Uppal

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Keshavaram
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 General Inspection Checklist
Plant:

Department/Section:

Location of Inspection:

Sr.No DESCRIPTION

General

1 NO Smoking' signage is clearly displayed at main gate

2 Illumination levels are maintaining / sufficient lighting provided
3 ventilation maintaining through natural / artificial way
4 Where heat stress is a problem, do all fixed work areas have air conditioning?
5 The work area clean and orderly
6 Permanent aisles and passageways clearly marked
7 Area is Free from leakages
8 Restrooms and washrooms kept clean and sanitary
9 Floors are free from oil & chemical spillage
10 Scrap / wastage storage & handling condition is good
11 Emergency phone numbers conspicuously displayed
12 Required employees trained and certified in first aid?
13 First aid boxes available with adequate requirements
14 Collection & storage of the Haz waste infrastructure is adequate & followed
Electrical safety - ( for electricians)
15 Are the electrical panels locked properly
16 Check
Check the continuity
double and
earthing conductivity
provided for- of wires
17 a) Motors
Are connecters used are appropriate
b) Panels
18 c) Distribution boards
19 Are local lockable isolators working good
20 Are panels provided with lockout systems
21 Are wires enclosed in conduits
22 Are cable clamped properly
23 Access control available for HT area
24 Over load & short circuit protection devices available
25 lighting, welding machines & power tools ELCB/RCCB provided
26 wiring / cabling condition is free from hanging / loose
27 Panel boards & surroundings kept free to access
28 Rubber mats provided for electrical main panels
29 PPEs like HT/LT gloves using & condition is good
30 SLD Available & displayed
31 Earth pits uniquely identified & resistance displayed
32 Industrial Extension boxes using & condition is good
33 First aid for electrical shock instructions available in electrical power room
34 Lightning arrestor available & properly grounded
35 PTW/LOTO followed for electrical breakdowns /maintenance
Mechanical
36 Are valves labelled properly?
37 Check all pipelines for marking
38 Check all pipelines for colour coding
39 Check insulation of pipelines. Any damages?
40 All Rotating/dangerous parts of the machines are guarded in 360 degree
41 High RPM Machine doors /guards having interlocks
All guards are good construction, adequate strength and well maintained?
42
43 Emergency stop / local isolation device is available for the machine
44 Provisions made to prevent machines from automatically starting when Power is restored after a power failure or shutdown?
45 PTW/LOTO followed for breakdowns /maintenance of the machine
Road safety

46 Basic Road condition inside the factory is good

47 vehicle movement & pedestrian walk ways are segregated

48 Speed limit, road signs are available & followed

49 convex mirrors for blind corners available & utilized

50 Speed breakers for speed control available

51 Parking facility for office vehicles available & followed

52 Parking facility for RM & FP vehicles available & followed

53 rest rooms for drivers provided & maintained

54 access control for vehicle at security is followed

55 all Vehicle drivers having valid licence

56 over loaded vehicle entry control available

 57 hand breaks applied & wheel chocks used during parking of the vehicle

General Storage & Material handling

58 Loading & Unloading points are clearly marked

59 RM & FP lots are made as per SOP

60 level indicators of the silo/ tanks are available

61 Lot storage height indication available & Followed

62 supports/ structure for restricting damages from the vehicle available

63 Access control for silo entry available

64 Hoist equipped with a limit device to stop the hook travel at its highest and lowest point.

65 system available for stop Hoist automatically if takes load up to 125% of its rated load

66 SWL & test date visibly displayed

67 cage , rope/chain & accessories condition is good

68 Operators of the Forklift are qualified & trained

69 Forklift have a warning device that can be clearly heard above the normal noise in the operating area

70 fork lift parking brake applied to prevent the vehicle from moving when unattended

71 forklift loads lowered while traveling

Chemical storage & Handling

72 Emergency shower and eyewashes available where corrosive liquids or materials are handled

73 Chemicals are stored as per compatibility chart

74 MSDS of the chemicals available & extraction of the MSDS displayed / available

75 fire cabinets are using for storage of flammable chemicals

76 PPEs Usage

77 Chemical wash water collection & neutralization and disposal

78 provision of secondary containers to avoid spillage of chemicals

79 house keeping in lab

Fall Prevention / Protection

80 All Floor openings /open pits are covered with Gates or hand rails , Mid rails & toe guard

81 Stairs and landings are in good condition, stable and free from trip hazards

82 All ladders& platforms are uniquely identified & maintaining good condition

83 Fall arrest system available& utilizing during height work

84 All fall arresting equipments are in good &working condition

85 PTW system using for non routine height works

HOD (Name):

Inspection Frequency: Weekly / Forthnightly / Monthly

Datesof Inspection:

Weekly
Forthnightly
Monthly
 Portable, Electrical Tools & Equipment Inspection Checklist
Plant: HOD (Name):

Department/Section: Inspection Frequency: Weekly / Forthnightly / Monthly

Location of Inspection: Date of Inspection:

Weekly
Sr. No DESCRIPTION Forthnightly
Monthly
Portable electrical tools and equipment

All electrical portable hand tools (except confined space work) must be of:
1 a) 110V AC rating with power drawn from venter-tapped transformer (55V-0-55V secondary) and the secondary tapping
connected to earth
b) or 240V rating with double insulation and backed up by 30 mA ELCB
2
Connections must be by 3-core cable and 3-pin plugs and sockets, except when tools are double insulated on a 2 wire supply
3
Use of extension cable is prohibited. But when absolutely necessary, metallic extension boxes with all precautions must be taken.
4 Twisted wire connections not provided
5
Cable jointing (if absolute necessary) must be done with proper clamping and with cable lugs (no tape joints should be used)
6 Portable electric lamps must be of 24V rating. Any other handlamps with higher rating is strictly prohibited
7 Handlamps must be of dripper type with caged protection for bulb
8 All extension boxes and terminal boxes must be provided with separate 30 mA ELCB

9 Double earthing connections must be provided for all panels, junction boxes, terminal & extension boxes, all other electrical
tools/equipment when powered by 415V AC system. However, single body earthing is sufficient when powered by 240V AC system
Electrical welding and welding machines
10
Welding machines in good conditions with proper body insulation
11
Welding machines must be provided with a local lockable isolators
12 Each machine must be connected to a terminal box with a 3-core cable for single-phase machines and 4-core cables for 3-phase
machines. DIRECT CONNECTIONS TO THE BUS BAR IS STRICTLY PROHIBITED
13
All machines must be properly earthed (double earthing to be provided) and insulated switches on the machine
14 The cables must be suitable rating and must be replaced immediately if damaged. The earth cable must extend upto the welding
pint. COMMON EARTH CABLE TO ANY STRUCTURE OR PIPELINE IS STRICTLY FORBIDDEN
15
Welding machines must be protected from earth faults by providing ELCBs
16
"B" & "C" type fire extinguishers must be available near welding machines
17
Proper PPEs like leather hand gloves, welding goggles/face shields, safety shoes, hard hats etc should be used by welders
18
Incoming supply side should be provided with MCCB protection followed by 30 mA ELCB/RCCB.
19
Welding DB should eb connected to two earthing conductors/earthpits of the plant or site
20
The earth wires of welding set should be minimum of 8 SWG G.I wire
21 Welding set should have voltage reduction device (VRD) on the output side, which limits the no load terminal voltage to <18 V and
prevents electric shock
22
Welding cable should be with lug and crimped (use of bare wires with bolt & nuts is prohibited)
Drilling, Grinding machines etc.
23 All portable tools should be of 110V
24 415V/110V/24V, 2.0KVA transformer should be used and should have protection on either side of the transformer
25 No cable joint should be found for the portable tools
26 ELCB protection is required for the portable tools
27 Adequate guarding to be provided for grinding machines

28
RPM of grinding tool as well as the wheel should either match or the designed RPM of wheel above the RPM of grinding tool
29 All portable tools should have 3 pin plug pin
Compressed air tools
30 All hoses and connectors must be suitable pressure rating as per standards
31 Compressed air should not be used for body cleaning etc.
Gas cutting tools
32 Gas cylinders used for gas cutting must be kept on trolleys and strapped/fastened with chains. Cylinders must be transported on
these torlleys
33 Gas regulators and cutting torches must be maintained in a healthy condition
 Boiler Area Inspection Checklist
Plant: HOD (Name):
Department / Section: Equipment Number
Location of Inspection: Inspection Frequency: Weekly / Forthnightly / Monthly
Date of Inspection: Weekly
Sr. No DESCRIPTION
Forthnightly
Monthly
Boiler Area
1 Any loose wiring
2 Are panels closed & locked
3 Is lux level adequate?
4 Is the area neat & clean
5 Is boiler license displayed
6 Is Safe Operating Procedure displayed?
7 Is the interlock system working fine?
8 Are the glass guages (Mowbray control) in good conditions
9 Is photo cell working fine
10 Is the low pressure switch working fine?
11 Is the high pressure switch working fine?
12 Is the blow down valve working fine?
13 Is the main stop cock valve in good condition
14 Are the feed water pumps working fine
15 Is the PH of the soft water correct (6.5-8.5)?
16 Is the harness of the soft water correct ( ) ppm?
17 Check the water line for leakages?
18 Any insulation got damaged for steam line?
19 Are the pressure guages working fine?
20 Are the overhead pipeline properly fixed?
21 Is the guarding proper?
22 Is the colour coding of the pipelines correct?
23 Are the glands in good conditions?
24 Are the valves accessible?
25 Are the VFDs & other interlocks working fine?
 Fire Safety Inspection Checklist
Plant: HOD (Name):

Department - Section: Inspection Frequency: Weekly / Forthnightly / Monthly

Location of Inspection: Date of Inspection:

Weekly
Sr. No DESCRIPTION Forthnightly
Monthly
Fire Safety

Check all fire extinguishers -

1 a) Physcial condition
b) full or empty
c) any obstructions
2 All smoke detectors and MCPs are working?
Hydrant Pumps
3
Is daily check for the fire pumps have been carried out
4 Is physical condition of jockey pump ok?
5 Is physical condition of main hydrant pump pk?
6 Is physcial condition of hydrant fire engine pump ok?
7 Is sufficient diesel available in day tank for hydrant fire engine?
8
Are all pressure guages of the pumps working?
9
Is fire engine servicing done as per schecule?
10
Is double earthing of motors ok?
11
Is the start and stop set point of hydrant jockey pump correct?
12 Is the start set point of hydrant main pump correct?
13 Is the start set point of hydrant engine pump correct?
14 Is there any water leakage in pump house
15
is water connection diagram displayed properly?
16
Is there proper ventillation present in pump house
17
Is drainage system maintained properly in pump house
18
Are all pipes properly colour coded as per standard
19 Is there proper markings on all fire pumps
20 Is the fire tank cleaning date updated

Fire Pump House

21 Is fire tank filled to its maximum capacity?
22
Is system pressure at set value
23
Is system in AUTO mode
 Electrical Safety Inspection Checklist
Plant:
HOD (Name):
Department - Section:
Location of Inspection: Inspection Frequency: Weekly / Forthnightly / Monthly
Date of Inspection:
Weekly
Sr. No DESCRIPTION
Forthnightly
MV panels areas Monthly
Fire
1 Check all the fire extinguishers (refilling/service slips, date etc.)
2 Check all sand buckets
3 Check all smoke detectors
4 Whether all exit paths are clear
Electrical
5 Whether insulated rubber mats are maintained properly?
6 Whether all MV panels are secured with double earthing?
7 Whether the MV system earth pit is in good condition?
8 Whether interlocks is working properly for ACB with panel door?
9 Whether the MV single line diagram (SLD) has been maintained properly?
10 Is MV operation procedure board present in the room?
11 Is there any wall openings or holes between HV & MV rooms?
12 Is there any hanging cables?
Slip & trip
13 Whether tiles provided are anti slip and maintained properly
14 Wheter all rubber mats are placed properly
15 Is the floor flat (without ups and downs)
16 Is illumination adequate?
17 Is there any seepage?
18 Is the wall maintained properly
19 Is the temperature of the room proper
Equipment/Mechanical
20 Check PPE (working condition, missing, anything needed extra etc.)
21 Whether MV gloves are maintained properly?
22 Whether mask present in the room
23 Whether axe present in the room
24 Is electrical shock treatment chart present in the room
25 Is the list of licensed electrician available and displayed?
26 Is important telephone numbers displayed in the room?
27 Is first aided board present?
28 Is LOCKOUT device, danger sign card available in appropriate box
UPS
UPS installations/rooms
29 Has the preventive maintenance done properly
30 Is the ventillation proper
31 Is the exhaust fan in good condition
32 Are the battery terminals and connections in good conditions
33 Is illumination adequate
34 Is the double earthin proper
35 Are the rubber mats in good conditions
UPS battery bank
36 Has cleaning done peoperly?
37 Is the ventillation proper
38 Is the exhaust fan in good condition
39 Are flame proof light fitting in good conditions
40 Is illumination adequate
41 Are the hydrogen/smoke detectors in good conditions
42 Is the battery MCCB cable in good conditions
43 Is the airconditioning proper?
High voltage area
Fire
44 Check all the fire extinguishers (refilling/service slips, date etc.)
45 Check all sand buckets
46 Check all smoke detectors
47 Whether all exit paths are clear
Electrical
48 Whether insulated rubber mats are maintained properly?
49 Whether all HV panels are secured with double earthing?
50 Whether the HV system earth pit is in good condition?
51 Whether interlocks is working properly for VCB with panel door?
52 Whether the HV single line diagram (SLD) has been maintained properly?
53 Is HV operation procedure board present in the room?
54 Is there any wall openings or holes between HV & MV rooms?
55 Are HV earthing trolleys labelled properly?
56 Is the trench covered and yellow marked?
57 Is there any hanging cables?
58 Is HV log book present in the room
59 Is trench filled with sand?
Slip and Trip
60 Whether tiles provided are anti slip and maintained properly
61 Wheter all rubber mats are placed properly
62 Is the floor flat (without ups and downs)
63 Is illumination adequate?
64 Is there any seepage?
65 Is the wall maintained properly
66 Is the temperature of the room proper
Equipment/Mechanical
67 Check PPE (working condition, missing, anything needed extra etc.)
68 Whether HT gloves are maintained properly?
69 Whether mask present in the room
70 Whether axe present in the room
71 Is electrical shock treatment chart present in the room
72 Is the list of licensed electrician available and displayed?
73 Is important telephone numbers displayed in the room?
74 Is first aided board present?
Transformer room
75 Are 11 Kv rubber mats present? Condition good?
76 Is the ventillation and illumination arequate?
77 Is the transformer door interlock with VCB, working properly?
78 Is the temperature relay working properly
79 Is double earthing proper
80 Is the transofrmer door lock in good conditions
81 Are smoke detectods working properly
82 Is the transformer neutral earthing in proper condition
83 Check for general housekeeping