SAFETY AUDIT QUESTIONNAIRE
SAFETY AUDIT QUESTIONNAIRE
(Clause 4.3.3.1)
HEALTH AND SAFETY POLICY
- Does the organization has a health and safety policy? (if yes, please attach one copy)
- Do you have any corporate safety policy? (if yes, please attach one copy)
- Who has signed the health safety policy? (indicate his position)
- Whether it is prepared as per guidelines of the statutory provisions?
- When was the safety policy declared and adopted?
- How many times it has been updated till now?
- Whether the policy is made know to all?
- Whether the safety policy was scrutinized by outside expert agency?
- What was the last date of updation?
- Does it find a place in the annual report?
SAFETY & HEALTH ORGANIZATION
(A) Safety Department
- Does the factory has a safety department?
- If yes, furnish the following information:
- Head of the safety department:
- Name
- Designation
- Qualification
- Experience
- Status
- Strength of the safety department including safety officers and staff.
- Head of the safety department:
- Does the head of safety department/safety officer report to the chief executive?
- How often are the safety officers retrained in the latest techniques of total safety management? What is the frequency of retraining?
- What additional duties the safety officer is required to do?
- What is the power of safety officer vis-a-vis unsafe condition or unsafe act?
(B) Safety Committee (s)
- Does the factory has a safety committee(s)? Give details of their types, structures and terms of reference.
- Is the tenure of the safety committee(s) as per the statute?
- How are the members of safety committee (s) selected? (elected/nominated)
- How often are the meetings of safety committee(s) held?
- What are the subjects? Are the problems discussed in the meetings? (Attach a copy of agenda and minutes of the last meeting)
- How are the recommendations of the committee(s) implemented?
- Are the minutes of the safety committee(s) meetings circulated among the members?
- Are the minutes forwarded to the trade union(s) and chief executive and occupier?
- How the management and trade union play their active roles in supporting and accepting the committee(s) recommen- dations?
- How are the safety committee(s) members apprised of the latest developments in safety, health and environment?
(C) Safety Budget
- What is the annual safety budget?
- How much percentage is this budget of the total turnover of the company.
- How much budget has utilized till date?
- Is the safety budget adequate?
- How is the safety budget arrived at?
- What is the pattern of expenditure for the last five years?
- What are the approved sanctions for the expenditure in this budget?
- Does this budget get reflected in the annual report of the company?
ACCIDENT REPORTING, INVESTIGATION AND ANALYSIS
- Whether the accident data for the last three years for reportable and non-reportable accident available?
- Is there any system of classifying and analyzing the near-miss incidents and accidents? Give the details.
- Are all near-miss incidents and accidents reported and investigated?
- For how many years are the investigation reports retained?
- By whom the accident statistics and data are maintained? 8
- How is the top management apprised of these data?
- Is the accident statistics effectively utilized? If yes, how?
- What nature of injuries occurred during the last three years?
- How do you ensure implementation of the recommendations to avoid the recurrence of the incidents and accidents?
SAFETY INSPECTIONS
- What type of safety inspections are carried out and what are their frequency?
- Is there any system of internal inspection?
- Who does the inspections?
- Are the check-list prepared for these inspections? (Specify item-wise, for example, housekeeping, fire protection, etc).
- To whom the recommendations are submitted?
SAFETY EDUCATION AND TRAINING
Training
- Is there any training department?
- Is there any programme of induction training?
- Mention the duration of induction training for each category of employees.
- Whether the assessment of the trainee worker is done or not?
- What infrastructural facilities with audio-visual support are available for training?
- Do the programmes cover the plant safety rules, hazard communication and any other special safety rules or procedures unique to the plant or specific departments?
- Whether the training programmes are conducted in the local language?
- Whether visits to safety institutions/organizations are arranged?
Periodic Training/Retraining
- Are all the employees trained and what is the frequency of such training?
- Do the training programmes cover safety and health aspects and if so how much (in terms of number of sessions/hours)?
- Do the trained supervisors train their own employees in safety and health aspects?
- Is the retraining performed whenever new hazards/process changes are followed/introduced?
- How are the senior management personnel trained in safety and health?
- How many employees have been trained in safety and health in the last five years? Give break up with details.
- How many man-days/hours are used in training the employees?
- How do you ensure that the training is put to use by the employees trained in safety and health.
- What is the training plan for the next two years? Give details.
- What documentation system has been established regarding safety and health training?
Safety Communication/Motivation/Promotion
- Does the factory has safety suggestion schemes? Give details.
- Does your factory participate in National Awards/Suggestion schemes?
- Has your factory been awarded during last five years?
- Are safety contests organized in the factory? Give details.
- What are the publications of your organization? Do they include information on safety and health subjects?
- Is the literature on safety and health made available to the employees?
- How is the safety and health publicized in your factory?
- Bulletin boards?
- Post serious accidents?
- New letter?
- Others? Specify
- Does the organization celebrate safety day/week or organize safety exhibition?
- When was the last safety day/week celebrated?
FIRST AID
- Are adequate number of first aid boxes provided? Give location details?
- Is there any first aid/ambulance room?
- Are qualified/trained first aid’s available in each shift?
- How many qualified/trained first aide’s are available at each plant/department?
- How many persons are trained/given refreshers training in first aid in a year?
OCCUPATIONAL HEALTH CENTRE
- Whether occupational safety and health center is provided or not?
- Does it conform to the provisions of the existing legislation? 9
- Are the Medical Attendants/Doctors available in each shift?
- Is ambulance van available in each shift?
- Any liaison with the nearest hospital(s)? Give details.
GENERAL WORKING CONDITION
(A) Housekeeping
- Are all the passages, floors and the stairways in good condition?
- Do you have the system to deal with the spillage?
- Do you have sufficient disposable bins clearly marked and whether these are suitably located?
- Are drip trays positioned wherever necessary
- Do you have adequate localized extraction and scrubbing facilities for dust, fumes and gases? Please specify.
- Whether walkaways are clearly marked and free from obstruction?
- Do you have any inter-departmental competition for good housekeeping?
- Has your organization elaborated good housekeeping practices and standards and made them known to the employees?
- Are there any working conditions which make the floors slippery? If so, what measures are taken to make them safe?
- Does the company have adequate measures to suppress polluting dust arising out from road transport?
(B) Noise
- Are there any machines/processes generating noise? Specify.
- Was any noise study conducted?
- Which are the areas having high-level noise?
- Have engineering and administrative controls been implemented to reduce noise exposure below the permissible limits?
- Is there a system of subjecting all those employees to periodic audiometric test who work in high level noise areas?
- Whether the workers are made aware of the ill-effects of high noise.
- Whether any personal protective equipment along with ear muffs/plugs are provided and used.
(C) Ventilation
- Whether natural ventilation is adequate or not?
- Whether dust/fumes/hot air is generated in the process? Give details.
- Is there any exhaust dilution ventilation system in any section of the plant?
- Whether any ventilation study has been carried out in the section(s) to check the record?
- Are periodic/preventive maintenance of ventilation system carried out and record is maintained?
- Does any ventilation system recirculate the exhausted air in work areas?
- Is the work environment assessed and monitored?
- Whether personal protective equipment are given to workers exposed to dust/fumes and gases? Give details.
Illumination
- Was any study carried out for the assessment of illumination level?
- Is there any system of periodical cleaning and replacing the lighting fittings/lamps in order to ensure that they give the intended illumination levels?
- Are the workers subject to periodic optometry tests and records maintained? Give details.
HAZARD IDENTIFICATION AND CONTROL
- Are all the hazardous areas identified?
- What are the types of hazards (physical- noise, heat, etc, and chemical-fire, explosion, toxic release, etc)?
- What steps have been taken to prevent these hazards? Give details.
- Are there any safety inter-locks, alarms and trip system? Give details.
- Are these tested periodically? How often? Please specify.
- Are there any ambient monitoring devices with alarms for leakage of hazardous materials? Give details.
- Are safety audit or HAZOP or any other studies carried out and the recommendations implemented? Give details.
- What has been the major modification done in plant/process and has the approval of the competent authority concerned?
- What decision and monitoring equipment are available and used for checking the environmental conditions in and around the plant? Give details.
TECHNICAL ASPECT
Safe Operating Procedures
- Are written safe operating procedures available for all operations?
- Whether the written safe operating procedures displayed or made available and explained in the local language to the workers?
- Whether the safe operating procedures are prepared jointly by the plant and safety departments?
- What system is used to ensure that the existing safe operating procedures are updated? Give details.
- Have the workers been informed of the consequences of failure to observe the safe operating procedures?
- Are contractor workers educated and trained to observe safety at workplace?
- Whether contractor’s workers are permitted on process/operations? Give details.
WORK PERMIT SYSTEM
- What necessary type of work permits exists in your factory? Give details.
- What are the hazardous chemicals handled?
- Are the keys kept for individual locks which are used for electrical lock outs with the supervisor concerned?
WASTE DISPOSAL SYSTEM
- Is identification done for various types of wastes? Give details.
- Are these quantities less than those specified by the hazardous wastes. (Management & Handling Rules, 1989)?
- What are their disposal modes?
- What are the systems/measures adopted for controlling air/water/land pollution?
- What is the system of effluent treatment plant and whether it is approved by the competent authority?
- How are the treated effluent used?
PERSONAL PROTECTIVE EQUIPMENT (PPE)
- Has a list of required PPE for each area/operation been developed and the required PPE is made available to the workers?
- Are the safety department and the workers consulted in the selection of PPE?
- Have the workers been trained in proper use of PPE?
- What is the system of replacement/issue of PPE?
- What are the arrangements for safe custody and storage of PPE provided to the workers?
- Are the contractor’s workers provided with the required PPE? Who is responsible? Give details.
- Are the PPE conform to any standard? Give details.
- Give the details of PPE and also specify the responsibility for their inspection and maintenance?
FIRE PROTECTION
- Indicate on a plant layout the location, number (Quantiy) and types of portable fire extinguishers available.
- Are the fire fighting system and equipment approved, tested and maintained as per relevant standard?
- What is the inspection and maintenance schedule of the above extinguishers? Who performs these functions?
- Which areas of the plant are covered by fire hydrants? Indicate the locations of the hydrant points and how the required pressure maintained in the system and ensured.
- What is the capacity of dedicated water reservoir for supply to the hydrants? What is the source of water?
- How is the power supply to the fire hydrant pump ensured?
- What is the Alternate source of supply in case of power failure? Give details.
- Are all personnel conversant with the fire prevention and protection measures? Give details.
- What percentage of plant personnel and staff and officers, have been trained in the use of portable fire extinguishers? Give details.
- Do you have fixed or automatic fire fighting installation(s) in any section of your plant?
- Are the fire alarms adequate and free from obstruction?
- Do you have fire department? If yes, give details.
- What is the system for conducting mock drills? Give details.
- Do you have any mutual aid scheme with any of your neighbouring industry or any local organization(s)?
- Give details of the existing fire resistant walls and doors.
- Do you have any system of colour coding for all the pipelines for hazardous chemical? Give details including marking of flow directions.
- Are there any safe containers for the movement of small quantities of hazardous chemicals? Give details. 11
- Are all self-closing fire doors in good condition and free from obstructions?
- How many major and minor incidents/fires were there in the factory during the last five years? Give department/plant-wise.
- Have all the fires/incidents been investigated and corrective actions taken? Give break up.
EMERGENCY PREPAREDNESS
- Is there an on- site emergency plan for your factory? (attach a copy of the plan)
- What is the frequency of conducting mock drills of on-site emergency plan?
- What are the number and location of emergency control centre, assembly points?
- Whether emergency team or the key personnel identified?
- Are suitable and adequate protective and rescue equipment available? How is the emergency rescue team trained to use these equipment?
- How is the emergency communication with local bodies and other organizations ensured? Give details.
- Is any alternate power source identified? Give details.
- What is the medical emergency response system? Give details.
- Are you a member of any MUTUAL-AID-SCHEME of your area? If so give details.
- How many emergency alarm system(s) is/are available? Give details.
PLANT LAYOUT AND AREA CLASSIFICATION
- What is the system of classification of hazardous zones in the plant for electrical installations? Please specify.
- Whether periodic inspection and preventive maintenance of electrical installations is done by a qualified person and record is maintained?
- Whether plant layout with area classification has been displayed at appropriate place (s)?
STATIC ELECTRICITY
- Whether the process(s) and equipment generate and accumulate static charge have been identified? Give details.
- Whether all such equipment are properly bonded and earthed?
- How is electrical resistance for earthing circuits maintained? Are periodic inspections done and recorded?
- Are adequate earthing arrangements made at the terminal points where hazardous chemicals are handled through pipes?
- Are anti-static charge devices fitted wherever necessary?
- Whether these devices are periodically checked and maintained by a qualified person?
PRESSURE VESSELS (FIRED AND UNFIRED)
- Give details of the plants, piping and vessels which are operated at a pressure greater than the atmospheric pressure?
- How is it ensured that the working pressure inside the pressure vessels/pressure plants will not exceed their maximum working pressure for which it is designed?
- What means of isolating the pressure vessels or means to prevent rise in pressure are installed?
- What standards/codes of practice are adopted for design, fabrication, operation and maintenance of the pressure vessels and records maintained?
- How are the pressure vessels tested? Give details.
- Is there any competent person for testing these pressure vessels? Give details.
- How are the recorded results verified?
- Give details of safety devices available for these pressure vessels?
- Whether log book for pressure vessel and pressure plant has been maintained?
NEW EQUIPMENT REVIEW
- What is the system for effecting any change in the existing plant, equipment or process? Whether it is approved by the appropriate competent authority?
- Whether the P & I diagrams and other related documents are updated accordingly?
LIFTING MACHINES & TACKLE
- Whether all the lifting machines are marked with their S. WL.?
- Are all the examinations and tests documented in the prescribed form?
- Are all the examinations and tests carried out and certified by competent person(s)? Give details.
- Are adequate lifting tackles provided at all the places where it is required? Give details.
- Are the trained operators engaged for operating the equipment? Give details. 12
- What is the system of training such operators?
- Are all the lifting machines and tackles maintained in good conditions and record maintained?
MOBILE EQUIPMENT AND VEHICULAR TRAFFIC
- Are all the mobile equipment in good condition?
- Are trained drivers engaged for fork-lift trucks?
- What is the system for identifying these drivers from other drivers?
- What system do you adopt to assess their standard of driving as poor/fair/satisfactory/good?
- Are there adequate number of warning signs/signals?
- Are the hazards associated with transportation within the plant identified and safety measure taken? Give details.
ACCESS
- Is adequate safe access provided to all places where workers need to work?
- Are all such access in good condition?
- Are portable access platforms necessary? If yes:
- Are these sufficient?
- Are these regularly inspected?
- Are these readily available?
- Are these provided with toe-boards and railings?
- Oiling and greasing points:
- Are these located and extended to safe place clear of moving parts?
- Are these easily accessible?
- Are these liable to drip into walkways?
- Whether such workers were trained and whether they are provided with fit-tight clothings and register is maintained?
- Are all drain covers in good condition and fitting flush?
MATERIAL HANDLING
- Are there adequate storage facilities available?
- Are these areas clearly defined?
- Are all racks and steel ages in good condition?
- Have you adequate equipment for handling materials?
- Do the workers know the hazards associated with manual material handling?
- Where manual handling is necessary, are the workers been trained?
- Do they practice this?
- Do workers follow safe procedures for storage of materials?
- Whether contractor workers are trained in safety?
- What is the system for handling over plant to the maintenance department and receiving back?
- Is the system consistently applied?
- What is the system for the preventive and predictive maintenance and how do you ensure its effectiveness? Give details.
TANK STORAGE VESSEL AREA
- Whether it is pressure vessel or not.
- Give storage vessels designation (exceeding threshold quantities specified in MSIHC, Rules 1989).
- Give the names of storage materials in each of them.
- What are the vessel sizes (capacity in tonnes)?
- What is the material of construction for each vessel and what standards followed in designing/fabricating the vessel?
- What are the operating pressure and temperature?
- What are the vessels location? (Please indicate on-site plan or plot plan)
- Indicate whether vessels are above ground/underground.
- If any of the tanks storing flammable material, whether electrical installations are flameproof or not?
- Are these storage vessels bunded/dyked?
- If yes, what is the capacity of the bunds/dykes?
- Are the vessels properly bonded and earthed and whether periodically checked and record maintained?
- How are vessels isolated in the event of a mishap?
- Are the vessels fitted with remotely controlled isolation valves?
- Are vessels provided with emergency vent, relief valve, bursting disc, level indicator, pressure gauge, overflow line?
- Where do such vents discharge?
- Are the vessels provided with alarms for high, level, high temperature and high pressure?
- Are stand by empty tanks provided for emptying in case of emergencies?
- What are the provisions made for firefighting/tackling emergency situations around the storage vessels?
- Has any consequence analysis been carried out for these vessels? (If yes, give details) 13
- What periodical testings are carried out on the vessels to find out the integrity of the vessels?
- Whether these tests are certified by the approved competent persons?
- Whether log sheets are filled up on daily basis for recording the parameters of these vessels?
ON-SITE GAS CYLINDERS STORAGE AREA
- What are the various gas cylinders used in the plant? (give details).
- What are the storage facilities?
- What are the measures taken for combating any emergency in the cylinders storage area?
- Are valid licenses available for storing all these cylinders?
- Whether integrity test certificates are obtained from the suppliers of the cylinders?
COMMUNICATION SYSTEM ADOPTED IN PLANT
- Are public address system available in all plant areas?
- Are public address systems provided with uninterrupted power supply?
- Whether public address system is checked periodically for its proper functioning?
- Is there any hot line provided to fire station?
- What is the means of communicating emergency in the plants?
TRANSPORTATION
- What potentially hazardous materials are transported to or from the site (including wastes)?
- What modes of transport are used:
- Road?
- Rail?
- Pipelines?
ROAD
- Does the company employ licenced vehicle of its own/outside sources?
- Are the loading/unloading procedures on- site and safety precautions displayed?
- Are loaded tankers or trucks parked in a specific area on-site?
- Do all truck and tanker drivers carry TREM card or instruction booklet?
- Do all truck and tanker drivers get training in handling emergencies during transport?
RAIL
- What hazardous materials are transported by rail?
- Does the company have a direct siding on site?
- Are tankers or others wagons used in transportation?
PIPELINES
- What materials are transported to and from the site by pipeline?
- Are the pipelines underground or overground?
- Are corrosion protection measures employed in pipelines?
- Whether intermediate booster pumps are used?
- What is the maximum, minimum and average transfer rates?
- Are the pipelines extended in the public domain?
- Are the pipelines dedicated for each type of chemicals?
- Are the pipelines fitted with safety equipment such as leak detectors, automatic shut-off valves, etc?
- What is the frequency and method of testing of the pipeline?
- Is there written procedure for tackling leakages in pipeline?
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