CHECK LIST FOR SAFETY AUDIT

(Documentation of information pertaining to applicable points only)

1. GENERAL INFORMATION:
Name of the Factory NMDC STEEL LIMITED

Name of the Occupier B R K SETTY

Name of the Factory Manager

Auditee Department / Section ENERGY MANAGEMENT DEPARTMENT

Nature of Process
Endothermic -
Exothermic -
Continuous Yes
Is Flow Sheet available? Yes
Is Piping & Instrumentation Diagram available? Yes
Main Activity Fuel gas and utility management.
Rated Capacity 3MTPA
Average Capacity -
Utilities(Consumption quantities and Operating parameter to be mentioned):
Steam 9 Kg/cm2-10 TPD
13 Kg/cm2 -50 TPD
16 Kg/cm2 -20 TPD
66 Kg/cm2 -30 TPD
Total generation-100~150TPD
Electricity -
Instrument Air 5000m3/Hr.(8~9Kg/Cm2)
Cooling Water -
Fuel Gases (CO/BF/LD/Hydrogen/Propane) COG-72000Nm3/Hr(800-1000mmwc),BFG-
400000Nm3/Hr.(800mmwc)
Fuel Oil (Furnace Oil/Petrol/Diesel)
Nitrogen Gas 1800Nm3/Hr (6~8Kg/cm2),
Manpower:
Executive 29
Non-Executive 23
Contractor’s Employee 65
2. ACCIDENT STATISTICS OF THE DEPARTMENT/SECTION:
Current Year 2024 (till date) Last three years Remarks
F R N.R F/Aid NM DO Year F R N.R F/Aid NM DO
2023 NIL NIL NIL NIL NIL 01
NIL NIL NIL NIL NIL NIL 2022
2021
N.B F: Fatal, R: Reportable, N.R: Non-Reportable Accident, F/Aid: First Aid Cases, NM: Near Miss, DO:
Dangerous Occurrences

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3. PROCESS:
a) HAZARDOUS CHEMICALS & GASES (As per Schedule-I of OSHWC code-2020)

Sl.
Name Nature of Hazard Production / Used Quantity
No.
1. Coke oven gas Gas Poisoning 72000Nm3/Hr/ Full
2. Blast furnace gas Gas Poisoning 400000 Nm3/Hr/350000Nm3/Hr
b) EXPLOSIVE LIMITS
Sl.
Name Lower Limit Higher Limit
No.
1. Coke oven gas 7% 30%
2. Blast furnace gas 45% 70%
c) GENERAL ASSESSMENT OF HAZARDOUS INSTALLATIONS

Sl. State of House

Name of Equipments etc. Accessibility Painting
No. Maintenance Keeping
1. Coke oven gas network Yes Healthy Good In progress
2. Blast furnace gas Yes Healthy Good In progress
3. Gas Boosting & Mixing Yes Healthy Good In progress
Station
4. Coke oven Flare stack Yes Healthy Good In progress
d) GENERAL ASSESSMENT OF CHEMICALS AND GASES IN STORAGE TANKS

Sl. Chemical/Gas Pressure Permissible

Type Nos. Capacity M3 Temp. Deg. C
No. Name Kg/Cm2 Pressure
1. -NA- -NA- -NA- -NA- -NA- -NA- -NA-
4. ACCIDENT REPORTING, INVESTIGATION & ANALYSIS
SN Points Auditee Reply Remarks
1. Reporting system for work place injuries (fatalities, Yes Attach an approved
Reportable & non reportable accidents) to IOF copy of Plant’s IOW
statutory authorities & local management procedure
2. Are work place injuries records being maintained in Yes Last injury record to
department? be produced
3. Whether dangerous occurrences / near miss cases Yes If so, attach list of NM
are reported & investigated? & DO cases occurred
during last 3 years
with date, location,
brief & cause. Along
with this, copy of last
investigation report
also to be furnished
4. Is there any system of classifying and analyzing the Yes, register is being What system exists,
near-miss incidents and accidents? Give details. maintained to record give details?
NM, DO in department
and plant wide NM,DO
are discussed in
monthly safety review
meetings.
5. For how many years are the investigation reports From Oct-22
retained?
6. Whether accidents (Fatal/ Reportable/ Non Reportable-Yes Copy of last report for
reportable) are investigated? each category
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 7. How do you ensure implementation of the - Give example of last
recommendations to avoid the recurrence of the case.
incidents and accidents?
8. Action taken details for all accidents and near miss Yes Copy of ATR for last
cases are documented properly or not? case
9. Analysis & documentation of all repetitive accidents - Copy of last analysis
and near miss cases. done
10. Documents pertaining to investigations maintained at Yes Copy of last few
Department? investigations
11. Whether counseling of employees meeting with an System exists If yes, counselling
accident is made? done at different levels
to be explained
12. Is there any system of reporting of repetitive Being reported to Explain the
accidents and near miss cases to Higher safety department methodology followed.
Management?

5. SAFETY STUDIES AND FORESEEABLE HAZARDS:

SN Points Auditee Reply Remarks
1. What are the possible major hazards? Fall of persons,
 Physical – Fall of persons & objects, traps, asphyxiation,
entanglement, Hit by objects / machines etc. fire, explosion,
 Chemical (Solid/ liquid /Gas) - Spillage, asphyxiation, toxic release,
fire, explosion, toxic release, etc. steam, noise,
 Electrical – electrocution, burn etc. heat, dust,
 Thermal- hot metal, slag, steam, sparks etc. oxygen
 Environmental / atmospheric – Noise, heat, dust, poor deficient
illumination, poor ventilation, oxygen deficient atmosphere,
atmosphere, confined space etc. confined space.
 Radioactive - UV, Infra red, laser, X- Rays etc.

2. What techniques adopted to identify the hazard? Inspections Give details

(Inspections / Audits/ HAZOP/ What If / FMEA etc)
3. What techniques adopted to assess the Risk? Qualitative Give details
Qualitative / quantitative ( HIRA / risk modelling ) (based on
experience)
4. Are results & recommendations documented? In SOP & SMP Furnish Copy
5. Implementation of recommendations. - Furnish copy of
measures taken
6. Is there any system of reviewing the effectiveness of - Furnish document
above implementation?
7. Major modification done in plant/process. Whether the Number of Furnish copy of record.
approval of concerned competent authority was obtained? modifications
were done:
1) Provision of
emergency
purge system
to maintain
network
pressure.
2) Acess
platforms for
operation &
maintenance.
3) Providing
extra valve in
3
 U-seals.
4) Coke oven
flare stack
control system
back up with
UPS.
5) Modification
of PCV actuator
system.
6) Purge In
&out system
have been
implemented in
GBMS area for
safe charging.
7) Condensate
pit along with
piping. Yes,
approval taken
from competent
authority.
8. Whether advanced safety management system e.g. - If so, attach copy of
OHSAS / ISO -45001 implemented. certification
9. List of HIRAC & OCPs prepared In progress Furnish updated list and
few sample copies of
both.
10. Whether legal & risk register prepared? No If so, attach copy
11. Date of Last internal & surveillance audit under OHSAS/ No Furnish copy of
ISO compliance report
12. System of following studies with report & compliance No Attach copy of last
- Internal safety audit studies
- External safety audit
- HAZOP

6. SAFETY POLICY:
SN Points Auditee Reply Remarks
1. Is a documented Safety & Health Policy signed by Yes
occupier available as per statutory provisions?
2. Is the safety target described? -
3. What was the last date of updating? Jan 2021 Furnish copy of last
updated policy
4. Is it displayed in the Offices and Notice Boards? Yes
5. Whether pocket size safety policy has been prepared in No If so, attach a sample
Hindi/ other language understood by majority of people of this.
6. Display of the Safety Policy at strategic locations on large Yes Mention the locations
boards/hoardings (in local language also).
7. What is system of review of safety policy ? - Explain

7. WORK PERMIT & PROTOCOL SYSTEM:

SN Points Auditee Reply Remarks
1. Are jobs requiring PTW and Preparation of protocols in Yes If yes, give the list.
the deptt. identified.
2. Plant Start-up and Shutdown Procedure. SOP Give details
3. Whether relevant MoS: Safety Guideline for Iron & Steel PTW evolved
Industry SG-04- PTW ( Opn & Maint) /IPSS 1-11-007-20 from safety
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 are incorporated in PTW system or not? department
4. Are protocols are prepared in line with IPSS / MOS Yes If so, attach a sample
guidelines protocol of last major job
executed
5. Whether concerned employees have knowledge of the - Record of training
standards?
6. Whether PTW is obtained for :
Working at Height (Refer: MoS:SG-02). Yes
Working inside Confined Space (as defined in MoS:SG- Yes Furnish copies of last
03). PTW taken in respects of
Hot work. Yes these jobs, if any
Cold work. Yes
Gas line jobs (Refer: MoS:SG-21 Handling of Fuel Yes
Gases)
Electrical jobs (Refer: MoS:SG-15 Elect Safety). Yes
Energy Isolation Yes
7. Whether LOTO system is followed along with PTW Yes If so, explain in brief
system?

8. Standard Working Procedures (SOPs , SMPs , WIs etc.):

SN Points Auditee Reply Remarks
1. Whether Safety Manual is available? (when was it last Yes Furnish Copy (Soft) of
updated) latest updated manual.
2. Are written Standard Working Procedures (SWP) Yes Furnish list of SWPs with
available for all activities? their document number
and date of last updation.
3. Whether JSA / JHA done before preparing SWPs ? - If so, attach sample copy
of JSA/JHA
4. Whether safety provisions detailed in SWP? Yes, Need of List of SWPs last
Update didn’t updated.
arise.
5. What is the system of SWP review & its frequency? Annually Detailed to furnish.
6. Whether the salient work instructions displayed or made No Display locations with
available and explained in the local language to the photograph to furnish
workers?
7. Who all are involved in preparation of SWPs? All concerned
In-charges.
8. Whether SWPs are available at point of use? Yes
9. Whether updated SWPs are available on web portal? No, Web portal
not available.
10. Have the workers been informed of the consequences of Yes
failure to observe the SWP?
11. How it is ensured that workers adhere to these Regular
procedures? interaction and
during tool box
talk.
12. How are the employees (regular)/ contract workers Copy of Record to furnish
trained on SWP?

9. ON-SITE GAS CYLINDERS & STORAGE AREA:

SN Points Auditee Reply Remarks
1. What are the various gas cylinders used in the LPG & Oxygen
Department? Give details. (Refer: MoS:SG-01 Storage,
Handling & use of Gas Cylinder followed)?
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 2. What is system of inspection of cylinders, their validity & Centrally
testing? procured.
3. What are the storage facilities? Are there separate areas Yes Furnish photograph of
for empty & filled cylinders? storage area
4. Whether cage with chaining arrangement is available for Yes
vertical storage of cylinders when not in use. Are valve
protection cap fitted?
5. Are the cylinder is painted with appropriate identification - Explain the code being
colours specified in IS:4379. followed.
6. What are onsite transportation facilities for cylinders? Manual Trolley
7. What are the measures taken for combating any Fire Give details
emergency in the cylinder’s storage area? extinguisher
provided near
storage.
8. Are the cylinders are marked & levelled as per provision
of Gas Cylinder Rules, 1981?
9. Whether the safety devices provided with gas cylinders as Explain
per IS-5903:1970.

10. SAFETY DEVICES, EQUIPMENT ETC.:

SN Types Auditee Reply Remarks
1. Whether interlocks are identified & categorized List of interlocks with last checking
as per criticality? What is the system & date
frequency of testing?
2. Are accessories to high Pressure equipments
like pressure relief valve, flow control valve,
temperature sensor, etc identified? What is
system & frequency of testing?
3. Machine / Coupling Guards (fixed & movable) / Furnish copy of last inspection
System of inspection (Refer: MoS:SG-09 for done for each
Equip. & M/c guarding & SG-11 for
Barricading)
4. Nos. of Pull chord, Belt Sway, Zero Speed
switches etc. What is system & frequency of
testing? (Refer: MoS: SG-24 for O&M of
Conveyor Belt)
5. System of checking safety devices in Cranes. Explain
6. What is the system of bypassing interlocks,
whether approval obtained & recorded? What is
the system of normalizing it?

11. Statutory Requirement (As per Factory Act, 1948, SMPV Rules, State factory rules etc.)
SN Types Auditee Reply Remarks
1. Pressure vessels Furnish the details of competent
persons & validity of authorization (in
- Internal
case they are plant employees) &
- External Copy of last test conducted.
- Hydro testing
- NDT

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 2. Lifting Machines (mobile &
EOT Cranes)
3. Lifting tools & tackles
- Chain Pulley Block
- Slings
- Hooks
- Shackles
- Eye bolts
- Winch etc.
4. Hoist & lifts

12. SAFETY OF PLANT, MACHINES AND EQUIPMENTS,

SN Points Auditee Reply Remarks
1. What is the system of Maintenance of Plant &
equipment?
2. Is there any system of granting approval of any System details and copy
modifications in process layout, Plant & equipment after of last approval to furnish
anlaysing the risks? Give details.
3. Are Schedule for preventive maintenance, checklists & Copy to furnish
SMPs available.
4. Schedule for inspection & preventive maintenance for Copy of schedule along
process critical Safety equipment (such as interlocks, with last inspection done
pumps, compressors, valves, storage tanks, relief valve, to furnish
sensors etc.).
5. Are all the motor couplings covered? What is system & Furnish some
frequency of inspection? photographs
6. Are all parts of moving machineries adequately Furnish some
guarded? What is system & frequency of inspection? photographs
7. How foolproof energy isolation is ensured before Documented Evidence
undertaking any repair / maintenance of equipment
( Refer MoS:SG-22 for Energy Isolation)

13. PIPELINES:
SN Points Auditee Reply Remarks
1. What materials are transported to and from the site by
pipelines?
2. Are the pipelines under ground or over ground?
2a. Gases
2b. Water P & ID of each diagram
2c. Chemicals to be furnished.
2d. Steams
3. Are corrosion protection measures employed in pipelines? System & frequency.
4. Are the pipelines extended in the public domain?
5. Are the pipelines fitted with safety equipments such as Furnish the list of safety
leak detectors, automatic shut off valves, flow monitoring, items
static charges discharge system etc.?
6. Is there any system of checking, testing and rectification Furnish the copy of last
of Safety equipments as mentioned above? Give details. inspection done
7. What is the frequency and method of inspection of the Furnish the copy of last
pipelines? Is it documented properly? inspection
7
 8. Is there any Committee or Task group constituted for Give details
checking condition of pipelines (Gas, Steam, Water etc.)?
9. Is there any written procedure for tackling leakages in Furnish doc. No. with title
pipeline?
10. Are pipelines colour coded as per IS specification / Plant
norms?
11. System for thickness measurement. (frequency, method, Furnish schedule, last
etc,). Acceptable thickness reduction criteria ? done
12. Is the observations documented properly in the register? Furnish copy of last
sheet
13. Is there any plan for repair / replacement of the pipelines Furnish the copy
of the deptt., during the year? Give details of the plan (for
different pipelines with their length).
14. Whether adequate isolation facilities provided in gas Explain
network for safe execution of jobs.
15. Have drain pots identified, numbered & inspected If so, give nos.,
periodically for safe working frequency of inspection,
& report of last inspection
with checklist
16. For detection of CO & other gases, how many portable / Furnish a list of such
fixed detectors are provided. How they are maintained in detectors location wise &
working conditions. last calibration done

14. METHOD OF STORAGE & HANDLING OF TOXIC / FLAMMABLE / EXPLOSIVE CHEMICALS

SN Points Auditee Reply Remarks
1. Name of the material stored.
2. Whether SWP exist for such job? Copy of SWP to furnish
3.
Is MSDS of each hazardous material available? Is
Signage/Warning/MSDS/instructions adequately
displayed?
4. What is the arrangement of discharge of static charge?
5. Whether Shut off valves/excess flow/ monitoring facilities
provided?
6. Tanker driver has TREM card? Whether he is aware of Attach sample TREM
the hazardous properties of material being transported & card
the precautions to be taken in the emergency.
7. Storage area away from buildings or structures, Attach layout diagram
(Distances as per the statutory regulations)
8. Alarm and indications (High level alarm, High pressure & Give details
high temperature alarms etc.)
9. Fencing
10. Distance between two tanks
11. Dyke with drainage facilities
12. Marking of tanks, connections & fittings,
13. Venting
14. Valves
15. HAC (Hazardous area classification) & Flame proof
fittings
16. Electrical grounding of the vessels and pipelines
17. Firefighting arrangement
18. Any advanced safety study as per legal requirement like
QRA & Safety report.

15. SAFETY INSPECTION:

8
SN Points Auditee Reply Remarks
1. What are various types of safety inspections carried out Give details different
and their frequency? (Plant level/Apex/SED/Deptt. etc.) types of inspection
prevalent
2. Is there any system of inspection by DSO inspection? Specify
3. Are the check-list prepared for these inspections?
(Specify item-wise, e.g. housekeeping, fire protection etc.)
4. Are the observation documented.
5. How compliance of recommendations is ensured?
6. How the critical non compliances are communicated to sr.
management

16. DETECTION OF LEAKS (chemicals, gas etc.) AND EMISSION (flare stack, chimney etc.):
SN Points
Auditee Reply Remarks

1. Methods applied to detect & its frequency: SWP may be furnish

Visual -
Equipment -
2. What is the system of recording and
communicating?
3. Who is responsible to take the corrective
measures?
4. What is the system of compliance? Last report may be
furnished
5. Any other point

17. SAFETY & HEALTH ORGANISATION:

a) Safety Set-Up:
SN Points Auditee Reply Remarks
1. i) Head of the department (Name, Designation,
Qualification)
Name:
Designation:
Qualification:
ii) Strength of the Safety Department including Safety
Officers and Staff.
2. Name of the Safety Officer (DSO, ASO etc.)? Furnish organization
chart with contact
details
3. What is the system of imparting training to Safety Officers Give details and record
about latest safety techniques? of last training.
4. What is the system of recording and implementation of Provide details
Safety Officers comments/suggestions?
5. Are they professionally qualified? To whom does DSO
report? Whether he is full time or with additional
responsibilities?
6. Occupational health services Set-up, roles &
responsibility, manning
etc.
7. Fire services Set-up, roles &
responsibility, manning

9
 etc.
8. Annual safety budget & expenditure. Give details of last 3
years

b) Safety Committee (s)

SN Points Auditee Reply Remarks
1. Details of structures, terms of reference and tenure of Furnish details
each committee (PLC/CSC, ZSC, DSC etc.).
2. How are the members of various Safety Committee Committee wise
selected? (Elected or nominated) details to be given
3. What is the frequency of each Safety Committee
meeting?
4. What is the system of apprising the safety committee
about Potential safety and health hazards, data on
accidents, health status of workers & result of work
environment surveys?
5. How are the recommendations of Committee Furnish
implemented? Provide system of compliance. documents
6. Are the minutes of the Safety Committee meetings Attach copies of
circulated among the members? Agenda &
Minutes of last
three meetings
7. Are the minutes forwarded to all the members including
Worker’s representatives(s), Chief Executive, occupier
and factory managers?
8. Implementation status of decisions taken (in %) and
measures taken for long pending points.

18. SAFETY EDUCATION AND TRAINING:

SN Points Auditee Reply Remarks
1. No. of employees joined/re-deployed during the year.
2. What is the system of imparting training? Training need
analysis
3. What is the system of Safety talk/ briefing before start of Furnish record
work/shift?
4. Is there any system of imparting safety training to
specified group of employees, after any accident in their
area involving them / other employees?
5. Safety Induction training to new/re-deployed employees Training record.
(Regular). Give the details.
6. What is the system of refresher safety training for regular
employees?
7. Safety Induction training for Contractor’s employees.
Give details.
8. System of on-the -job safety training to contract workers?
9. What is the duration of induction training for each
category of employees?
10. Whether training modules have been prepared for
identified topics for each category?
11. Persons covered in Height pass training.
12. Employees trained in First Aid.
13. Employees trained in Gas Safety.
14. Percentage of employees trained in the year (out of total
employees of the Department)

10
 15. How many employees have been trained in Safety, Health Ye Saf Fir Hea
and Fire in the last five years (including current year)? ar ety e lth
Give break up with details.

16. What is the training plan for the two years? Give details. Current Previous
year year

17. What documentation system has been established

regarding Safety, Health and Fire training?
18. How do you ensure that the training is put to use by the
employees (Regular & contractual) trained in Safety,
Health and Fire? Give details.
19. Whether the trainings are imparted to the employees
(Regular & contractual) in local language?
20. Whether there is system of assessing the learning
acquired by the participants?
21. Mode of imparting training (lectures/ presentation/ safety
films / e learning modules etc.)
22. Refresher training for contract workers (with in-house /
external faculties)
23. Whether employees are exposed to external training
programs / workshops on safety?
24. What infrastructural facilities with audio-visual support are
available for training
25. Is the department has unit training center for imparting
need based specific training?
26. Whether employees are acquainted with SOPs/ SMPs/ Total nos. of
IPSS procedures / MOS guidelines persons covered
under such
training in last 1
year

19. SAFETY COMMUNICATION/MOTIVATION/PROMOTION/ PENALTY & REWARD

SN Points Auditee Reply Remarks
1. Does the factory/department have safety suggestion
schemes/Quality Circle etc. taking up safety issues? Give
details.
2. Have your department been recognized in Plant/National
level competitions?
3. Are safety contests / competitions organized in the
factory/department? Give details.
4. How safety conscious employees & contract workers are
recognized & motivated?
5. Have your factory/department been awarded during last
five years?
6. How is the Safety, Health and Fire publicized in your
factory/department?
Bulletin boards?
Post-serious accidents?
Others? (Specify).
7. What are the promotional schemes for reporting Near
Miss cases?
11
 8. What are the safety promotional activities carried in the List of activities &
organization /department (NSD, SSD, WSD, Safety its record
Day/Week, Safety Exhibition etc.) in a year?
9. How the incidents/ accidents occurred in Plant/ other SAIL
plants are communicated to all employees for preventing
recurrence?
10. Are contractors penalized for violation of safety norms by Give details of
their workers or for any accident? last 1 year
11. Is there is any consequence management system for Attach copy of the
regular employees working in the department for scheme with
repetitive safety violations? details
12. What are the safety drives & campaigns (like platform &
railing, PPEs, Illumination checking etc) organized.
Whether there is any scheme for organizing monthly
theme bases drives?

20. HOUSEKEEPING
SN Points Auditee Reply Remarks
1. What is the system & schedule for monitoring of Furnish schedule
housekeeping in different section/areas in and around & committee
department? details along with
last report.
2. Are all the passages, floors, stairways, cellars (MoS:SG- Give photographs
10 for Hydraulic System Safety), cable galleries
(MoS:SG-15 & 16 for Elect & Fire Safety) etc. in good
condition? (Accumulations /debris /scraps/ dust/ sludge
etc.)
3. Whether walkways (including E.O.T cranes) are clearly Give photographs
marked and free from obstructions?
4. Is there Water accumulation due to rainwater/tap
water/process water and system of its removal?
5. Condition of floors: (Slippery or free from oil, water,
grease etc.)
6. What is the system to deal with the spillage?
7. Are drip trays positioned wherever necessary? How many
location and
produce
photographs
8. Are the floor (drain pit/ cellars/ cable alley etc.) covers produce
fixed properly? (Refer: MoS:SG-17 for Excavation) photographs
9. What is the system of scrap storage & removal? Give photographs
10. Provision of sufficient disposable bins clearly marked and
suitably located?
11. What are the inflammable material (DA/LPG cylinder,
diesel etc.) kept on the floor?
12. Is there a dedicated walkway earmarked for persons? photograph
13. Is the ventilations/exhaust system functioning properly? List
14. Unsafe conditions. photograph
15. Is there any system of organizing plant / zone level
15 Housekeeping competitions? Does the department takes
part in them?

21. CONDITION OF CABLE GALLERIES & TUNNELS AND THEIR MAINTENANCE:

SN Points Auditee Reply Remarks

12
 1. How many cable galleries/ tunnels are there in
department?
2. What is the system of monitoring condition of cables and
cable racks?
3. What is the system to detect fire in cable gallery?
4. Is the layout of cable gallery displayed?
5. How many fire walls are there in cable tunnels?
6. Is FRC coating done on cables?
7. What is the system for firefighting?
8. Whether HT & LT cables laid separately? pic
9. What is the ventilation system?
10. What is the Illumination level? (Refer: MoS:SG-05
Illumination at workplace)
11. Types & nos. of Fire Extinguishers.
12. Status of FDA system with extinguishing media
13. System of inspection (dept., joint with FS etc.). How the Frequency, Last
compliance is ensured? 2 reports.
14. Compliance to precautions given in SG-16 Fire safety

22. MOTOR ROOMS AND CONTROLS ROOMS INSIDES:

SN Points Auditee Reply Observations
1. Conditions of the Electrical panels, Switchboards etc.
Indication lamps/Panel lights glowing.
2. Are all panel doors closed?
3. Is proper insulating mat /paint provided in front of panels?
4. Are the keys for individual locks used for electrical
lockouts kept with the concerned Supervisor?
5. Are all panels demarcated with nomenclature (front and
rear)?
6. Whether resuscitation (Shock treatment) chart displayed
in all location?
7. Whether SLD (Single line diagram) displayed in all
locations?
8. What is the system to detect fire?
9. What is the ventilation system?
10. Is all the electrical motors are properly earthed?
11. Condition of electrical tools, portable tools, inspection,
testing, storing and their discarding procedure.
12. Any other point.

23. USE OF PPEs BY THE EMPLOYEES:

SN Points Auditee Reply Observations
1. What are different types of PPEs used in dept. & how it is
issued?
2. What is the system to ensure availability & usage of PPEs
by regular and contractor employees? (Refer: MoS: SG-
18 on PPE management)
3. Are suitable instructions for job specific PPEs displayed at
work site? (PPE matrix)
4. Have the workers been trained in proper use of PPEs?
5. What is the system of need analysis, procurement
inspection & maintenance of all PPEs?
6. Are defective PPEs replaced on priority?
7. Are the PPEs conform to tech. specifications of IS/ EN. Give details
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 8. Are new / latest PPEs are procured? If yes, give
examples.

24. FIRST AID:

SN Points Auditee Reply Remarks
1. Total nos. of First Aid boxes provided & its location Furnish List
2. Are the numbers of F/Aid boxes adequate?
3. Is it filled with required items? List of items.
4. Who is responsible for maintenance?
5. How many qualified / trained First Aiders (CPR trained) List of F/Aiders.
are available at department?
6. Whether name of qualified / trained First Aiders along with Specify location
contact details are displayed?
7. How many persons are trained/given refreshers training in
F/Aid in a year?
8. How the availability of F/Aid boxes in particular place is
known to employees.
9. Any other point

25. EOT CRANES:

SN Points Auditee Reply Remarks
1. Total number of EOT cranes.
2. Does SWP for Crane Operation & Maintenance exist?
(Refer: MoS: SG-14 for EOT crane)
3. Whether anti collision system installed in Cranes?
4. Condition of operator’s cabin. Fire Extinguisher provided?
5. Are the operator’s cabin glasses clean?
6. Condition of warning bells.
7. Are the crane operator ringing bells when moving with
load?
8. Are audio visual system installed while in operation?
9. What is the system of monitoring effectiveness of Master
Controller and operating levers?
10. Are the power indication lights on crane bus bar working?
11. Do operators test load before lifting?
12. Are the lights in crane girder working?
13. Whether the person giving signals to the crane operators List & record to
are trained? provide.
14. Availability of belt guards/coupling guards etc.
15. Closure of Panel doors
16. Caution boards displayed.
17. Up-keep of walkway, girder, trolley etc.
18. Loose/stray objects left on the girders/trolleys.
19. Crane operator’s register/log book available. Photo
20. Condition of stairs, platforms, railings.
21. Checking schedule for limit switch and emergency Provide
interlocks/switches are available. document
22. Checking results/observations are documented.
23. Limit Switches of the Crane (Cam/Spindle/Counter Weight Record
L/S):
 Main Hoist (Single / Dual )
 Auxiliary Hoist
 Long Travel drive (Single/Dual)

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 24. Condition of end buffers.

25. Condition of the rails. Whether there is rolling at any Record

particular position?
26. Condition of the hooks/ropes. Record
27. Periodic inspection & testing. Record
28. Is SWL and next date of testing is displayed on the
crane?
29. Training of Crane Operators. Record
30. Vision Testing of Crane Operators, Signalers. Record
31. Provision of corner switches to switch off power during
ascending / descending
32. Whether standard signaling codes are used?
33. Is clear space of not less than 50 cm between crane
operating on the track and any column is provided and
barricaded for safe movement of persons?
34. Communication facility with signalers & other ground
staffs
35. Whether stopper block, red flags etc. are used during
shutdown.
36. Whether Load testing with safe working load is done if
there is any structural change made after commissioning.

26. ELECTRICAL:
SN Points Auditee Reply Remarks
1. What is nos. of earth pits of different types (for Body
Records
earthing, Neutral earthing & Electronic)?
2. What is checking schedule of Earth Resistance, what
Records
were pit-wise values in last testing?
3. Whether all pits are marked properly with nomenclature,
last test date & next due date?
4. What is nos. of the lighting arresters identified? What is
Records
checking schedule?
5. Whether earth pits are provided for lightening arrestors?
Records
What is schedule for checking continuity with earth?
6. What is total nos. of Man Coolers (with wire mesh),
Welding Machines, and Water Coolers identified and Records
numbered?
7. Whether all the Man Coolers, Welding machines, water
coolers double earthed properly and what is schedule for Records
checking double earthing?
8. Whether RCCB/ELCB and VRD has been provided in
welding machines? (Refer: MoS:SG-08 on Arc Welding
& arc cutting)
9. Whether all man coolers are guarded properly with
chicken mesh?
10. Electrical Authorization Register is maintained, how many
Records
persons are authorized?
11. Electrical measuring tools (e.g. Meggar, Multimeter, tong
tester etc.) are identified and what is calibration schedule Records
& results?
12. Nos. of Insulated Rubber gloves & their testing schedule
Records
& last test details?

15
 13. Whether sources of Static Electricity have been identified
and appropriate measures taken like earthing/ bonding?

14. Whether provision of intrinsically safe & explosion proof

fitting/ equipment has been made in the installations
storing flammable & explosive chemicals?
15.
Are the junction boxes and switches covered properly?
16.
Various protection systems in Transformers against fire. Details
17. IER/ CEA regulation compliance for Rubber mats in front
of panels, Single line diagram, restricted entry board
etc.in MCC/ substation etc.
18. Availability of qualified / licensed personnel to work on Attach Relevant
electrical job. certification
obtained from
state Electrical
Inspectorate

27. RADIATION SAFETY:

SN Points Auditee Reply Observations
1. Whether radiological hazard exist in dept.

2. Is there Radiation Safety Officer?

3. Whether radiation hazard displayed near
source?
4. Whether SWP available?
5. Are the work areas displayed with relevant
safety signs?
6. Whether suitable personal protective If so, specify
equipment are provided to workers exposed
to radiations?

28. STRUCTURES:
SN Points Auditee Reply Remarks
1. What is the system of structural stability test/ Residual life Record
assessment?
2. System of scheduled structural inspection by Competent Frequency,
Group exists? schedule
3. Are cracks / damaged plaster of walls/roofs/building Specify
visible?
4. Condition of roof & side sheets
5. Periodic roof dust cleaning.
6. Condition of columns & gantry.
7. Condition of structural columns, beams, girders.
8. Condition of rainwater gutters/troughs.
9. Condition of stairs to roofs. Are accesses to roofs
prohibited? If yes, how?
10. Painting schedule:
 Buildings
 Steel Structures
 Equipments/Pipelines
11. Compliance of last structure inspection report Attach ATR

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12. Condition of platform & railing

29. FIRE SAFETY:

SN Points Auditee Reply Remarks
1. What is the system of fire detection and mitigation in the
department?
2. Are fire protection and prevention facilities available in the
Shop?
3. Are Portable Fire Extinguishers provided?
4. Details of:
 Number of Fire Alarm System. Condition Rea
No. son
OK Not s for
OK not
OK
 Number of Fire Detection System.
 Numbers of Fire Extinguishers. (Type-wise)
 Number of Fire buckets.
 Fire Hydrant points. Inside Shop
Outside Shop
5. What is the water pressure in the Fire Hydrants?
6. Schedule of inspection of above items.
7. Are Fire Extinguishers inspected for general condition &
operability and noted on the inspection tag?
8. What is the inspection and maintenance schedule of the
above extinguishers?
9. Number of employees trained in First Aid Fire Fighting Planned and
(FAFF) & Fire Safety? actual record
10. What percentage of employees of the department have Give details.
been trained in the use of fire extinguishers?
11. Periodic removal of shrubs, weeds and unwanted grass
and other inflammable items from areas around the Shop.
12. Painting of cables with fire retardant paint in vulnerable
galleries inside the Shop.
13. What is the system of conducting Mock Drills? Give Compliance of
details.( Nos.in last year, location etc.) last drill
14. Number of Fire incidences during last three years. Give
brief account of the same in separate sheet:
 Minor
 Medium
 Major
15. Whether fires/incidents investigated and corrective Give records
actions taken?
16. Are ‘No Smoking’ sign prominently posted in areas
containing combustible and flammables?
17. Fire prevention measures for ( Refer MoS:SG-16) Pl specify, as
- Conveyor galleries applicable
- Hot metal & slag handling
- Fuel gases handling
- Diesel equipment
- Coal yard
- Coal chemical areas
- Oil cellars & hydraulic rooms
- EOT cranes
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 18. What are the passive fire protection provided (fire door / Give details with
compartmentalization / barrier / sealing etc.) location

30. OCCUPATIONAL HEALTH SERVICES:

SN Points Auditee Reply Remarks
1. Whether Occupational Safety and Health center is
provided? How far from dept.
2. Are the Medical Attendants/Doctors available in each
shift?
3. Total nos. of ambulance van available, how many in each
shift?
4. Health check-up during last five years including current Year Ex Non. Total
year. What is the frequency? Ex

5. Whether records of above PME maintained in the deptt.

6. Noise survey. Frequency,
Record
7. Dust survey. Frequency,
Record
8. Illumination survey. Frequency,
Record
9. Ergonomic study. Frequency,
Record
10. Optometry Test. Frequency,
Record
11. Compliance of work environment survey report Record
12. System of medical examination of contract workers Specify
13. Special medical examination of persons engaged in Give area wise
hazardous chemical handling areas coverage, if any.

31. EMERGENCY PROVISION:

SN Points Auditee Reply Observations
1. Whether On-site emergency plan is prepared?
2. Is emergency preparedness plan approved by statutory Attach relevant
authority ? doc.
3. What are different emergency situations identified in dept.
and its mitigation plan?
4. Whether all employee are aware of emergency plan?
 Causes of emergencies
 Reporting emergencies
 Fire fighting procedures
 First Aid
 Assembly Point Nos. & location
 Evacuation procedure
5. Whether Mock Drills are conducted regularly?
6. Emergency Control Centers and Evacuation Centers
identified?
7. Does the emergency control centre have direct
communication links with the fire station and the plant

18
 control room
8. Whether emergency team or the key personnel identified?
9. Are the duties and responsibilities assigned to the
designated officials during emergency
10. Are suitable and adequate protective and rescue
equipment available? How is the emergency rescue team
trained to use these equipment?
11. How is the emergency communication with local bodies
and organizations ensured? Give details.
12. What is the medical emergency response system?
13. Are you a member of any MUTUAL-AID-SCHEME of your
area? If so give details.
14. What are the communication facilities (emergency alarm
system / public address system) available for declaration
& termination of emergency? Give details.
15. System of review / updation of emergency plan

32. TYPE OF EMERGENCY DRILL:

SN Types of Emergency Drill Auditee Reply Remarks
1. For Gas Safety
2. For Fire Safety
3. For power failure
4. As per Emergency Plan
5. Special drill (like NDRF etc.)

32a. DRILL (AMBULANCE / TRANSPORT)

Whether reported
Name of Organization Distance in (Kms) Time of First Information
punctual or late

32b. DRILL: FIRE BRIGADE

Whether Whether
Name of Fire Name of Fire Distance from Reported
equipment equipment
Brigade Station Factory Punctual/Late
worked system adequate

33. WELFARE/ OTHER AMENITIES as per OSHWC Code-2020:

SN Points Auditee Reply Observations
1. Is there any system for Customers Safety?
Give details.
2. Drinking water facility
3. Sanitation
4. Rest room

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Signature Signature
(Safety Officer) (Head of Department)

DETAILS TO BE MADE AVAILABLE

SN Points Auditee Reply Remarks
1. Safety Policy of the Company.
2. IOW register, accident investigation reports.
3. Accidents and dangerous occurrences – statistics &
analysis (Previous & Current year).
4. Housekeeping inspection records.
5. Medical check-up record/registers.
6. Issue of PPE register.
7. Electrical/Mechanical shutdown registers.
8. Sling testing/EOT cranes/Lifts/Lifting tools & tackles
testing register.
9. Training of employees, (Regular & Contractor) register.
(Safety, Fire, First Aid & OHS).
10. Record of Plant Safety inspections.
11. Job Safety training register.
12. Structural inspection.
13. Gas Line Inspection register.
14. Other relevant records like opening of valves, blowing of
fuses etc.
15. Maintenance and testing records of Fire Fighting &
Detection/Alarm checking register.
16. Record of work permits & Protocols.
17. On-site Emergency Plans and record of Mock Drills.
18. Calibration and testing records.
19. Shutdown maintenance procedures.
20. Records and Minutes of Safety Committee Meeting.
21. SOPs & SMPs
22. Eye testing records of Crane Operators.
23. Pressure vessels testing & their Safety valve testing.
24. Work environment monitoring
25. Safety Budget

20