form 1. Application to be made
Page | 62
No
68 Maintain record of hazardous wastes handled in Form 3. Will be done after receipt of
authorization from MPCB
69 Submit to the SPCB, an annual return containing the details as specified NA

in Form 4, on or before 30th day of June following to the financial year to
which the return relates.
70 Ensure submission of renewal application for authorization in Form 1, NA

before expiry date.
71 The occupier generating hazardous wastes specified in Schedule IV may

sell it only to the recycler having a valid registration from the CPCB for
recycling or recovery.
72 Ensure that hazardous wastes are packed and labelled, based on the
composition, in a manner suitable for safe handling, storage and transport as per
the guidelines issued by CPCB time to time.
73 The labelling and packing shall be easily visible and be able to withstand
physical conditions and climatic factors.
74 Transport of hazardous wastes shall be in accordance with the provisions

of this rule and also Motor Vehicles Act.
Page | 63
No
75 Provide the transporter with relevant information in Form 11.
76 Mark the hazardous waste containers as per Form 12.
77 Prepare 6 copies of Manifest in Form 13, comprising of colour code as

specified in the rules.
78 The occupier generating hazardous wastes shall maintain records of such

operation in Form 3.
79 The occupier shall send annual returns in Form 4 every year to the State
Pollution Control Board.
Batteries (Management & Handling) Rules, 2001
80 Deposition of used lead acid batteries with the dealer or collection centres Procedure for disposal of
batteries are available
The Noise Pollution (Regulation & Control) Rules, 2000 amended

2002
81 The Ambient Air Quality standards in respect of noise for industrial area
shall be as specified below-
Page | 64
No
82 Day time (between 6 am to 10 pm) - 75dB (A) Leq. Day time level is 68 dB
83 Night time (between 10pm to 6am) - 70dB (A) Leq. Night time level is 63 dB
The Central Motor Vehicles Rules, 1989 amended 2001
84 The vehicles shall possess valid PUC Certificate. PUC certificates are
checked during vehicle
inspection at gate and same
records are maintained
The Public Liability Insurance Act, 1991 amended 1992
85 Provide relief, as specified, in case of death, or injury to any person (other Insurances provided
than workman); or damage to property from an accident occurring while
handling specified hazardous substances, on the principle of no fault.
86 Owner to draw insurance policies more than the paid-up capital of the Available
undertaking, but less than Rs. 50 Cores, before handling any hazardous
substances.
Page | 65
No
87 Owner to pay additional amounts, as prescribed, to the insurer not Available

exceeding the amount of premium, as contribution to the Environmental relief
Fund.
Page | 66
CHAPTER – 4 STUDY ON HAZARD IDENTIFICATION OF BITUM EN FACILITY
Page | 67
Hazardous Event Causes Possible Consequences Proposed Prevention and Mitigation Control Measures
1. Explosion within 1. Build-up of flammable gases from 1. Damage to the tank 1. Bitumen tanks have frangible roofs to prevent excessive
a bitumen tank or the bitumen with subsequent and possible injury to explosion overpressures developing and also include large
vessel source of ignition (such as people nearby, e.g. by diameter emergency vents.
2. Hazardous Area Electrical Equipment standards applied.
electrical equipment). ejected bitumen.
3. Control of ignition sources throughout the terminal.
2. Welding on a tank with Potential for missile
4. All equipment is to be earthed.
bitumen generation and 5. Hot work permits for maintenance.
still present. propagation to nearby 6. Unblocking procedures are based on the storage and
3. Unblocking pipes or vents with equipment. handling of bitumen products standard (DR 07435 CP;
direct flames. Explosions can result previously AIP CP 20).
4. Low level in the bitumen tanks in a bitumen fire. 7. The storage tank temperatures are automatically
with exposure of the heating 2. For historical tank controlled at about 140 C.
tubes. This can lead to explosions, some 8. Heating is by coils via hot oil and no direct flame
temperatures above the auto tanks have rocketed heating.
ignition point for the vapours in away from the 9. Hot oil high temperature is limited with alarms and
the tank. trips.
foundations
10. Storage tanks designed to maintain minimum level above
5. Overheating a tank and hence heating floor coils (normal draw-off point higher than upper
the potential for greater heating coil level).
flammable vapour generation. 11. Stripper drain locked closed except for maintenance
6. Smouldering of deposits on the purposes (procedural control to isolate heating etc.).
underside of the roof can lead to 12. Fire protection facilities available, e.g. ring main with
high enough temperatures (if hydrants
sufficient oxygen is present) for
the flammable vapours to auto
ignite
2. Self-ignition of 1. Bitumen heated and exposed to 1. Tank fire (typically 2. Low likelihood event given the proposed bitumen grades have
bitumen. air. slow burning) with low sulphur content.
Page | 68
2. Deposits can build-up, e.g. toxic products of 3. The storage tank temperatures are automatically
under tank roofs due to the combustion and controlled at about 140 C.
Note that when condensation of hot vapours, radiant heat emitted. 4. Heating is by coils and no direct flame heating.
oxygen levels fall which can auto-ignite around Potential for injury to 5. Hot oil high temperature is limited with alarms and
below 3%, the tank 190oC or at lower temperatures people nearby and trips.
condition favours the if iron sulphide is present. environmental impact 6. Storage tanks are balanced with atmospheric air in
Deposits can also self-heat if
their thickness exceeds critical breathing (21% oxygen).
formation of 7. Storage tank roofs are not heated but they are insulated.
Pyrophoric materials. values.
8. Deposits within tanks are to be removed during ten year tank
Deposit formation will increase
Smouldering of shutdowns when the tank is cool and high pressure water
with overheating, i.e. excessive jetting or mechanical cutting tools are used
deposits can lower vapour generation
the oxygen levels to
below 3%
3. Burns or 1. People exposed to hot bitumen 1. Burn injuries. 1. The piping design is to comply with existing Vopak and
exposure to from losses of containment. 2. Potential for toxic Australian Standards, e.g. AS4041, to minimise the
hydrogen 2. People exposed to hydrogen impact from hydrogen likelihood of losses of containment.
sulphide. sulphide from losses of sulphide. This may 2. Trained first aiders available from Site B for elevated
Note that these containment or entering confined result in fatality if the temperature bitumen burns.
events will not spaces dose is high enough. 3. Safety showers are to be located throughout the bitumen
contribute to Note that people may processing facility for quick quenching of any hot bitumen
off-site risk suffer loss of smell at that may be stuck on people’s skin or for cooling of any burns.
but are high concentrations of 4. Road tanker loading is enabled by the driver being in a
included for hydrogen sulphide,
completeness protected booth and fumes are extracted from area.
e.g. 300 ppm
5. Confined space entries, risk assessments and permits are
included in the Vopak safety management system.
6. The bitumen will not be heated above 200oC in the
Page | 69
storage tanks nor road tankers to avoid generating too
much fumes.
7. Fumes / vapours are handled by extracting / treating or
returned to source tanks and are not free vented to limit
exposure potential.
8. Emergency response including ringing 000 to get an
ambulance for the affected people to get to hospitals for
further treatment.
9. 200 ppm of H2S in tank (typically as tested in tank ullage),
i.e. typically below fatal level for short exposures.
10. Access to the tank bunds to be banned (signage / chain
across stairs to be installed) and as well as banning access to
the tank tops during shipping discharges.
11. Tanks will vent to a combustor via ducting during shipping
discharges (note H2S hazard in combustor area).
12. Confined Space Entry Rules to apply to bund access.
13. Special, enclosed type sampling devices to be used
4. Tank boil over 1. Water entering a tank and 1. Steam will be 1. All tanks to be kept above 100oC to prevent water
being heated generated with the condensation.
potential to 2. Tanks will have a large diameter emergency vent as well as
overpressure the tank, open goose neck vents.
causing failure, and 3. Steam will not be used to heat the tanks (hot oil used).
resulting in a loss of 4. Frangible roofs
containment
5. Overflowing a 1. Incorrect conversion factors 1. Potential for burns. 1. Bitumen tanks safe fill level to be nominated and included in
bitumen tank for changes in bitumen Potential for a fire if the level monitoring and alarming system.
temperature. Failure of the exposed to source of 2. Level instrumentation to be included in the existing Vopak
level instruments ignition with injury to preventative maintenance systems.
people, damage to 3. Redundant independent level systems on all tanks with
equipment and additional alarms.
environmental impact
4. Tanks are bunded.
from products of
combustion 5. Control of ignition sources in the bunded areas
6. Major 1. Metal fatigue 1. Large spillage of 1. Tanks designed to API 650.

mechanical 2. Faulty fabrication bitumen in bund. Fire 2. Bitumen solidifies quickly when heating removed.
failure of tanks 3. Corrosion of tank base / weld if ignited. 3. Regular maintenance and inspection procedures.
Page | 70
4. Adjacent tank on fire 2. Impact to people 4. Tank and site fire protection facilities available
(radiant heat and/or
exposure to products),
property and the
environment (products
of combustion)
7. Loss of 1. Pipe failures, e.g. due to corrosion, 1. Potential for burns. 1. Regular maintenance and inspection procedures.
containment from valves left open, hose failures, Potential for a fire if 2. Emergency isolation valves on the outlet lines of the new
piping systems pump seal, shaft or exposed to source of tanks.
casing failures and water in the hot ignition with injury to 3. Firefighting system.
oil system people, damage to 4. Most pipes in bunded areas; all pumps are bunded.
equipment and 5. Pipelines surge study.
environmental impact 6. The piping is designed to ASME 31.3 / AS 4041 to resist the
from products of combined effects on internal pressure due to contents, wind
combustion. loads, earthquake forces and hydrostatic test loads.
2. Hot oil transfer / return 7. Trained first aiders on site for elevated temperature
pipe work leaks bitumen burns.
8. Safety showers are to be located throughout the bitumen
processing facility for quick quenching of any hot bitumen
that may be stuck on people’s skin or for cooling of any
burns.
9. Operators to wear additional appropriate PPE for handling
bitumen if they have potential for exposure; i.e. heat
resistant gauntlet gloves, face shield and hood (all skin
protected).
10. Bitumen hoses to be included in the existing
11. Vopak Hose Register with routine inspection, testing and
replacement.
12. The hot oil system includes an expansion tank with a 200
mm free vent and a vessel pressure rating of 400 kPa to cope
with overpressure should water ingress occur
8. Loss of 1. Pipe failures, e.g. due to 1. Potential for burns. 1. The piping design is to comply with existing Vopak and
containment at corrosion, valves left open, hose Potential for a fire if Australian Standards, e.g. AS4041, to minimise the
the berth failures. exposed to source of likelihood of losses of containment.
ignition with injury to
Page | 71
2. Hose rupture on an emergency people, damage to 2. Operators to wear additional appropriate PPE for handling
shutdown valve (ESV) closure equipment and bitumen if they have potential for exposure; i.e. heat
environmental impact resistant gauntlet gloves, face shield and hood (all skin
from products of protected).
combustion. Potential 3. Safety showers are located at the BLB for quick quenching of
for bitumen to enter any hot bitumen that may be stuck on people’s skin or for
the water, sink and cooling of any burns.
hence environmental 4. Trained first aiders on site for elevated temperature
impact bitumen burns.
5. Bitumen hoses to be included in the existing Vopak
Hose
Register with routine inspection, testing and
replacement
6. Surge study will be done on the wharf line system. There will
be a slow closure rate for the ESV’s. Slow line velocity (300
mm line at 400 m3 per hour) to limit surging
9. Loss of 1. Pipe failures, e.g. due to 1. Most likely outcome is 1. Regular maintenance and inspection procedures.
containment in corrosion, thermal a spill onto the ground with 2. Emergency isolation valves.
the Pipeline overpressure, pipe thermal subsequent cooling and 3. Firefighting system.
Corridor expansion or third party solidification. Few 4. Pipelines surge and thermal expansion study.
activity / malicious act sources of ignition exist 5. Routine inspections during transfers
in the Pipeline Corridor.
Note, however, when
solid deposits are
heated, there is the risk
of flammable vapours
being evolved with
subsequent ignition and
burning of the bitumen
10. Insulation fires 1. Loss of containment of bitumen 1. Potential for fires, i.e. 1. Small amount of bitumen adsorbed as limited to about 50 mm
into the piping, tank or vessel from burning of the thick insulation around tanks.
insulation. bitumen and/or
flammable vapours,
Page | 72
2. Light ends dripping from the tank top and hence 2. Flammable vapours are limited and H2S is readily
vents propagation to the noticeable at low odour levels of 0.005 ppm well before
adjoining system LEL.
3. Combustible product.
4. Firefighting systems.
5. Tank top vent design includes drip catchment (for light
ends).
6. The insulation specification includes waterproofing and
minimised roof top openings to handrail supports etc. (that may
allow ingress)
11. Failure of a hot 1. High temperature induced failure, 1. Potential for bitumen 1. Hot oil piping designed to suit conditions.
oil heater coil (in cycling of the metal temperature, and flammable 2. Hot oil piping system is higher pressure (usually 5 to 10
a tank) corrosion, material of vapours to enter the bars) than bitumen storage so leaks are into bitumen system.
construction failure heating circuit. The The top of the bitumen tanks are designed for Zone 1 so no
flammable vapours immediate ignition sources.
could ignite, e.g. when 3. Regular testing and monitoring of hot oil for degradation and
exiting the hot oil head in turn contamination.
tank 4. Firefighting systems
12. Hot oil fires 1. Loss of containment of hot oil 1. Hot oil fire with the 1. Hot oil is combustible product at maximum temperature.
with subsequent ignition, e.g. potential to burn 2. Furnace leak likelihood low due to routine visual inspection and
pump seal failures or sprays from people and/or damage routine NDT (non-destructive testing).
a joint failure, or failure of a hot oil nearby equipment. 3. Furnace explosion side panels. Fire fighting
tube within the furnace Products of
combustion, e.g. smoke,
will have an
environmental impact
13. Explosion within 1. Operating the oil at high 1. Potential for the hot oil 1. The hot oil temperature is limited to 270 C. High
the hot oil system temperatures for a significant to crack to lighter temperature trip (in the emergency shutdown system
period of time hydrocarbons which [ESD]). SIL study to confirm adequacy of the overheat
can accumulate within protection.
the vessels, e.g. the hot 2. Regular sampling and replacement of the hot oil.
oil expansion tank. If 3. Control of ignition sources within the facility. Hot work
ignited, these lighter permits for any spark producing activities
Page | 73
hydrocarbons can
lead to an explosion
(i.e. they have lower
flash points than the
bitumen)
14. Loss of 1. Pipe failure, e.g. corrosion, flange 1. Potential for a jet fire, 1. Piping is welded steel or brazed copper and at low
containment of failure or impact. Valve left open flash fire or vapour pressure.
natural gas cloud explosion 2. Piping is designed and constructed to AS 2885, Gas
(particularly if some degree Pipelines code.
of confinement 3. Fully welded pipeline with no flanges in the natural gas
exists), if ignited. pipeline except at regulator; metering and control valve
These events can lead to stations / areas.
injury and/or radiant 4. All drain and vent valves are plugged.
heat / explosion 5. Annual pipeline inspection as part of the regular
overpressure damage to maintenance and inspection procedures.
equipment. In the 6. Piping is located in open areas promoting good
absence of dispersion
confinement, most
of buoyant gas.
probable outcome will
be jet or flash fires if 7. Gas is odorous and periodically patrolling enables easy
ignited detection if leaking
15. Internal 1. Passing natural gas isolation valves 1. Potential for an 1. Double isolation valves as automatic shutdown with a
explosion within during a shutdown and the internal explosion certified burner management unit. Pre-purge before start up
the oil heaters heaters are not adequately within the heater which sequence.
purged at start-up can result in 2. Testing of shutdown and pre-purge sequence on a regular
injuries to nearby basis to AS 3788 as part of regular maintenance and
personnel and/or damage to inspection procedures.
equipment. Historically, 3. Furnace explosion side panels
the effects of these
types of incidents are
generally local to the
heaters
Page | 74
16. Internal 1. Gas mixture is in the flammable 1. Potential for an 1. Detection of no flame closes the double isolation valves.
explosion within region, e.g. during a start-up, and a internal explosion 2. Pre-purge before start up sequence.
the vapour source of ignition is present, within the combustor 3. Testing of shutdown and pre-purge sequence on a regular basis
combustor e.g. flame igniter which can result in to AS 3788 as part of regular maintenance and inspection
injuries to nearby procedures.
personnel and/or 4. Detonation arrestors fitted at tanks, road tanker loading
damage to equipment.
Historically, the effects and vapour combustor. These will be included in the
of these types of preventative maintenance system for routine cleaning
incidents are generally
local to the combustors
(the combustor is an
open ended burner in a
vertical chamber)
17. Transformer fires 1. Short circuiting, build-up of 1. Potential for an initial 1. Low load, sealed 11KV transformer.
/ MCC fires flammable gas (hydrogen) in the explosion followed by 2. Testing schedule for transformers and oil degradation.
oil with subsequent ignition, loss of a fire involving the 3. Separated from plant and people activity areas.
containment of oil with transformer oil. 4. Emergency Response Plan includes fire events. Smoke
subsequent ignition Potential for damage detection within the MCC. Flammable and combustible
to the electrical materials will not be stored within the MCC
equipment within the
MCC. Potential to
damage nearby
equipment and/or
injure people
18. Leak during filling 1. Failure of loading arm. 1. Leak of bitumen in 1. High level of surveillance and immediate access button to
of road tanker 2. Leak from valves or fittings. loading area. shutdown systems.
3. Road tanker overfills. 2. Fire if ignited. 2. Drivers are well trained so as to minimise chance of
4. Switch loading (Class 3 fumes 3. Impact to people operator error and ensure quick response to leaks.
from cutback bitumen tankers). (radiant heat and/or 3. Driver Pre-Checklist in place.
exposure to products), 4. Ignition sources controlled at top of road tanker.
Page | 75
5. Boil over (water traces in RTL property and the 5. Road tanker overfills shutdown system.
compartment) environment (products 6. Firefighting systems.
of combustion) 7. Driver training including a slow start to filling where the
driver can listen for water (will create cracking / popping
sounds if present in road tanker).
8. Proposed entry traffic lights to prohibit entry into the
neighbouring bay during the initial start sequence
19. Road tanker 1. Failure of procedures and 1. Leak of bitumen in 1. Driver training.
drive-away hardware interlocks loading area. 2. Driver not in cab during filling but monitoring at same
incident (i.e. driver 2. Fire if ignited. elevation as loading arm.
does not 3. Impact to people 3. Automatic loading system instructs driver on actions
disconnect the (radiant heat and/or required.
arm and drives exposure to products), 4. Ignition sources controlled at top of road tanker.
away from the property and the 5. Firefighting systems.
loading bay) environment (products 6. Traffic lights (or boom gates) to be installed.
of combustion).
7. Walkway and loading arm not rigidly connected to vehicle,
4. Loading arm break-
therefore, expect minor damage only
away
20. Road accident 1. Bad road or traffic conditions 1. Most likely outcome is 1. Design of road tankers to survive accident without a loss of
(off-site) no loss of load. containment - pipes and running gear designed to shear off
2. Leak may occur, without product loss
leading to fire. 2. Driver training and choice of routes to reduce accident
3. Impact to people potential
(radiant heat and/or
exposure to products),
property and the
environment (products
of combustion)
21. Strong winds, 1. Strong winds cause equipment 1. Loss of containment 1. The tanks are designed API 650 / AS 1692 / AS 1170 to
earthquakes, damage etc. leading to a fire if resist the combined effects on internal pressure due to
floods ignited (as above) contents, weight of platforms, ladders, live loads, wind
loads, earthquake forces and hydrostatic test loads.
2. Operations stopped in adverse weather conditions
Page | 76
22. Breach of 1. Disgruntled employee or intruder 1. Possible release of 1. Security measures include fencing, CCTV, security patrols,
Security / product with operator / driver vigilance. Pressure tests prior to
Sabotage consequences as per commissioning transfer. Pipe inspections prior to
above commissioning transfer; regularly during ship discharge and
otherwise on a periodic basis
Page | 77
CHAPTER – 5 INCIDENT INVESTIGATION
XYX, (NAME HIDDEN) was start recording incident and HSE performances from March
2012.
Every accident is classified in two categories
Reportable accident - If injured person has not reported for the duty with in 48 hrs then this
accident is considered as reportable accident.
Non-reportable accidents - If injured person resumes the duty with in 48 hrs after accident, then
it is considered non-reportable accident.
Reportable accidents are further analysed on department basis, causing agent, man-days lost etc.
These reports are prepared by following method.
1. Frequency rate: - As per IS: 3786-1983. It is a ratio of number of lost time injuries per
million man hour worked.
F.R is one of important measures to know and judge the safety performance of the industry.
It is calculated as given below formula.
F.R = Nos of lost time injury x 106
Man hrs worked
2. Severity rate: - Severity rate of injuries is the ratio of number of days lost due to all disabling
injuries per million man hours worked.
S.R. is a measure to know the seriousness of the injury. S.R is calculated as given below.
S.R. = Nos. of Man days lost due to lost-time injuries x 106
Man hours worked
Page | 78
3. Frequency severity index
This given combined result of Frequency Rate and S.R. and calculated by the formula.
F.S.I. =
F.R. x S.R.
1000
Accident Analysis
Above histogram shows, as the root cause and contributory cause of accident is attacked by approved
action plan items for implementation. Number of accidents over the year has shown sharp decline.
Regular and refresher training to be imparted to all employees.
Y(10-11)
May-11
Aug-11
Nov-11
Sep-11
Dec-11
Jun-11
Apr-11
Oct-11
Jul-11
Safety USCI 40 19 13 19 22 24 26 26 26
Performance
USCE 31 14 8 15 19 20 20 20 20
SP 77.50 73.68 61.54 78.95 86.36 83.33 76.92 76.92 76.92
HSE CE 8.38 0.00 7.00 7.56 5.50 2.5 11 0.00 0.00 9.00
Training
Man days CTE 4.63 0.00 1.50 0.00 0.00 0.00 5.00 0.00 0.00 5.63
Injuries - FAI 1 0 0 0 0 1 0 1 0 0
Company
Employees MI 1 0 0 0 0 0 0 0 0 0
RI 0 0 0 0 0 0 0 0 0 0
FAI 4 0 1 2 0 0 0 0 1 0
MI 6 0 0 0 0 1 0 0 0 0
Page | 79
Injuries - RI 0 0 0 0 0 0 0 0 0 0
Contract
Workmen
Reportable CE 33542 3040 3016 2904 2920 3248 3024 2416 2416 2416
Accident
free man- CTE 27437 2960 1968 1576 1244 1786 1714 1536 1536 1536
hours
FAI - First Aid Injuries
MI - Minor Injuries
CE - Company Employee
CTE - Contract Employee
USCI - Unsafe conditions identified
USCE - Unsafe conditions eliminated
RI - Reportable Injuries
Page | 80
Safet y Performance
100.00
80.00
60.00
40.00
20.00
0.00
USCI USCE SP
Reportable Accident free man-hours

3500.00
3000.00
2500.00
2000.00
1500.00
1000.00
500.00
0.00
CE CTE
HSE Training M andays

12.00
10.00
8.00
6.00
4.00
2.00
0.00
CE CTE
Page | 81
Case – I: Incident Investigation Report
Date: December 10 2012
Address : -----------
Incident : HCl Day tank was leaked from inlet flange valve
Location of Incident : HCL day Tank
Date of Incident : December 08 2012
Time of Incident : 10 pm
Description of Incident
1. HCl day tank inlet valve found leak on 22/08/2010 at 10.30 PM

2. Nut bolt of inlet valve’s flange was broken that cause flange got open
3. Immediately security guard call to PM & PE
4. PE & PM reach at plant immediately and fixed the problem
Page | 82
Person Affected
No personal injury happened
Results of incident investigation
1. Incident was happened due to corroded bolt of inlet valve flange of HCl day tank
2. Tool box instrument not found in place at the time of leakage
3. Acid tank pump shaft was corroded
Root Cause of Incident
1. No inspection scheduled in place for acid tank area

2. Maintenance scheduled not in place for replacing the nut & bolt of HCl day tank
3. Area not clean properly
Action Plan
Actions Taken Responsibility Target compl.

date
To make scheduled for maintenances and inspection Plant Engineer Complete ( SAP )
of acid tank and auxiliary
Replace the inlet valve of tank Plant Operator Complete
Cleaning of Acid area Plant Operator Complete
Replace all nut bold of inlet and outlet line of acid tank Plant Operator Complete
Replace acid pump shaft & bearing Plant Operator Complete
To make Tool box show case board with required Plant Operator Complete
instrument
Page | 83
CHAPTER – 6 INTERNAL AUDIT REPORT AND RECOM M
Audit Type ENDATIONS
: Internal Audit
Address : ------------
SUMMARY OF AUDIT
An Internal audit of the XYX, (NAME HIDDEN). Quality System was conducted on the above date
by Internal Auditee team in accordance with the requirements outlined in IMS procedures of XYX,
(NAME HIDDEN). The purpose of the audit was to verify compliance of the implemented system to
the requirements of the company quality manual, associated procedures and ISO 9001:2008, ISO
14001:2004, OHSAS 18001:2007
Audit Team
Team Leader: Pravin Mali
Auditors: Nil
Auditee:
Department Representative Name
Production and maintains Plant Engineer
Quality Lab Analyst
Accounting and dispatch Plant JA
Page | 84
Legal/ regulatory requirements
(Functioning of legislation, Regulation periodic evaluation & reviews)
Applicable legal requirements are identified in “Legal Register” and report on the periodic evaluation
(Quarterly) is evident in the system. Review on the compliance of the legal requirements is taken in
last MRM.
Compliance of important legal requirements is verified as follows-
⸎ Air (Prevention & Control of Pollution) Act, 1981 amended 1987 & Rules, 1982 Water
⸎ (Prevention & Control of Pollution) Act, 1974, Amended 1988 & Rules, 1975
⸎ Water (Prevention & Control of pollution) Cess Act, 1977, amended 1992, Cess Rules 1978
& Water (Prevention & Control of Pollution) Cess (Amendment) Act, 2003 Environment
⸎ (Protection) Act, 1986, amended 1991 & Rules, 1986 amended 2006 The Noise Pollution
⸎ (Regulation & Control) Rules, 2000 amended 2002
⸎ The factories act, 1948 and the Maharashtra factories rules, 1963
⸎ Petroleum Act, 1934 And Petroleum Rules 2002 e.g. following Licences verified- State
⸎ pollution control board consent to operate- Consent No. --------------
⸎ Explosive licence issued by controller of explosive- Licence number- ------------
Two cycle of integrated internal audit is completed and verified during the audits. The frequency
of the internal audit is 6 monthly. Audit is conducted by external trained auditor.
11 NCRs are raised and all were closed before time limit given in the audit.
Audit Observations
⸎ Records of the business enquiries in SAP were not evident with the sales function.
⸎ Records of the telephonic verbal orders are not maintained adequately.
⸎ Review of the fire extinguishing arrangements at kerosene storage area should be done.
There is no arrangement done to communicate general safety rules for visitors and
⸎ contractors.
Mandatory PPEs mentioned in SOP are not worn by contractor workers inside plant.
⸎ E.g. helmet, goggle, hand gloves etc. as verified during plant round.
Contract condition with the subcontractors doesn’t mention specific requirement of provision
⸎ of suitable PPEs to transport personnel as well as general HSE requirements.
Page | 85
⸎ Operating procedure no.HCL/SOP/110 for transferring bitumen into pressure tank do not
address the instructions for restricting likelihood of fire since it is identified as significant risk
in register.
⸎ No coupling guards on filling motors no. 1, 2, 3 observed during plant round
⸎ Support of electrical switch panel of filling pumps no.1, 2, and 3 found to be de-rooted from
ground and rusted.
⸎ Fire extinguishers are not periodically checked for its fitness. PPE
⸎ Issue and stock register is not maintained.
Opportunities for Improvement
⸎ Record of incidences causing environmental impact can be maintained e.g. incidence of leakage
& spill from the kerosene pump on ground is not evident.
⸎ No proper route map or marking for vehicle movement with safe distance from fix installations
like storage tanks, pipelines, .building structure etc.
⸎ Training can be provided for contract employees regarding emergency plan and firefighting.
⸎ Electrical cabling and panel installations need to be checked for its fitness.
⸎ Awareness about the QHSE policy amongst staff and contractors needs further improvement.
⸎ Mock drill can be conducted when the operation is in full swing.
⸎ Proper dress code is not observed for contract workers inside plant
⸎ General display about HSE in the form of slogans, posters, sign boards, instruction can be
improved further
⸎ Hand operated emergency siren is not easily approachable and remotely placed near fire pump
House
⸎ Review can be done on the remote location of fire water pump house, which may restrict its
⸎ operation while handling fire emergency situations
⸎ Instrument for measuring flammability in the work area before giving hot work permit is not
available.
⸎ Checklist for transport vehicle inspection may be implemented
Page | 86
Positive findings and support for continuous improvement:
⸎ Involvement of the top management
⸎ Actions have been taken for Stage-I audit observations.

⸎ Identification of processes and documentation of SOP related to all identified processes.
⸎ Plant automation
⸎ Adherence to quality plans at all levels in the production process.
⸎ No customer complaints or product rejections in last year.
⸎ Legal Compliance and its evaluation
⸎ Involvement of the top management in the implementation with young, dynamic &
competent team
⸎ Resource provision by top management for implementation of the system
⸎ Integration of documentation and record system with SAP
Conclusion
All non-conformities raised during the audit are of minor nature. Management has given commitment
for taking up corrective actions and identify root cause of the non-conformities.
Legal compliance and mechanism to do significance evaluation for EMS and OHSAS aspects is
effectively implemented. Involvement of process owners in identification of risks is observed.
Overall training and competency of the people working in the organisation found adequate for
continual improvement.
Page | 87
CHAPTER – 7 CONCLUSIONS AND RECOM M ENDATION
Recommended HSE management program for XYX, (Name Hidden) Mumbai Plant are given
below
1 Preheater for Thermopack heater no. 06, this will help to reduce fuel
2 Hooter system for Thermopack heater no. 06 for high temperature and pressure alarm
HCl fumes collector - arrangement for HCl storage tank Guards for
3 modified bitumen tanks agitators for safe operation CO2 Flooding
4 arrangement for MB production tank no. 106
5 Reinforcement padding for Modified Bitumen tank for minimising vibration
6 Modified bitumen tank cleaning Tank for removing collected rubber partials on
7 edge
Supporting wall at back side of plant
8 XXXXXX arrangement for bitumen emulsion production for reduction of bitumen in
9 production by increasing viscosity of the material
Renovation of sanitary system
10 flying insects killer machines for lunch room MS
11 Scrap removal from drum filling shed area
12 PMB high shear mill for reduce fuel consumption and compressing batch time Extra
13 one Safety shower – eye fountain at HCL storage tank.
14 Stare case and ladder for FO tank for easy movement on FO tank
15 Colouring for chimney
16 one extra emergency gate for plant
17 Replacement of bitumen emulsion tank no. 8 & 9 due to corrosion Recommended HSE
18 Objective for XYX,(Name Hidden) Mumbai Plant are given below
19
Page | 88
Suggested OHSE Objective for XYX, (NAME HIDDEN), Mumbai Plant
Sr. OHSE OBJECTIVES Performances Indicator Targets

No.
1 Reduced Electricity Electricity Consumption per Ton ( 9.60

consumption 5 % of FY 10 -11 kwh/T)
3 Reduce Fuel consumption by 5 Fuel Consumption per Ton ( Lt/T) 6.80

% FY 10 - 11
4 Improve HSE performances % USCE 85%

eliminated 85 % of USCI USCE
5 Improve Turnaround time of % adherences to turn around time 100%

vehicle - Not exceed 3 Hrs for target of 3 Hrs
bulk and packed products
6 Improve customer satisfaction Customer Satisfaction survey score 80%

Index Achieve 60% out of 80 %
7 QHSE Training Training man days 125
8 Statutory Compliances Adherences to schedule 100%
Where: - USCI: Unsafe Condition Identified, USCE: Unsafe Condition Eliminated
Page | 89
Annexure – I
IMS Policy of XYX, (NAME HIDDEN)
Page | 90
Annexure – II
MINUTES OF MANAGEMENT REVIEW MEETING
Page | 91
Annexure – III WORK PERMITS
Page | 92
Page | 93
Page | 94
Page | 95
Page | 96
Page | 97
Page | 98
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Page | 101
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------------- END -----------
Page | 103

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PROJECT REPORT ONHSE MANAGEMENT

AND HAZARD IDENTIFICATION IN

HSE MANAGEMENT AND HAZARD IDENTIFICATION IN PETROCHEMICAL INDUSTRIES

ADVANCED DIPLOMA COURCE IN INDUSTRIAL SAFETY

XYX, (NAME HIDDEN), ADDRES, NAVI MUMBAI

PRAVIN NIMBA MALI

MAHARASHTRA STATE BOARD OF TECHNICAL EDUACTION, MUMBAI

THANE BELAPUR INDUSTRIES ASSOCIATION,

TECHNICAL INSTITUTE: 408

Place: Navi Mumbai

1. Discussions with concerned officials, supervisory staff and workers

CHAPTER – 1: COM PANY PROFILE...................................................................................................... 7

CHAPTER – 2 HSE M ANAGEM ENT SYSTEM ..................................................................................... 12

2.1 HSE Objectives: ...................................................................................................................... 12

2.2 Organization Commitment ..................................................................................................... 12

2.3 HSE Policy .............................................................................................................................. 13

2.3.1 Policy Commitment ......................................................................................................... 13

2.3.2 Based on these guiding principles.................................................................................... 14

2.4 M onitoring reviewing of IM S system ...................................................................................... 15

1. HQO: IM S management review committee M embers should be ..................................... 15

2. PLANTS: IM S management review committee M embers should be ................................. 15 2.4.3 The

agenda of M RC meetings has as below. .................................................................... 15

2.4.4 M anagement Review M eeting Output ............................................................................ 16

2.5 M anagement Orientation (Training Programs)....................................................................... 16

2.5.1 HSE orientation for new Joinee ....................................................................................... 16

2.5.2 HSE orientation for experienced employee ..................................................................... 17

2.5.3 HSE orientation for visitors.............................................................................................. 17

2.5.4 HSE orient at ion for cont ract ors....................................................................................... 17

2.6 Housekeeping Practices ......................................................................................................... 18

2.6.1 Elem ents of a good housekeeping campaign ................................................................... 18

2.6.2 XYZ, (NAM E HIDDEN) Check list for Housekeeping........................................................... 19

2.7 Work permit system .............................................................................................................. 20

2.7.2 HOT WORK PERM IT......................................................................................................... 21

2.7.3 CONFINED SPACE ENTRY PERM IT .................................................................................... 22

2.7.4 WORKING ON PIPE LINE CARRYING FLAM M ABLE, CORROSIVE OR TOXIC......................... 23

2.7.6 EXCAVATION PERM IT...................................................................................................... 24

2.7.7 ELECTRICAL SAFETY......................................................................................................... 24

2.8 Personal Protective Equipm ent .............................................................................................. 26

2.8.1 St atutory requirement .................................................................................................... 26

2.8.2 M aintenance and Upkeep of PPE .................................................................................... 26

2.8.3 Training on use of PPE..................................................................................................... 26

2.8.4 Work Specific PPE ........................................................................................................... 27

Provision of PPE to employees ........................................................................................ 30

2.9 Risk assessment at XYZ, (NAM E HIDDEN) ............................................................................... 31

2.9.2 On-Sit e Em ergency Preparedness & Response Plan (OSEP).............................................. 31

Communication of the Plan and Training......................................................................... 32 2.10 Safet y

Audit ......................................................................................................................... 32 2.10.1 Benefit of

2.10.2 Suggest ed Check List for Audit....................................................................................... 34

CHAPTER – 3 STUDY ON STATUARY COM PLIANCES........................................................................ 42

CHAPTER – 4 STUDY ON HAZARD IDENTIFICATION OF BITUM EN FACILITY...................................... 67

CHAPTER – 5 INCIDENT INVESTIGATION.......................................................................................... 78

CHAPTER – 6 INTERNAL AUDIT REPORT AND RECOM M ENDATIONS ............................................... 84

CHAPTER – 7 CONCLUSIONS AND RECOM M ENDATION ................................................................... 88

XYX, (NAME HIDDEN) is an engaged in the business of Manufacturing and Marketing of

⸎ Cationic Bitumen Emulsions

In the ongoing “Golden Quadrilateral” and “ North-South-East-West” corridor projects,

Sr. No. Raw Material

10 HDPE Drums – 200 kg