audit compiance

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Sr.No. Description Responsible Compliance Status Target Date Priority

PLL/GDF-A/2012-13/P01

Main Recommendation : To consolidate your

maintenance practices in a maintenance policy and a

maintenance strategy

Chief Mangaer

Maintenance

PLL/GDF-A/2012-13/P02

Main Recommendation : To make mock drill exercises

more realistic in order to increase the return on

experience.

PLL/GDF-A/2012-13/P03

Observation : Regularly (frequency to be determined

upon local constraints) cleaning operations of the

insulation cladding

PLL/GDF-A/2012-13/P04Observation : Verification of all equipment comply withthe Indian regulation and the Indian electrical norms to

which the regulation refers

PLL/GDF-A/2012-13/P05Observation : The hydraulic hoses on the arms could

be more guided to prevent wear and tear

PLL/GDF-A/2012-13/P06

Comment :ELENGY does not recommend painting

stainless steel pipes (including unloading arms). It is not

clear to us whether corrosion issues occurred due to the

lack of painting or due the painting itself. For instance,

cracks on the painting may retain salty water and thus

initiate corrosion. Terminals with a similar environment

(see photo of Melaka terminal) have chosen to go for

unpainted arms.

GDF SUEZ AUDIT 2012-13 ( October 9 - Otober 12)

AUDIT OBSERVATIONS LOG ACTIONS LOG



Sr.No.

Description Suggested Measures

Responsible

Compliance

Status

Target

Date Priority

PLL/Ener-A/2012-13/P01 Electrical System

Energy saving potential by replaces existing

fixtures by LED & installation of solar

power pack

PLL/Ener-A/2012-13/P02Air Compressor Cooling

Water Pumping System

Energy saving potential by replacement all

pump sets

PLL/Ener-A/2012-13/P03Hot Water Pumping

System at Phase - I


pump sets

PLL/Ener-A/2012-13/P04Chilled Water Pumping

System


pumps

PLL/Ener-A/2012-13/P05 Air Compressor System Energy saving potential by excess air

PLL/Ener-A/2012-13/P06 Blower System

Energy saving potential by clean the filter &

overhauling of pressurized air blower in

phase - I & II

ACTIONS LAUDIT OBSERVATIONS LOG

Energy Audit 2012-13 (Nov 20th to Dec 1st )



Remarks

G



Sr.No. Description

PLL/Insu-A/2012-13/P01

Thermographic survey for Process lines for

detection of corrosion under insulation incryogenic services and also the condition of

insulation in LNG systems is not done.

PLL/Insu-A/2012-13/P02Hydrocarbon analysis for Air Separation

Unit(ASU)

PLL/Insu-A/2012-13/P03In Trip Bypass procedure,there is no criteria

decided with time limit

PLL/Insu-A/2012-13/P04Vibration measurement for Intank pumps is not

available


In the absence of recondensor,regasification

capacity is reduced by 75% and is major

potential for business interruption

PLL/Insu-A/2012-13/P06Audit recommendations follow up and closing

are not being done effectively

PLL/Insu-A/2012-13/P07Diesel day tank is very near to the diesel pumps

and no containment is provided.

PLL/Insu-A/2012-13/P08Flexible hose connection is provided for diesel

filling in diesel storage tanks


Oil insulated transformers should be separated

from each other by firewalls,spatial separation

or other approved means for the purpose of

limiting the damage and potential spread of fire

from a transformer failure.

PLL/Insu-A/2012-13/P10Inspection of LNG pipeline between jetty and

terminal is not being done.


Flexible hose connection for Nitrogen injection

into LNG line is isolated by manual isolation

valve and incase of passing of isolation

valve,LNG can enter nitrogen header(which is of

carbon steel metallurgy) and has potential for

fire due to damaging nitrogen header.

Risk Ins

AUDIT OBSERVATIO



Recommendation Responsible

Compliance

Status

Target

Date Priority

Thermographic survey for process lines to bedone.

Periodic purging from liquid loop(draining of

column and reboiler).

Time limit for a trip bypass to be mentioned.

To provide vibration measurement system for

intank pumpsClosed

Installation of second recondensor.

Consolidated audit recommendation follow up

and closing system to be established.

Provide containment around diesel day tanks.

Permanent pipeline for diesel filling.

Firewall between the transformers extending

upto a height of atleast 1m above the

transformers.

Prepare a schedule for different type of

inspection like visual inspection for health of

insulation,energy loss through insulation and

corrosion under insulation.

Provide end bling at both the end of theheaders(nitrogen and LNG) and a system should

be established to ensure normalising of the

facility after any maintenance actitivites.

rance Audit 2011-12 ( Feburary 27 - 28, 2012)

ACTIONSNS LOG



Remarks

OEM is unable to provide

online vibration measurement

in the current set-up.

OG



Sr.No. Description Responsible

Compliance

Status

Target

Date Priority

PLL/NSPC-A/2012-13/P01

During the sampling audit there was an evidence to show that the

Port has not suspended the cargo operations of the vessel inspite

of wind speed exceeding 35 knots. There is evidence indicating

that the wind speed on 26th June 2012 exceeded the parameter

l imits from the period 1500 hrs to 1900 hrs while LNGC Aseem

was at berth carrying out cargo operations. Also on 19th June

2012 from 1400 hrs to 1800 hrs when LNGC SS Disha was carrying

out cargo operations wind exceeded the required parameters of

speed limit. This is a violation of the set guidelines and the

procedures as set in Terminal operation environment Guidelines.

Necessary documents of evidence attached.


The Port Facility has carried out the draft survey through their

contractor (Fugro Survey India Pvt Ltd.) on Jan 2013. The earlier

survey was carried out on Oct 2011 (Fugro Survey India Pvt Ltd.)

both these survey reports need to be approved by GMB Charge

Hydrographer or NHO.


Following equipment non-operational / erratic in jetty Control

Room.

a) Navtex printer non operational.

b) Radar non-operation.

c) Aneroid barometer requires calibration. Last calibration

done 22nd march 2009.

PLL/NSPC-A/2012-13/P04The staff needs training for firefighting operations and use of

extinguishers.

Complied.

AUDIT OBSERVATIONS LOG ACTIONS LO

NSPC AUDIT 2012 (Feb 19th 2013)




During the fire fighting drill one of the fire tender could not build

pressure in the DCP fire extinguishing mode. No record of any

routine check of the fire extinguisher sighted to reflect

continuous monitoring / working of the equipments.

Complied.


Port facility is constructing new jetty of LNG terminal. Port facility

to notify NHO to issue a T & P notice to that effect.



Remarks

Third party assessment in

progress to ascertain the

weather parameters for

ship operations.

Both survey reports have

been submitted to GMB

and NHO. Awaiting

approval.

a)Navtex sent to Elab for

repairs expected by 15th

May.

b)Radar repaired

c)Barometer sent for

repairs expected by 15th

Ma



Request for notification of

‘T & P notice’ for

construction of new LNG

jetty has been sent to GMB

for promulgation.



Sr.No. Date Description Responsible

Compliance

Status

Target

Date Priority

AUDIT OBSERVATIONS LOG ACTIONS LO

ISPS Annual Verification Audit (Feb 19th 2013)

PLL/ISPS-A/2012-13/P03 More drills to be conducted in

order to make people familiar with

Complied.

PLL/ISPS-A/2012-13/P01 Barbed wire on south side of the

jetty broken.

Complied.

PLL/ISPS-A/2012-13/P02 More training required to staff

working on Port with regard to

Complied.



Remarks



Audit Start

Date

Audit

TypeNo.

Stat

us

2012-12-28 PA4 1 O

2012-12-28 PA4 2 O

2012-12-28 PA4 3 O

2012-12-28 PA4 4 O

2012-12-28 PA4 5 O

2012-12-28 PA4 6 O

2012-12-28 PA4 7 O

2012-12-28 PA4 8 A

2012-12-28 PA4 9 A



2012-12-28 PA4 10 O

2012-12-28 PA4 11 O

2012-12-28 PA4 12 O

2012-12-28 PA4 13 A

2012-12-28 PA4 14 O

2012-12-28 PA4 15 O

2012-12-28 PA4 16 O

2012-12-28 PA4 17 O

2012-12-28 PA4 18 O

2012-12-28 PA4 19 O



Description and Consequence

Calibration:Calibration frequency of Digital Insulation Meter is not found adhered. Fluke make digital insulation meter vide sr. no.

95320032 is calibrated on 15th March'2011 & was due in 14th March'2012. However its recalibration was conducted

on 2nd July'2012. i.e.after more than 12 months. During this period this meter was used to measure IR value of one

of the LT motor on 2nd April'2012

Maintenance:

Refer LT Motor Maintenance report for 2nd April'2012. As per documented SOP (PLL/ELECT/SOP/13)Inductance

has to be measured however this is not measured since April'2012. The IR Value limit is >1.230 Mohms in motor sr.

no. 302B However reading recorded is 1.15 MOhms.

Control Conditions:

In the Field Log Book (PLL/OPR/FRM/05) Many parameters are not recorded since Aug';2012. Reasons recorded in

log book is "Busy at Jetty" & other reasons. No further actions are taken.

Enviornmental Monitoring :

Night time Noise monitoring not found evident as per the requirements

Hazard & Risk Assesment:

1. Mooring Activity has been considered as one activity in Risk Assesment in Port Operations having hazard of injury

to mooring crew.

2. Sub activites like Pilot boarding, tug fastning to Ship, bearthing , Cargo operations etc resulting in different hazards

have not been identified seperately and focused for risk assesment.

3. Injury is not defined as Cuts/Fracture/ head injury related to body part. Existing control is not focused on type of

injury and body part in SOP1 & 3 (bearthing & mooring).

4. Construction risk (task based) not found identifed in risk register for Civil.

5. Hazard identification and risk assessment (Risk Register) are not evident for office management / activities. E.g.,

Work involved in HR and Information Technology Departments.

Incident Investigation:

Incident investigations found inadequete as per below details:

1. Workers Participation is not evident in incident investigations.2. Correction, Corrective Actions, Verification of effectiveness of corrective action is not evident.

3. Reference to change in System documentation with revision no.

4. Risk register is updated for additional hazard with controls refering to SOP which has not been revised for

adequecy. Eg. Incident Report of Fracture in leg of Mr Shyam Singh during mooring operations at Port on

21.07.2011.

Canteen - Hygiene & Safety:

Safety and hygienic conditions in all canteen found inadequete :

1. Cooked & semi cooked foods are found stored without lids.

2. Evidence of regular monitoring of hygene of 30 canteen workers are not evident, nails of workman found not

acceptable.

3. Insect catching devices and wire mesh nets on windows are not evident.

4. Elctrical wires found hanging without identification at some places.

5. Canteen workers found not aware about LPG safet .Internal Audit :

Clausal references, recorded in some of the Internal Audit Nonconformity Reports and List of Findingsare not

appropriate to the nature of the findings. eg. 16th IMS IA held on 25th & 26th October 2012- POIA 16-002 and HSEIA

16-059.

HR & Training :

In a few of the Training Feedback records, effectiveness evaluation part has not been completed by the HOD /

Section Head. Numerical raring has not been indicated and/or comments column on effectiveness are left blank. The

date of effectiveness evaluation is not indicated though time frame of 3 months has been documented in Process



Control Conditions:

Refer Analysis report of M/s GE dated 17th Nov'2012. Which suggested to add 20 Kgs. Of BT4301 however this

addition of BT4301 was not recorded in respective dosing register.

Document Control:

1.Latest version of documents not found at point of use.SOP followed by Electrician for LT Motor Maintenance vide

document no. PLL/ELECT/SOP/13 is Rev.01 however latest version available is Rev.02.

Maintenance:

Maintenance is following Electrical Electronic Log system to monitor preventive maintenance parameters. However this doesn't cover all checkpoints as defined in data logging format FRM/11. Equipment wise checklist needs to be

prepared to effectively monitor & follow all preventive maintenance related parameters

Aspect-Impact Assesment :

Environmental aspects and associated impacts (Aspect-Impact Register) and hazard identification and risk

assessment (Risk Register) are not evident for office management / activities. E.g., Work involved in HR and

Information Technology Departments.

Legal Requirement:

PNGRP regulation for third party approval of ERP is not identified as applicable legal requirement.

Document Control:

1. Amendment Status Record for HIRA does not have provision to capture discription of existing and proposed

change.

2. Identification of change is not evident in hard copy as shading in soft copy is not visible.

Health Monitoring :

10 persons Medical check up of 10 persons are pending, form no. 33 and 32 is not addressing requirements like

name of hazardous process and employees exposed as per safety index report , Nov-12

Operation Control:

1. Refer Work Permit No. 2191 Issued at Tank No. 04. LEL is not checked on issued date i.e. 27th Dec'2012 at

Operation- Tank Storage.

2.New Civil construction found being carried out without any permit available at site (1st floor of Suryakiran). MSDS

of bituman found not available, entry in civil maintenace pending from 18/12/12, Monitoring of metal scrap generation

not found done.

Emergency Preparedness :

Mock drill not found conducted for identified potential emergency of roll over on LNG tank leading to sudeden rise in

tank pressure due to abnormal BOG generation

Enviornmental Monitoring -Horticulture :

IMP No. 86 with target date of 30/11/12 for treatment of sanitory water using bacterial culture not found monitored.Status of green belt, survival rate of trees not found monitored. Monitoring of mangroves growth to be done half

yearly is not evident.



Categ

ory of

Findin

g

Focu

s

Area

Proces

s/

Area/

Depart

ment

Standar

dClause

DNV-

auditor's

Initials

Analysis of Basic Cause

of Nonconformity,

Distribution of

Responsibility Within

Organization

Minor FA Electrical

Mainten

ance

ISO9001:200

8

7.6 VB

Minor FA Electric

al

Mainten

ance

ISO

9001:200

8

6.3 VB

Minor Operati

on

ISO

9001:200

8

7.5.1 VB

Minor MR -

IMS

ISO

14001:2004

4.5.2.1 HD

Minor MR IMS OHSAS

18001:20

07

4.3.1 SC

Minor MR IMS OHSAS

18001:20

07

4.5.3.1 SC

Minor Cantee

n

OHSAS

18001:20

07

4.4.6 HD

Observ

ation

MR -

IMS

ISO

9001:200

8

8.2.2

4.5.5

4.5.5

GN

Observ

ation

HR

Training

ISO

9001:200

8

6.2.2

4.4.2

4.4.2

GN



Observ

ation

Operati

on

(STV)

ISO

9001:200

8

7.5.1 VB

Observ

ationFA Electric

al

Mainten

ance

ISO

9001:200

8

4.2.3 VB

Observ

ation

FA Electric

alMainten

ance

ISO

9001:2008

6.3 VB

Observ

ation

MR -

IMS

ISO

14001:20

04

4.3.1

GN

Observ

ation

MR -

IMS

OHSAS

18001:20

07

4.3.2 HD

Observ

ation

Electric

al

Mainten

ance

OHSAS

18001:20

07

4.4.5 SC

Observ

ation

OHC OHSAS

18001:20

07

4.5.2.1 HD

Observ

ation

Operati

on

(Tank

Storage

)/Civil

OHSAS

18001:20

07

4.4.6 VB

Observ

ation

Operati

ons -

Port

OHSAS

18001:20

07

4.4.7 HD

Observ

ation

Horticult

ure

ISO

14001:2004

4.5.1 HD



Correction to Eliminate Basic

Cause of Nonconformity

Corrective Action to Eliminate Basic

Cause of Nonconformity

Deadline for

Implementation

of Corrective

Action



Verification of

Corrective Action

and Evaluation of

Effectiveness

Date CA

Accepted

DNV

Auditor

Verifying

NC

DNV-auditor's

Verification of

Corrective

Action and

Effectiveness

DNV

Auditor

Closing

NC

Date for

Closure of

Non-

conformity



Sr.No. Responsible

Compliance

Status

Targe

Date

PLL/RG-A/2012-13/P01

The ‘Terminal Information and Port Regulations Manual’ does not contain all of the

Information that is routinely provided to or required of ships calling at the terminal.

Information requirements and instructions are only provided by email message. Oneexample is the requirement for ships to report mooring line service hours and condition, this

is not mentioned in the ‘Terminal Information and Port Regulations Manual’ in effect at the

time of the review.

Complied

PLL/RG-A/2012-13/P02

a. Vessel Vetting Verification and Acceptance Policy and Procedures were observed in 3-

different documents with inconsistencies noted between them. E.g. ‘LNG Ship Approval

Procedure’ is a stand-alone Document without issue date or Revision number; it is not

identified as a Controlled document, Standard Operating Procedure, and is not consistent

with Data required per Standardized email communications or requirements noted in the

‘Terminal Information and Port Regulations Manual’

Complied

PLL/RG-A/2012-13/P03

PLL/RG-A/2012-13/P04The Sampling System does not comply to ISO 8943 Requirements due to lack of Controls in

the existing arrangement. (ISO 8943 /sections 693, 8) ------remote control facility is not

there,however data is being monitored remotely and local supervision is done.

PLL/RG-A/2012-13/P05

a. The Sampling System does not comply to ISO 8943 Requirements due to lack of Specific

Calculations for Sub-cooling degree and Vaporizer heating capacity are not provided. (ISO

8943 /section 693)

Description

Ras-Gas AUDIT 2012

AUDIT OBSERVATIONS LOG ACT



Sr.

No.OBSERVATION RECOMMENDATION

P3

1

It was not evident that safety committee

members are kept appraised of latest

developments in a safety, health and

environment.

Special Safety Training programmes,Talks and

Presentations may be arranged for Safety

Committee Members and record of such training

should be maintained

2Budge for Safety is not reflecting in Annual

report of the company.

May be considered in future

3

Workers are trained, however it was not evident

that they are aware of consequences in case

deviation.

Needs to address in refresher training.

4Few SOP’s found displayed in work area such as

chemical Unloading station.

SOP’s at of critical operations should be

displayed in Bold /easily readable format.

5

Company ensures that PPE’s are given by

contractor as per specifications provided,

However reluctance in use of PPE’s needs to

controlled. All tools and tackles are provided by

company.

Needs attention.

6

Contractors do not have their own safety

organization except for the project site.

It is recommended that Safety Officer of

the company should take full

responsibility for educating /training of

contractor employees and Supervisors

in Safety and ensure that only good

quality and effective PPE’s are issued

and used by Contractor employees.

7

There are hazardous operations in the plant

including, loading and unloading of highly

flammable LNG.

Existing system is good and effective

however more vigil needs to be in

place.

8

Ambulance is available all the time but it is not

trauma care ambulance van.

Needs attention to provide ambulance

van as prescribed in Gujarat factory

rules.

9Workers are aware of their mistakes which can

prejudice safety.

BBS trails should consider in near miss safety.

10Workers found admitting their mistakes System of personal counseling is recommended.

3.3 SAFETY MANUAL

NSC - Safety Audit Report 4th

- 6th

Feb 2

OCCUPATIONAL HEALTH AND SAFETY MANA3.2 OH & S ORGANIZATIONAL SET-UP

3.2.2 Safety Committee

3.2.3 Safety Budget

3.4 SAFE OPERATING PROCEDURE

3.6 CONTRACTOR’S SAFETY SYSTEM

3.7 PLANT DESIGN AND LAYOUT

3.8 MEDICAL MANAGEMENT OF ACCIDENTS

3.11 SAFETY CULTURE

3.11.2 Attitude of Workers

3.14 JOB SAFETY ANALYSIS



20

PH-1 area: EOT crane was parked in BOG

without any work. EOT lifting hook not marked

with capacity & last date of testing. (Refer site

visit observation sl. No. 64, 65).

recommended that:

a. SWL should be painted on lifting

Hook, except for the Cranes,

where capacity of Crane changes

with angle of Boom.

21

GTG Area: EOT kept in the mid of rail without

any work. (Refer site visit observation sl. No.

90). Workshop: EOT not parked in parking bay.

(Refer site visit observation Sl. No. 94).

The parking bay to be marked

(yellow /black strips) for each EOT

or HOT cranes on its main girder &

transverse girders & Lift shall be

parked accordingly, when not I

use.

22

Fire Water Pump House: EOT found mid of its

rail whereas no work was going, Also parking

area not defined. (Refer site observation Sl. No.

44). No marking for Final Isolation switch on

EOT pendent, it require in case of emergency

when pendent switch malfunctioning. (Refer site

observation Sl. No. 45). These are accident

hazards.

The Control panel to also have

proper parking place instead of

coming in the way of persons

walking.

23

T-103: The hook of EOT lifting trolley heavily

rusted. (Refer site visit observation sl. No.75).

It is recommended for regular

inspection & servicing of all lifting hoists

in field areas is suggested.

24

Testing of Hydraulic jacks and screw jacks are

not included in the list of regular testing by a

competent person.

It is recommended that the testing of

Hydraulic jacks, screw jacks & any

other similar lifting tackles to be

included in the list of regular testing by

a competent person.

25

It is observed that generally lifting tackles are

regularly examined/ tested and records are

made available. However, the specific

identification number, SWL and date of test/due

date are not written on the tackles.

It is recommended that all Slings, Dshackles,

Eye Bolts etc. to have

metallic/aluminum tags fixed with such

details, as per Rule 62 (2) (b).

26

In workshop: Chain block Sl. no 1077, 1078,

1079 were found Without safety lock/latch. It is

may cause accidental slip of sling from the hook

leading to injury. (Refer site visit observation S.

No.96).

It is recommended that lifting hooks of

all lifting tackles like pulley blocks,

EOT/HOT Cranes, to have Safety

latches, to avoid any accidental slip of

sling.

27

Workshop: One of the Hydraulic Jack

(painted yellow colour) did not have any

identification no. & last tasted date etc.(Refer site visit observation sl. No.97).

a. All lifting tackles & equipment to

have its specific identification tag

no., & its test records.b. All tools & tackles are mapped in

SAP system.

c. All testing schedules & records are

mapped in SAP for better follow up.

4.3 MANUAL AND MECHANICAL MATERIAL HANDLING

4.4 HANDLING & STORAGE OF GAS CYLINDER



28

Observation at site refers point sl.

No.77: Tank T-103 DCP-EX-41 tied

with aluminum wire on Tank top.

It is recommended that all cylinders be

placed with proper stand & clamping

arrangements.

Securing needs to be done & marking &

Labeling be done as per Gas Cylinder

Rules 2004 (Chapter V rule 37/42).

Marking to be done as per Rule 6 and

Labeling/colour coding of cylinders as

per Rule 9 of Gas cylinder Rules 2004.

29

Observation at site refers point sl.

No.91: GTG-C, Inside CO2 panel many

unwanted items are found lying.

It is recommended that CO2 cylinder

rack panel be kept free of any

unwanted materials. In case any spare

items need storage, a separate cabinet

be placed.

As per Rule 8 of Gas Cylinder Rules

2004 & IS 4379, the cylinders are to be

painted for its contents & colour coding.

All arrangement for storage & handling

should be done as per various

provisions of Gas Cylinder Rules 2004.

Relevant safety posters to be displayed

in the area.

30

Material Safety Data Sheets (MSDS) &

“Dos & Don'ts” are not displayed in

various Cylinder storage & Usage areas

It is suggested that MSDS/Dos & Don'ts

be displayed. Also relevant safety

posters be displayed for general

understanding of those, who handle it.

31

All machines and dangerous areas

have been guarded adequately except

for the following observations:

Adequate guarding needs to be

provided for all rotating parts of

machines.

32

For certain hazardous plant, the

process flow chart be displayed in the

field areas for better understanding of

all concerned.

Display of process flow charts at

prominent places in Hazardous plants

is suggested.

33

Pit cover plates at many places are

dislodged or not kept securely. (E.g.:

Isolation Valve Chamber of Fire ring

main VC-54 pit near T-104 south side

covers were fixed wrongly/ upside

down, as all lifting handles are

downwards. (Refer observation sl.

no.1).

A good engineering practice to be

followed & after any use, the

Chequered plates or cover plates are

properly secured after working for the

respective pits / areas below.

34

Most crossovers on storm water drain

channels, leading to fire hydrant & hose

boxes do not have railings, which may

lead to trip & fall injury. (Refer

observation sl. No. 04, 67).

Same as above. It is suggested to raise

the railings on both sides of the cross

over pathways, above the drain

channels, to avoid trip & fall injury,

especially during emergencies.

4.5 GUARDING OF MACHINES & DANGEROUS AREAS

4.6 MEANS OF ACCESS, PLATFORMS & RAILINGS



35

Jetty Upper deck: FRP Grating placed

near ULA found damaged. (Refer

observation sl. No. 21).

Any damaged grating be replaced immediately

lest it leads to an accident.

36

At many places Safety Chains for cat

ladders or monkey ladders are either

not provided or are not kept in latched

condition. This is a trip & fall hazard.

(Refer observation at sl. No.22, 53).

a. To identify the places where it needs

to be incorporated & incorporation of

Safety chains for Monkey ladders be

done for all such places.

b. A display Stickers be placed at all

locations for Users, to latch these

safety chains after its use.

37

Toe-guards are missing at many places

in platform railings & ladder stairs.

(Refer observation sl. No. 26, 52, and

54).

a. Identify all such locations where the

toe guards are to be placed for

platforms/ landings & stairways.

b. Incorporate these, wherever

possible with hot work as per good

engineering practice.

c. If hot work not possible, the bolted

arrangement of fixing toe guards be

considered.

38

GTG area: Near toilet, to reach to

ground level from GTG level, it is steep

down is more & may cause a trip & fall

hazard. (Refer to observation sl.

No.92).

It is recommended to provide suitable

railing & steps, to avoid trip & fall

hazard.

39Near east side of PH-1A/H: Drain pit found without

any cover.

It is recommended to place suitable cover plate /

grating.

40

PH-2 STV Area: STV drain header is found normally

used as walkway. (Refer sl. No.60).

Recommended to widen this path as

per engineering standard at places

where it is smaller, to avoid trip & fall.

41

T-103: Lift door opening orientation is

not proper & causes undue hindrance &

congestion at the landing area.

(Refer sl. No. 71).

It suggested to review, the possibility of

change of orientation for opening of the

door, in consultation with the OEM

/supplier.

42

Tank-103: At E-V1104B-092 and E-

1104A-089, floor openings without

cover plate / gratings.

Recommended to place such covers after

completion of site jobs.

43

At Jetty Operator room: The ear plug dispenser

was found to be empty.

It must be ensured that regular

replenishment of PPEs like ear plugs ismade at all locations in plant areas

especially distant areas like Jetty

Control room or Jetty Operator’s room.

4.7 VENTILATION, ILLUMINATION, NOISE

4.8 HOUSEKEEPING



44

Jetty Operator’s room at the top deck is

cluttered with many unwanted items

kept in room. (Refer Sl. No. 25).

All operations areas be maintained

spruced up & no unwanted items be

allowed to be placed or parked. This

room not to be used as stopgap storage

space.

45

Jetty Control Room: Many unwanted

items kept in control room, someblocking easy access to BA set.

It is suggested that a review be taken to

spruce up & decongest the room, whichin our opinion may give rise to

additional 20% floor space, by proper

stacking & mounting of essentially

required items.

46

PH-1 Air Pre-heater: Many small &

loose items found in air pre-heater area,

which may cause fall accidentally &

cause injury. (Refer sl. No. 51).

a) A regular housekeeping visit is

made, to avoid such situations.

b) Contractors be advised to use

plastic or wooden tool kits boxes to

47

Top of tank-103: Loose piece of MS

plate & small items like nut / bolts are

lying. (Refer sl. No.74 & 81).

keep all small loose items, at

respective work place.

All unwanted & left over items are removed after

work is over.

48

GTG Area; Vegetation growth in cable

tray of GTG-A observed. (Refer sl. No.

89).

Operations / Maintenance to

ensure before respective work

permit are returned.

49

Workshop Area: In front of workshop

entrance pathway, many loose

items/equipment are kept like

Motors/spring support/SS Hose etc.

without any identification tags or

marking.

a) In case items are not usable these

be moved for disposal.

b) In case items are required for reuse

later, the same shall be

preserved & identification tags be

used for each of such item.

50

The Tyco test bench is being calibrated once in a

year internally.

The test bench be calibrated & tested

through any third party agency like

Godrej.

51

It is observed that the instrument related PMs are

not loaded in SAP.

All activities are mapped in SAP. Also it

is recommended that all PMs related to

maintenance are loaded on SAP also.

52

A system is in place for instrumentation

maintenance. Regular calibration checks are done

at predetermined frequencies.

A very good practice to continue. It is

suggested that all instrument PMs are

mapped & results are loaded in SAP.

53

GTG package equipments are checked once in 4

months & other GTG instruments are as per

service of OEM.

A good practice to continue.

These activities of Package be mapped

in SAP too.

54

For Pressure & Temperature gauges

there is no fixed schedule of regular

calibration. However, it is done based

on feedback from Operations.

It is suggested to consider inclusion of

these instruments which are important

for field indications, in regular list of

calibration schedule.

4.9 PREVENTIVE MAINTENANCE SYSTEM AND RECORDS PSVs/TSVs Maintenance:



55

Petronet LNG has a good practice to

get all the spring supports of pipeline

checked through a third party M/s Pipe

Support India & last check was done on

22/02/2012. It is learn that 43 nos. of

defective supports were attended /

replaced. However these reports arenot available in SAP. Sample of Spring

support SS-E1002 verified & found OK.

This good practice to continue.

However, it is recommended that these

reports be made available in SAP

system for future reference & to trace

back the history.

56

Near LDB-103-B3-24, Jetty to CR

Head: Cable tray main supports are

badly corroded. (Refer sl. No. 27).

Near L-04-3005 Transformer at Jetty

CR: Main supports of cable tray are

badly corroded. (Refer sl. No. 29).

It is suggested that regular inspection

be done for other than spring hanger

supports, not only for pipelines but for

other facilities & structures, for its

proper contact, transfer of loads, decay

due to rusting, corrosion etc.

57

The work permit system has a separate

permit system for working inside the

“vessel” & same is being used for

working at “confined spaces” as well.

The conditions for working in confined

space could be different from working

inside a Vessel.

This permit to be titled as “Working in

Confined space / Inside Vessels.

The conditions for working in “confined

space” could be different from working

inside a Vessel, to be elaborated

accordingly.

58Exhaust silencers of Diesel pump at fire water

pump house are badly corroded.

To be attended immediately, lest it causes an

accident.

59

GTG Area: Ph-1 GTG SOx and NOx

analyzers out of order. Many cableswere found loose / out of tray for these

analyzers. (Refer sl. No. 85 &87).

It is recommended to ensure that all

environment related instruments/analyzers are maintained in good

working condition. The cable are

properly laid, saddled & clamped to the

respective cable trays.

60

Refer to Recycled Plastic Manufacture

& Usage Rules; Amendment 2003;

Plastic Waste (Management & handling

Rules) 2011.

It is suggested that accounting of

Hazardous wastes like e-Waste, Old

used Batteries, Oil soaked Cotton

Waste, Oily Drums & other

HDPE/Plastic containers of hazardous

chemicals is properly maintained &

disposed.

P5

4.10 WORK PERMIT SYSTEM

4.12 MONITORING OF WORK PLACE & STACK EMISSION (TREATMENT & DISPOSAL OF WASTES & EFFL

CHEMICAL & PROCESS SAFETY5.1 STORAGE & HANDLING OF HAZARDOUS CHEMICAL



61

17 nos. Relevant MSDS are available in

the system.

The display is done at few places field

areas as well.

However, there is need to develop

posters for “do’s & don’ts”

It is suggested to wide spread the

display of posters on “Do’s & Don’ts”

related to hazards while handling of

various chemicals. These to be

displayed at its place of storage &

usage.

62 Fire orders are available. Call response procedure may be displayed

63

Emergency Procedure is available. It is suggested that Communication

Chart may be included in ECP. Also in

absentia of Key persons may be

defined.

64

Emergency lights are available. Periodic testing, cleaning and

calibration should be done and record

should be maintained.

65

There are no fire call points; however

telephone booths/ Paging facility is

available.

Arrangement is Satisfactory, Shall need

further extension during expansion of

factory activities and Increased

inventory.

66

Distance between storage of

Flammable and Combustible material is

adequate as per layout which is well

designed.

Company may consider to purchase

Fire tender with Water Mist/Fog

generator.

67

Flame proof fittings are available as per HAC in

entire premises.

MMC Panel room on jetty (Below Jetty

C.R. should be provided with flame

proof Fitting though area is not in HACmapping to exhibit similarity.

68

Emergency procedures are displayed if form of

caution boards, Do’s and Don’ts and MSDS.

Worth appreciating efforts however few

boards found faded and needs

repainting as mentioned in enclosed list

of survey points.

69

There are no manual fire call points

however internal telephone facilities

with dedicated Tel Nos. Telephone

booths and Paging booths are

available. Two booths found O/O during

audit.

Corrective action for proper functioning

70

There are four electrical driven, two diesel driven

pump and jockey pump.

It is suggested that these pumps are

maintained in good working condition

all the time. Repair and maintenance

should be of top priority.

5.2 FIRE AND EXPLOSION HAZARDS

5.2.1 Built in safety in Civil design and Construction

5.2.2 Built in safety in Electrical Circuits and Equipment’s

5.2.4 Fire safety in handling Flammable and explosive material

5.2.5 Fire Detection and Alarm System

5.2.7 Fixed fire Extinguishing system

5.2.8 Portable Fire Extinguishers



71

Fire extinguishers are located at

conspicuous positions. It was observed

that foam type extinguishers were kept

in factory hospital.

Area wise extinguisher location map should be

prepared.

72

Two Fire DCP/Foam/Water fire tender is available. Consider purchase of fire tender in as

company is expanding, as proposedand discussed.

73

Firefighting equipment’s is having

proper access. However few hydrant

locations needs reorientation as storm

water drains are in proximity as listed in

site observation points.

Corrective action may be planned.

74

Fire drill is carried out by ERT during mock drill

only.

It is recommended that Fire drill and

training may be extended to employees

also to further strengthen fire fighting

capability of factory.

75

For Fire there is having dedicated internal

telephones.

There is adequate communication

facility. However instillation and use of

public address system may be

considered. This facility is of multi

utility and can also be used for

important announcements.

76

Mock drills are conducted quarterly.

No drill is conducted in night shift.

Feed back of the drill is documented.

There is Mutual Aid Scheme, andresponse of nearby industries is

satisfactory.

It is recommended that Fire mock drill

for different Scenarios of emergency

should be conducted at least once in a

quarter. Fire mock drill involving outside agencies should also be

conducted at least once in a year. One

of the mock drill should be in the Night

and/or Sunday/Holiday. Mock drill

report Should be prepared and

deficiencies should be corrected.

Mock drill report should circulate for the

understanding of outcome.

Mutual Aid Scheme is highly useful to

combat actual Emergencies. It is

suggested that Safety Officer may take

initiative in Mutual Aid Group.

P6

77

No Specific noise study has been done and

required.

It is suggested that meter should be

kept in good working condition,

Periodically calibrated and should be

use for Nose monitoring.

5.2.9 Firefighting equipment and Facilities

5.2.10 Fire Drills

INDUSTRIAL HYGIENE & OCCUPATIONAL HE6.1.3 Noise



78

Safety section is having Noise meter which was in

operational during the Audit.

Noise readings outside factory

boundary wall should be measured

during the Night time for the compliance

of Noise Act 2005.

79

Audiometric test is not conducted during periodic

medical checkup.

Audiometric test should be conducted

periodically for the persons who

suppose to be deployed in noisy area.

80Minimum one person at each work station is

qualified first aider.

It is suggested to display names and Tel no, of First

aider on First Aid Box.

81Trained first aiders available, however their names

are not displayed.

Names are to be displayed as near the First Aid

boxes.

82

List of required PPE for each hazardous

is available. During the audit survey

round it was observed that appropriate

PPE are available in work areas.

Helmets made available, Aprons PVC

Suits, Nitrile gloves Asbestos gloves,

and Ear muffs/Ear plugs were available.

Workers are also found wearing PPE.

Use of Safety glasses was not

observed.

Employees should be encouraged to

use Safety goggles on regular basis as

general precaution.

83Feedback from workers is not evident. It is suggested that workers may be involved in PPE

selection process.

84

PPE’s are available in Stores and issued to Plant/

Departments.

It is Suggested that safety Dept should

take a lead role to recommend and

release of PPE’s and should maintainthe record of issue.

85PPE’s purchased are of IS Standard. Always ensure procurement of good quality PPE’s

Only.

86

Site area map including layout access

roads and assembly points is not

available in Control room.

It is recommended that such map should be

displayed in Control room.

87

Hierarchy of emergency response

personnel is well identified in

Emergency Control Plan.

It is suggested that ‘Statement ‘ for

taking over charge by lower level official

in case of absentee of key personnel

should be included. There by system

will be automatically effective.

88

During the audit enquiry the siren for

declaration of emergency is not known

to all Employees especially contractor

employees

Standard practice of wailing Siren for

three minutes and Continuous siren for

one minute for Declaring emergency

and all clear should be followed and

should be communicated to employees.

6.5 PERSONAL PROTECTIVE EQUIPMENT (PPE) & EMERGENCY EQUIPMENTS

6.3 FIRST AID FACILITY AND OCCUPATIONAL HEALTH CENTRE

6.7 EMERGENCY PREPAREDNESS

6.7.1 Site Specific details

6.7.2 Duties and Responsibilities of Key personnel



89

Scenarios of various nature including

natural calamity such as earth quake

may be taken for mock drill and

emergency evacuation.

Different scenarios for mock exercise

should be taken. System of head count

should also be practiced.

90

Chances of off-site emergency areremote; however transport emergency

situations are not considered.

It is suggested that management mayconsider public awareness training in

future on off-site emergency plan and

transport emergency situations as well.

91

Check list for periodic inspection, such as

• Storage of Hazardous Chemicals

• Electrical hazards

• Fire safety

• Hand tools and portable tools

• Machine guarding

• Lifting equipment’s are not available

• House keeping

• Emergency equipment’s

• Gas cylinder. are in place

It is recommended that, such check list should use

for inspections.

DEPARTMENT OBSERVATIONS

ELECTRICAL 7FIRE 13

FINANCE 1

HORTICULTURE 1

HR & ADMIN 2

HSE 17

INSTRUMENT 4

MECHANICAL 19

OHC 4

OPERATION 19

PORT OPERATION 2

PROJECT 1

SECURITY 1

Total 91

Department wise Audit Findings

6.7.6 Periodic drills/exercises

6.7.7 Public awareness programme

6.8 SAFETY INSPECTIONS



Department Target Date Remarks

HSE

FINANCE

HSE

OPERATION

HSE

HSE

OPERATION

OHC

HSE

HSE

13

GEMENT



OPERATION

HSE

HSE

HR

MECHANICAL

MECHANICAL

MECHANICAL

MECHANICAL

MECHANICAL



MECHANICAL

MECHANICAL

OPERATION

MECHANICAL

MECHANICAL

MECHANICAL

MECHANICAL

MECHANICAL



FIRE

ELECTRICAL

OPERATION

MECHANICAL

OPERATION

FIRE

PROJECT



MECHANICAL

MECHANICAL

MECHANICAL

ELECTRICAL

OPERATION

OPERATION

ELECTRICAL

OPERATION

PORT

OPERATION



OPERATION

PORT

OPERATION

OPERATION

OPERATION

HORTICULTURE

MECHANICAL

MECHANICAL

INSTRUMENT

INSTRUMENT

INSTRUMENT

INSTRUMENT



MECHANICAL

ELECTRICAL

HSE

OPERATION

ELECTRICAL

HSE

ENTS)



OPERATION

FIRE

FIRE

ELECTRICAL

FIRE

FIRE

ELECTRICAL

OPERATION

FIRE

OPERATION



FIRE

FIRE

FIRE

FIRE

FIRE

FIRE

HSE

LTH



HSE

OHC

OHC

OHC

HSE

HSE

HSE

HSE

OPERATION

OPERATION

HSE



SECURITY

HR

OPERATION

audit compiance

Documents