health audit 2020 - nacl industries limited

OCCUPATIONAL SAFETY AND HEALTH AUDIT NACL INDUSTRIES PVT LTD UNIT-I

PROACTIONEERING CONSULTANTS-SAFETY


2020

Prepared by

PROACTIONEERING CONSULTANTS-SAFETY 78-4-9, SYAMALANAGAR RAJAHMUNDRY EAST GODAVARI DSTRICT ANDHRA PRADESH

[email protected]

NACL INDUSTRIES PVT LTD UNIT-I ETHAKOTA RAVULAPALEM MANDAL EAST GODAVARI DISTRICT ANDHRA PRADESH



OCCUPATIONAL SAFETY AND HEALTH AUDIT

2020

NACL INDUSTRIES PVT LTD

UNIT-I ETHAKOTA

RAVULAPALEM MANDAL EAST GODAVARI DISTRICT

ANDHRA PRADESH

Prepared by

PROACTIONEERING CONSULTANTS-SAFETY 78-4-9, SYAMALANAGAR

RAJAHMUNDRY EAST GODAVARI DSTRICT

ANDHRA PRADESH [email protected]



AUDIT REPORT DETAILS Safety Auditor from PROACTIONEERING CONSULTANTS-SAFETY Lead Auditor : Mr. B. RangaRao

Auditor : Mr. B. Ravindra

Co-ordinator from: NACL INDUSTRIES PVT LTDUNIT-I :Mr. KoteswaraRao

Asst. Manager Safety

Audit valigityupto: :May 2021



INDEX

CONTENTS PAGE No.

FORE WORD

1) INTRODUCTION 6

2) SPECIFIC OBSERVATIONS AND RECOMMENDATIONS 6

3) SCOPE AND OBJECTIVES OF AUDIT 8

4) ABOUT COMPANY AND PROCESS DESCRIPTION 8

5) AUDIT MEETINGS AND PARTICIPANTS LIST 8

6) FACILITIES & DETAILS OF DEPARTMENTS AND ORGANIZATION CHART.

9

7) ELEMENTS OF OCCUPATIONAL SAFETY AND HEALTH SYSTEM CHECKED

10

8) TYPES OF RECORD EXAMINED DURING THE SAFETY AUDIT 11

9) SYSTEMATIC OBJECTIVE AND DOCUMENTED EVALUATION OF OCCUPATIONAL SAFETY AND HEALTH SYSTEMS AND PROCESS

12

10) ACKNOWLEDGEMENT AND DISCLAIMER

37

11) DETAILS OF ANNEXURES AND ENCLOSURES 38



PREAMBLE:

The M/S NACL INDUSTRIES PVT LTDLIMITEDUNIT-I, Ethakota, RavulapalemMandal,

East Godavari District ,Andhra Pradesh. This factory was constructed and started

production on 1991.

M/S NACL INDUSTRIES LTD has assigned M/s PROACT SAFETY CONSULTANTS

PVT LTDto undertake the External Safety Audit. The auditors from PROACT visited the

Factoryon 28-05-2020 and conducted a Systematic Examination of the Facilities, safe

systems of Operation, Maintenance, Layouts and Records to study the suitability and

appropriate developments for further improvement of the existing Safe work methods,

documentation recording and safety management system.

The Audit was conducted based on the elements described in the code of practiceIS

14489:1998.The contents in this report are based on information and documents

provided by the company besides field observations and discussions, interviews made

by the Audit team.

Audit meeting was conducted on date 28-05-2020 in Training hall of Unit – II and

explained by the Auditor about the Occupational Safety and Health Audit, and Audit

Requirements, Audit Standards, Audit Scope and Methodology.The list of participants of

the meeting is enclosed in the ANNEXURE.Services of staff from the departments such

as Maintenance, Quality Control, Laboratory. Occupational Health Centre, H P Dand

Safety are commonly used for both the Unit-I and Unit II.

SPECIFIC AUDIT SAFETY OBSERVATIONS AND RECOMMENDATIONS:

During plant visits the following safety points are observed:

SUBJECT MATTER OBSERVATION/ RECOMMENMDATION

1. Covid-19 checks, sanitization, applying mask and maintaining the physical distance being followed as mandatory in the plant.

OBSERVATION

2. All are checked for Covid-19 at Main entrance gate.

OBSERVATION

3. Safety Policy is distributed to all but to make aware all in the plant about Safety Policy, its content. andit’s important.

RECOMMENMDATION

4. Occupational health centre to RECOMMENMDATION



maintain frequent occupational health problems of individual.

5. Health status of individuals with Blood Pressure, Diabetic and permanent diseases to help easily diagnose in serious health problems of individuals.

RECOMMENMDATION

6. Safety Officer to attend safety trainings for professional development in Safety techniques.

RECOMMENMDATION

7. Inter departmental competition on Good Housekeeping. A rolling shield and Awards may be proposed for creating interest in Safety among employees.

RECOMMENMDATION

8. Periodic safety training on effect of Noise to be conducted.

RECOMMENMDATION

9. Hazard analysis and risk assessment may be conducted for all jobs to identify hazards at each level.

RECOMMENMDATION

10. Statutory caution on chemical effect: Statutory caution boards to be displayed at all chemical storage and handling area that “ if any contact with body or eye wash thoroughly with plenty of running water minimum 15 minutes” then provide medical care.

RECOMMENMDATION

11. Road safety self protection: Safety helmets and Seat belts must be used by all factory people while driving on the roads.

RECOMMENMDATION

12. Foot protection for some of the workmen: Some of the personnel are working without safety shoes. Safety shoes may be provided to all in the plant.

RECOMMENMDATION



2. SCOPE AND OBJECTIVE OF AUDIT:

This report presents the findings and recommendations of the Safety Audit carried out

at all sections ofNACL INDUSTRIES PVT LTDLIMITED,Unit-I

This Audit is intended to identify to the Management the IS standard and the activity and

to advise whether they have been correctly assessed and appropriate steps to be taken

to prevent hazards and minimize their effects.

This Audit Aim is to promote contact with individual departments as manifestation of

management's interest, awareness and concern to gain their involvement, to encourage

suggestions relating to Safety and Occupational Health and entire co-operation.

3. ABOUT THE COMPANY AND PROCESS DESCRIPTION

Introduction to the company.

UNIT-I PROFILE

M/sNACL INDUSTRIES PVT LTDLIMITED,Unit-I is located in

Door. No .1-48. atEthakota village, RavulapalemMandal in East Godavari district

of Andhra Pradesh. The plant covers an area of 2.59 Acers and the plant is

adjoining the National Highway-5. The industry is 4 km away from Ravulapalem.

Core Activity of the Factory is to produce PESTICIDES and INSETICIDES.

NACL INDUSTRIES PVT LTDUNIT-I is engaged in production of Pesticides and

insecticides. These processes are associated with certain degree of hazards and

necessitate keen awareness and vigilance on process hazards, safety mechanisms

and safe handling practices.

4.AUDIT MEETING WAS HELDAT UNIT- II

The list and photographs of participants attended for the Audit opening and Audit

closing meetings are enclosed in the annexure



5. FACILITIES AND DEPARTMENTS:

NACL INDUSTRIES PVT LTDLIMITEDUNIT-I is having its water supply system from their bore well water facility. The major sections, departments and facilitiesNACL INDUSTRIES PVT LTDLIMITED

UNIT-I

The following process areas and facilities are there in the plant:

1. Production Blocks -3 Nos.

2. Packing material godowns-2 Nos.

3. Finished goods godowns- 2 Nos

4. Raw material godowns -2 Nos.

5. Laboratory-1

6. 10 ACM mill-1

7. Canteen building

8. Waste material yard

9. Wash room and change room-1

10. Administration Office building-1

11. Maintenance works shop-1

12. Electrical switch yard

13. Fire water tank, fire water pump, fire hydrants and fire fighting

equipment,

14. Drum hoist-1

15. Lifting hoist

16. Security

And average 50 persons are working in this plant.

Utilized the Safety services of Unit-II Safety officer, Mr. P. KoteswaraRao in this unit-

INACL INDUSTRIES PVT LTD Unit-II is the sister concern of the same NACL

INDUSTRIES PVT LTD group. The safety officer is attending for all safety requirements

and emergencies. NACL INDUSTRIES PVT LTDUnit-II is about 3 Kilo meters away.



6. The following elements of OS&H systems in the factory are checked during occupational safety and health Audit,

ELEMENTS OF SYSTEM CHECKED REMARKS

1. Occupational Safety & Health Policy Available

2. OS & H organizational setup Available

3. Educational and Training Available

4. Employees participation in OS & H Management Safety committee

5. Motivational and promotional measures for OS & H Available

6. Safety manual and rules Safetymanual Available

7. Compliance with statutory requirements Available

8. New equipment review / inspection Available

9. Accident reporting analysis investigation and implementation of recommendations

Available.

10. Risk assessment including hazard identification Internal departmental evaluation reports available. Recommended to cover the entire plant.

11. Safety inspections Available

12. Health & Safety improvement plan / targets Available

13. First aid facilities – occupational health center Available

14. Personal protective equipment Available

15. Good housekeeping Available

16. Machine and general area guarding Available

17. Material handling equipment Test cert. available

18. Electrical and personal safeguarding Being maintained

19. Ventilation, illumination and noise Being monitored

20. Work environment monitoring system Available

21. Prevention of occupational diseases including periodic medical examination

Available

22. Safe operating procedures Available.

23. Work permit systems Available

24. Fire prevention, protection and fighting systems Available

25. Emergency preparedness plans (on-site) Available

26. Process plant modification procedure Available

27. Transportation of hazardous substances Being followed

28. Hazardous waste treatment and disposal Being followed

29. Safety in storage and warehousing Checked

30. Contractor safety systems To be improved

31. Safety for customers (including material safety data sheets)

MSDS Available



7. The following Records are examined during OS&H Audit.

RECORDS EXAMINED REMARKS

1. OS & H policy Examined

2. Safety organization chart Examined

3. Training Records on Safety Fire and First aid Examined

4. Record of plant Safety Inspections Examined

5. Accident investigation reports Examined

6. Accidents and dangerous occurrences – statistics and analysis Examined

7. Record of tests and examinations of equipment and structures as per statutes

Examined

8. Safe operating procedures for various operations Examined

9. Record of work permits Record of monitoring of flammable and explosive substances at work place

Examined

Examined

10. Maintenance and testing records of fire detection and firefighting equipment

Examined

11. Medical records of employees. Examined

12. Records for industrial hygiene surveys ( noise, ventilation, and levels, illumination levels, air borne and toxic substances, explosive gases)

Examined

13. Material safety data sheets Examined

14. On-site emergency plans and record of mock drills Examined

15. Records of waste disposal Examined

16. Records of effluent discharges to the environment Examined

17. Housekeeping inspection records Examined

18. Minutes of Safety committee meetings Examined

19. Approval of layouts and other approval from statutory authorities

Examined

20. Records of any modifications carried out in plant or Process

Examined

21. Maintenance procedures records Examined

22. Calibration and testing records Examined

23. Shut down maintenance procedures Examined

24. In service inspection manuals, records including that of material handling

Examined

25. Safety budget Available

26. Inspection books and other statutory records Examined

27. Records of previous audits Available

28. Safety in transportation of hazardous substances Examined



8. SYSTEMATIC OBJECTIVE & DOCUMENTED EVALUATION OF

OCCUPATIONAL SAFETY AND HEALTH SYSTEM & PROCESS

SAFETY AUDIT POINTS STATUS.

Health and Safety Policy

1. Does the organization has a health and safety policy? Yes, it is in place

(If yes, please attach one copy)

2. Do you have any corporate safety policy? Yes corporate policy is there.

(If yes, please attach one copy)

3. Who has signed the health safety policy? (indicate his position)

Signed by Managing Director

4. Whether it is prepared as per guidelines of the statutory provisions?

Yes, The New safety policy is under preparation. Reviewinprogress at Managing Director.

5. When was the safety policy declared and adopted? Revised In January2019

6. How many times it has been updated till now? Updated in January 2019

7. Whether the policy is made know to all? To be improved among the employees.

8. Whether the safety policy was scrutinized by outside expert agency?

Yes, by IMS Auditors.

9. What was the last date of updation? January 2019

10. Does it find a place in the annual report? Not known.

Safety & Health Organization

A) Safety Department

11. Does the factory has a safety department? Safety department is these.

12. If yes, furnish the following information:

i) Head of the safety department: Asst. Manager (safety)

a) Name Mr. P. KoteswaraRao



b) Designation Asst. Manager-Safety for (Unit-II and For Unit –I)

c) Qualification B Sc. One year Industrial Safety certificate course from AP SBTET, Diploma In Industrial Safety from Annamalai University, M.Sc Environmental science. Dr. B.R.Ambetkar University.

d) Experience 10 years

e) Status Asst. Manager-Safety

ii) Strength of the safety department including safety officers and staff

One Safety officer and one safety Supervisor.

13. Does the head of safety department/safety officer report to the Chief Executive?

Yes, he is reporting to Plant Head.

14. How often are the safety officers retrained in the latest techniques of total safety management? What is the frequency of retraining?

Every year 2 or 3 external trainings retrained to safety officer. Recently trained in ISO 45001-2018 OHS management system, and Statutory regulations. Yearly two

15. What additional duties the safety officer is required to do? Nothing other than safety.

16. What is the power of safety officer vis-a-vis unsafe condition or unsafe act?

Immediate intervention

B) Safety Committee(s)

17. Does the factory has a safety committee(s)? Give details of their types, structures and terms of reference.

Safety Committee is there. The details are enclosed.

18. Is the tenure of the safety committee(s) as per the statute? Two years

19. How are the members of safety committee(s) selected? Selected



(elected/nominated)

20. How often are the meetings of safety committee(s) held? Once in three months

21. What are the subjects? Are the problems discussed in the meetings? (Attach a copy of agenda and minutes of the last meeting)

A copy is enclosed

22. How are the recommendations of the committee(s) implemented?

Discussed in daily meetings and implemented

23. Are the minutes of the safety committee(s) meetings circulated among the members?

Minutes of safety committee meetings are circulated.

24. Are the minutes forwarded to the trade union(s) and chief executive and occupier?

No trade union

25. How the management and trade union play their active roles in supporting and accepting the committee(s) recommendations?

No trade union

26. How are the safety committee(s) members apprised of the latest developments in safety, health and environment?

Discussing the safety matters regularly in safety committee meetings.

C) Safety Budget

27. What is the annual safety budget? 30 Lakhs+ 50 Lakhs

28. How much percentage is this budget of the total turnover of the company.

0 .45

29. How much budget has utilized till date? 80%

30. Is the safety budget adequate? Yes

31. How is the safety budget arrived at? Based on the requirement.

32. What is the pattern of expenditure for the last five years? All major activities completed, Fire HYDRANT SYSTEM, FIRE alarm , water pondscrubbers.

33. What are the approved sanctions for the expenditure in All major activities completed,



this budget? Fire HYDRANT SYSTEM, FIRE alarm, water pond. scrubbers.

34. Does this budget get reflected in the annual report of the company?

Yes it is.

ACCIDENT REPORTING, INVESTIGATION AND ANALYSIS

35. Whether the accident data for the last three years for reportable and non-reportable accident available?

Yes availableNo reportable accidents till date. *There is no Fatal accident and Non-fatal reportable accidents in our NACL Industries Ltd, Ethakota in the last 20 years. F.A injury: 2019-1, 2018-2 Near misses: 2019-1, 2018-4, 2017-1.

35. Is there any system of classifying and analyzing the near-miss incidents and accidents? Give the details?

Yes, the forms enclosed in Annexure list.We have been using Root cause analysis for all the accident investigations.

36. Is there any system of classifying and analyzing the near miss incidents and accidents? Give the details?

Near miss reports are there but to be encouraged for more reports.

37. Are all near-miss incidents and accidents reported and investigated?

Few near miss reports are found.

38. For how many years are the investigation reports retained?

Three years

39. By whom the accident statistics and data are maintained? By safety Department.

40. How is the top management apprised of these data? Monthly review meetings

41. Is the accident statistics effectively utilized? If yes, how? By publicizing the learning points.

42. What nature of injuries occurred during the last three years?

Minor injuries



43. How do you ensure implementation of the recommendations to avoid the recurrence of the incidents and accidents?

Discussed in meetings and implemented recommendations and monitored after implementation

SAFETY INSPECTIONS

44. What type of safety inspections are carried out and what are their frequency?

Theinspection system is in place.

45. Is there any system of internal inspection? Yes

46. Who does the inspections? Safety department.

47. Are the check-list prepared for these inspections? (Specify item-wise, for example, house keeping, fire protection, etc.)

Enclosed in the annexure.

48. To whom the recommendations are submitted? Marked to VICE PRESIDENT

SAFETY EDUCATION AND TRAINING

A) Training

49. Is there any training department? Coordination of training is done HPD department. Safety officer conducting safety trainings as per their schedules.

50. Is there any programme of induction training? Yes, we are following the safety induction training to new employees.

51. Mention the duration of induction training for each category of employees.

Basic safety induction one and half hour.

52. Whether the assessment of the trainee worker is done or not?

Available

53. What infrastructural facilities with audiovisual support are available for training?

Training hall available

54. Do the programs cover the plant safety rules, hazard Contents are enclosed.



communication and any other special safety rules or procedures unique to the plant or specific departments?

55. Whether the training programmes are conducted in the local language?

Yes trainings are being conducted in Telugu Language.

56. Whether visits to safety institutions/organizations are arranged?

No visits

B) Periodic Training/Retraining Available schedules is enclosed

57. Are all the employees trained and what is the frequency of such training?

The scheduled programs enclosed.

58. Do the training programmes cover safety and health aspects and if so how much (in terms of number of sessions/hours)?

Safety trainings done by safety department. The details are enclosed.

59. Do the trained supervisors train their own employees in safety and health aspects?

Training conducted specimen copy enclosed.

60. Is the retraining performed whenever new hazards/process changes are followed/introduced?

Yes at all new process introduction time.

61. How are the senior management personnel trained in safety and health?

All HOD’S and Sectional Heads trained in OHS management systems.

62. How many employees have been trained in safety and health in the last five years? Give break up with details.

Out Of 15 Employees all are trained in Safety firefighting, drills, PPE, chemical handling safety

63. How many man-days/hours are used in training the employees?

789man hours in 2015-2016 for unit 1 and 2.

64. How do you ensure that the training is put to use by the employees trained in safety and health?

By practice

65. What is the training plan for the next two years? Give details.

Training planner enclosed.



66. What documentation system has been established regarding safety and health training?

As enclosed.

c) Safety Communication/Motivation/Promotion By posters, signages.

67. Does the factory has safety suggestion schemes? Give details.

Pragathi suggestion scheme available.The scheme covers the following areas, conservation of energy, fuel, water, etc.Ideas on cost reduction, Ideas on operational simplification ideas on cycle time reduction. Ideas on maintenance operations. Ideas on environment & safety

68. Does your factory participate in National Awards/ Suggestion schemes?

Yes participated for safety awards along with Unit-II.

69. Has your factory been awarded during last five years? No safety awards.

70. Are safety contests organized in the factory? Give details. Yes, organized during National safety day celebrations

71. What are the publications of your organization? Do they include information on safety and health subjects?

Monthly news letter

72. Is the literature on safety and health made available to the employees?

Soft copies to all sections

73. How is the safety and health publicized in your factory?

i) Bulletin boards? Notice boards and posters.

ii) Post serious accidents?

iii) News letter? News letters by soft copies from corporate office.

iv) Others? Specify

74. Does the organization celebrate safety day/week or organize safety exhibition?

March 2017-National Safety week performed.

75. When was the last safety day/week celebrated? A week of March 2017.



FIRST AID

76. Are adequate number of first aid boxes provided? Give location details?

Yes , 3 first aid boxes available Security-1, QC, Office,

77. Is there any first aid/ambulance room? Available at Unit –II

78. Are qualified/trained first aid's available in each shift? Available at Unit-II

79. How many qualified/trained first aide's are available at each plant/department?

As on date03 persons available.

80. How many persons are trained/given refreshers training in first aid in a year?

Trained 05 persons.

OCCUPATIONAL HEALTH CENTRE

81. Whether occupational safety and health center is provided or not?

Centre is provided at Unit-II the details are enclosed. All required services are getting provided byNACL INDUSTRIES PVT LTD Unit-II, a sister concern of the same industrial group.

82. Does it confirm to the provisions of the existing location? located near by Admin building of Unit-II

83. Are the Medical Attendants/Doctors available in each shift?

Medical attendant in regular basis and Medical doctor visits thrice a week at Unit-II

84. Is ambulance van available in each shift? Ambulance van is available at Unit-II

85. Any liaison with the nearest hospital(s)? Give details. Yes, Liaison with Bhavani Hospital Ravulapalem for emergency cases. We have medical officer MBBS with agreement. For any emergency doctor available at 2 km distance.

GENERAL WORKING CONDITION

A) House Keeping Satisfactory



86. Are all the passages, floors and the stairways in good condition?

Yes.

87. Do you have the system to deal with the spillage? Available

88. Do you have sufficient disposable bins clearly marked and whether these are suitably located?

Yes it is there

89. Are drip trays positioned wherever necessary? Not applicable.

90. Do you have adequate localized extraction and scrubbing facilities for dust, fumes and gases? Please specify.

Scrubbing system in place

91. Whether walkways are clearly marked and free from obstruction?

Yes, Walk ways are clear with marking.

92. Do you have any inter-departmental competition for good housekeeping?

Suggested to have a competition among departments.

93. Has your organization elaborated good housekeeping practices and standards and made them known to the employees?

Good housekeeping will be improved by internal competition.

94. Are there any working conditions which make the floors slippery? If so, what measures are taken to make them safe?

At present no slippery conditions are there

95. Does the company have adequate measures to suppress polluting dust arising out from road transport?

No dust in the plant from road transport

B. Noise

96. Are there any machines/processes generating noise? Specify.

No such hazards in the plant All of our employees are aware about noise effects. Every year we have conducted hearing tests in medical health checkups.

97. Was any noise study conducted? Yes, the third party study certificate enclosed.

98. Which are the areas having high-level noise? DG room and 10



ACMmachine area etc.

99. Have engineering and administrative controls been implemented to reduce noise exposure below the permissible limits?

Acoustic system, Ear muffs and ear plugs are supplied to the area persons.

100.Is there a system of subjecting all those employees to periodic audiometric test who work in high level noise areas?

Medical tests are conducted.

101.Whether the workers are made aware of the ill-effects of high noise?

Conducted training on effect of noise. All are aware. Every year we have conducted hearing tests in medical health checkups

102.Whether any personal protective equipment along with ear muffs/plugs are provided and used.

They are in place

C) Ventilation

103.Whether natural ventilation is adequate or not? Many areas of operation are in open buildings

104.Whether dust/fumes/hot air is generated in the process? Give details.

No hot air, if any chemicals and fumes to be exhausted by turbo ventilation.

105.Is there any exhaust dilution ventilation system in any section of the plant?

No exhaust dilution ventilation at present..

106.Whether any ventilation study has been carried out in the section(s) to check the record?

No.

107.Are periodic/preventive maintenance of ventilation system carried out and record is maintained?

No

108.Does any ventilation system re-circulate the exhausted air in work areas?

Not Applicable

109.Is the work environment assessed and monitored? Third party pollution checks records are in place.

110.Whether personal protective equipment are given to workers exposed to dust/fumes and gases? Give details.

All required types of PPE used in the plant are



enclosed

111.Was any study carried out for the assessment of illumination level?

Yes.

112.Is there any system of periodical cleaning and replacing the lighting fittings/lamps in order to ensure that they give the intended illumination levels?

It is part of maintenance management program.

113.Are the workers subject to periodic optometry tests and records maintained? Give details.

Periodical medical checks done.

114. Are all the hazardous areas identified? Yes identified, the major hazardous area is LPG fuel manifold area boiler connection

115. What are the types of hazards (physical-noise, heat, etc. and chemical-fire, explosion, toxic release, etc.)?

All hazards are addressed and minimized with all possible control measures. And no abnormal heat, chemical fire.

116. What steps have been taken to prevent these hazards? Give details?

In case of any Fire/Gas leak in the LPG area, to control the fire/gas leak within the minutes, we have provided Auto fire control Balls at the top of the manifold area. We operate the Water Sprinklers Within minutes for cooling LPG cylinders and control the manifold adopter valves. We have Provided LPG Gas detectors, automatically it raise siren and we will act with in minutes.

1) We have Well

equipped Emergency

control Centre with all

equipment’s near

Assembling point.

2) Well trained

Emergency Rescue

team (Fire Fighters &

First Aiders) available



round the clock.

3) Security Team also

trained in Fire Fighting

and Rescue

operations.

4) Well Laid Above

ground Fire Hydrant

System has been laid

throughout the

premises as per the

TAC guideline,

keeping in mind area

wise hazard

categorization, based

on which the distance

of hydrant posts were

provided. To maintain

minimum hydrant

pressure of 7 kg/cm2 .

Jockey Pump , Main

Pump and Diesel

Driven Pumps are

provided at fire pump

house near water

reservoir.

117. Are there any safety interlocks, alarms and trip system? Give details.

We have provided fire alarm and smoke detection system to the all buildings. All Building having ELCB if any current or high voltage, ELCB will Tripped

118. Are these tested periodically? How often? Please specify Tested periodically Skip Hoists-Half yearly Fire Alarm –every quarterly Power panels -monthly

119. Are there any ambient monitoring devices with alarms for leakage of hazardous materials? Give details.

No



120. Are safety audit or HAZOP or any other studies carried out and the recommendations implemented? Give details.

Every year we have conducted safety audit with external auditor, and recommendations complied, HOZOP not done due to it is only mixing and packing formulation unit.

121. What has been the major modification done in plant/ process and has the approval of the competent authority concerned?

We have, change control procedure for any modification or process. Statutory approvals taken for major approvals.

122. What decision and monitoring equipment are available and used for checking the environmental conditions in and around the plant? Give details

Third party checks for environment.

TECHNICAL ASPECT

Safe Operating Procedures

123. Are written safe operating procedures available for all operations?

Standard operating procedures are available in the plant which are to be reviewed to incorporate safety aspects

124. Whether the written safe operating procedures displayed or made available and explained in the local language to the workers?

Work instructions are there

125. Whether the safe operating procedures are prepared jointly by the plant and safety departments?

Yes

126. What system is used to ensure that the existing safe operating procedures are updated? Give details.

Not applicable

127. Have the workers been informed of the consequences of failure to observe the safe operating procedures?

Yes informed in training classes.

128. Are contractor workers educated and trained to observe safety at workplace?

We have given training to all contract workmen. Induction training to new workers.



Firefighting, PPE, Chemical handling training given to contract workers.

129. Whether contractor's workers are permitted on process/ operations? Give details.

Not directly/ not individually permitted. They are engaged only for loading,unloading and packing of the materials.

WORK PERMIT SYSTEM

130. What necessary type of work permits exists in your factory? Give details.

Work permit system is there in the plant. The specimen copies of work permits are enclosed in Annexure.

131. What are the hazardous chemicals handled? The list of chemicals is enclosed.

132. Are the keys kept for individual locks which are used for electrical lock outs with the supervisor concerned?

Yes We follow Lock Out Tag out procedure to all equipment’s isolation

133. Is identification done for various types of wastes? Give details.

Identification of Various types of waste is done.

134. Are these quantities less than those specified by the hazardous wastes. (Management & Handling Rules, 1989)?

Yes, it will be complied with consent

WASTE DISPOSAL SYSTEM

135. What are their disposal modes? The hazardous waste being disposed to the recognized vender.

136. What are the systems/measures adopted for controlling air/water/land pollution?

Periodical Air pollution monitoring is going on. No chemical waste water discharge.

137. What is the system of effluent treatment plant and whether it is approved by the competent authority?

Not Applicable

138. How are the treated effluent used? Not Applicable

PERSONAL PROTECTIVE EQUIPMENT (PPE)

139. Has a list of required PPE for each area/operation been developed and the required PPE is made available to the workers?

Yes.



140. Are the safety department and the workers consulted in the selection of PPE?

Yes.

141. Have the workers been trained in proper use of PPE? In induction training these points are discussed. Topics are enclosed.

142. What is the system of replacement/issue of PPE? Periodical issues and need based issues.

143. What are the arrangements for safe custody and storage of PPE provided to the workers?

Lockers provided.

144. Are the contractor's workers provided with the required PPE? Who is responsible? Give details.

Company is responsible to provide PPE for contract workers.

145. Are the PPE conform to any standard? Give details. IS standard.

146. Give the details of PPE and also specify the responsibility for their inspection and maintenance?

Individual are responsible for inspection of PPE.

FIRE PROTECTION

147. Indicate on a plant layout the location, number (Quantity) and types of portable fire extinguishers available?

Plan layout with all firefighting equipmentdetails is enclosed in ANNEXURE.

148. Are the fire fighting system and equipment approved, tested and maintained as per relevant standard?

Yes.

149. What is the inspection and maintenance schedule of the above extinguishers? Who performs these functions?

Third party/ Safety Department Maintenance and inspections are available.

150. Which areas of the plant are covered by fire hydrants? Indicate the locations of the hydrant points and how the required pressure maintained in the system and ensured.

All areas of the plant are covered.

151. What is the capacity of dedicated water reservoir for supply to the hydrants? What is the source of water?

Details are enclosed.

152. a) How is the power supply to the fire hydrant pump ensured?

Alternative D G power

b) What is the alternate source of supply in case of power failure? Give details.

D.G.sets are available



153. Are all personnel conversant with the fire prevention and protection measures? Give details

All departmentspersonnel are Trained in fire prevention and firefighting.

154. What percentage of plant personnel and staff and officers, have been trained in the use of portable fire extinguishers? Give details.

100 % of the employees trained in Fire Fighting and use of portable extinguishers.

155. Do you have fixed or automatic fire fighting installation(s) in any section of your plant?

Yes, the locations and detailed list is enclosed.

156. Are the fire alarms adequate and free from obstruction? Yes

157. Do you have fire department? If yes, give details. Safety department is looking after fire department.

158. What is the system for conducting mock drills? Give details.

The specimen copy of a mock drill is enclosed.

159. Do you have any mutual aid scheme with any of your neighboring industry or any local organization(s)?

Yes, it is there

160. Give details of the existing fire resistant walls and doors. At present No fire resistant walls.

161. Do you have any system of color coding for all the pipe lines for hazardous chemical? Give detail including marking of flow directions.

Yes color coding system is there.

162. Are there any safe containers for the movement of small quantities of hazardous chemicals? Give details.

Chemical containers.

163. Are all self-closing fire doors in good condition and free from obstructions?

No self closingFire doors in the plant.

164. How many major and minor incidents/fires were there in the factory during the last five years? Give department/ plant wise.

No fire incidents.

165. Have all the fires/incidents been investigated and corrective actions taken? Give break up.

Not Applicable

EMERGENCY PREPAREDNESS

166. Is there on-site emergency plan for your factory? (attach On site Emergency plan



a copy of the plan) isavailable in site.

167. What is the frequency of conducting mock drills of on- site emergency plan?

Presently Once in three months.

168. What are the number and location of emergency control centre, assembly points?

OneEmergency control centre and 1Nos.of Assembly point

169. Whether emergency team or the key personnel identified?

Yes.

170. Are suitable and adequate protective and rescue equipment available? How is the emergency rescue team trained to use these equipment?

Trained bysafety department. They practice in Mock drills.

171. How is the emergency communication with local bodies and other organizations ensured? Give details.

As detailed in the emergency management plan.

172. Is any alternate power source identified? Give details. D G power is available.

173. What is the medical emergency response system? Give details.

As detailed in the emergency plan..

174. Are your a member of any MUTUAL-AID-SCHEME of your area? If so give details?

As detailed in the onsite emergency plan.

175. How many emergency alarm system(s) is/are available? Give details.

Four types of Emergency alarm available in the plant

1. Electrical siren 5 KM Range

2. Megha apahone-1 Hooters and manual call points at all blocks.

PLANT LAYOUT AND AREA CLASSIFICATION

176. What is the system of classification of hazardous zones in the plant for electrical installations? Please specify?

The plot plan is enclosed.

177. Whether periodic inspection and preventive maintenance of electrical installations is done by a qualified person and record is maintained?

Inspections are done. We followed all procedures, Maintained all records.

178. Whether plant layout with area classification has been displayed at appropriate place(s)?

Displayed at entrance of the gate.



STATIC ELECTRICITY

179. Whether the process(s) and equipment generate and accumulate static charge have been identified? Give details.

Care is taken at all operations of batch process.

180. Whether all such equipment are properly bonded and earthed?

All electrical equipment are earthed.

181. How is electrical resistance for earthing circuits maintained? Are periodic inspections done and recorded?

Periodic inspections are recorded.

182. Are adequate earthing arrangements made at the terminal points where hazardous chemicals are handled through pipes?

Earthing provided.

183. Are anti-static charge devices fitted wherever necessary? Not Applicable

184. Whether these devises are periodically checked and maintained by a qualified person?

Not Applicable

PRESSURE VESSELS (FIRED AND UNFIRED)

185. Give details of the plants, piping and vessels which are operated at a pressure greater than the atmospheric pressure.

Fired boiler is being inspected by the Inspectorate of boiler and certified.The unfired pressure vessels are being maintained by the plant department and inspections done by competent person.

186. How it ensured that the working pressure inside the pressure vessels/pressure plants will not exceed their maximum working pressure for which it is designed?

Pressure gauges and overpressure safety relief valves are paced with pressure vessels.

187. What means of isolating the pressure vessels or means to prevent rise in pressure are installed?

Overpressures are controlled by continuous monitoring and auto blow valves.

188. What standards/codes of practice are adopted for design, fabrication, operation and maintenance of the pressure vessels and records maintained?

The pressure vessels are of standard companies such as Elgi, United engineering and Atlas copco.

189. How are the pressure vessels tested? Give details. Ultrasonic thickness tests and hydrostatic test as requiredby the factories Act and A.P.



Factories Rules.

190. Is there any competent person for testing these pressure vessels? Give details

Specimen copy of test certificate is enclosed.

191. How are the recorded results verified? Test certificates are verified and enclosed.

192. Give details of safety devices available for these pressure vessels?

Pressure relief valves, pressure gauges and cutoff valves and continuous pressure monitoring system.

193. Whether log book for pressure vessel and pressure plant has been maintained?

Maintenance records being maintained

NEW EQUIPMENT REVIEW

194. What is the system for effecting any change in the existing plant, equipment or process? Whether it is approved by the appropriate competent authority?

Discussions and approval system is in place

195. Whether the P & I diagrams and other related documents are updated accordingly?

Not applicable.

LIFTING MACHINES & TACKLE

196. Whether all the lifting machines are marked with their S.W.L?

Marked.

197. Are all the examinations and tests documented in the prescribed form?

Yes

198. Are all the examinations and tests carried out and certified by competent person(s)? Give details.

Tests have been conducted by a competent person. The specimen copy of certificate is enclosed.

199. Are adequate lifting tackles provided at all the places where it is required? Give details.

At required places the lifting equipment are provided.

200. Are the trained operators engaged for operating the equipment? Give details.

Operating by experienced persons.

201. What is the system of training such operators? Inplant safety training by safety department.

202. Are all the lifting machines and tackles maintained in The lifting machines and



good conditions and record maintained? tackles records are maintained.

MOBILE EQUIPMENT AND VEHICULAR TRAFFIC

203. Are all the mobile equipment in good condition? No motorized mobile equipment is used in the plant. Hand trolleys are available, people are trained in operating these equipment.

204. Are trained drivers engaged for fork-lift trucks? Not Applicable

205. What is the system for identifying the drivers from other drivers?

Not Applicable

206. What system do you adopt to assess their standard of driving as poor/fair/satisfactory/good?

Not Applicable

207. Are there adequate number of warning signs/signals? Not Applicable

208. Are the hazards associated with transportation within the plant identified and safety measure taken? Give details.

Not Applicable

ACCESS

209. Is adequate safe access provided to all places where workers need to work?

Yes, all work places have easy access.

210. Are all such access in good condition? They are in Good condition.

211. Are portable access platforms necessary? If yes: Fixed access by stair cases and no platforms in working areas.Portable ladders are provided at required places.

a) Are these sufficient? Yes they are sufficient.

b) are these regularly inspected? Yes. These are inspected.

c) are these readily available? Ladders are portable.

d) are these provided with toe-boards and railings? No such stair cases or stair cases.

212. Oiling and greasing points:

a) are these located and extended to safe place clear of No oiling and greasing points



moving parts? in the plant.

b) are these easily accessible? Not applicable

c) are these liable to drip into walkways? Not applicable

d) whether such workers were trained and whether they are provided with fit-tight clothing and register is maintained?

Not applicable

213. Are all drain covers in good condition and fitting flush? All drains are covered

MATERIAL HANDLING

214. Are there adequate storage facilities available? Yes available

215. Are these areas clearly defined? Yes defined

216. Are all racks and steel ages in good condition? They are in satisfactory condition.

217. Have you adequate equipment for handling materials? Adequate equipment are there.

218. Do the workers know the hazards associated with manual material handling?

Yes, By Safety training.

219. Where manual handling is necessary, are the workers been trained?

Yes. They are trained.

220. Do they practice this? Yes. They follow.

221. Do workers follow safe procedures for storage of materials?

Yes. They follow.

222. Whether contractor workers are trained in safety? Yes contractors are trained.

223. What is the system for handing over plant to the maintenance department and receiving back?

Permit to work system.

224. Is the system consistently applied? Applied consistently

225. What is the system for the preventive and predictive maintenance and how do you ensure its effectiveness? Give details.

We have followed Maintenance module in SAP online system for Preventive maintenance, Breakdown maintenance, and general



modifications as per the work order issued by Users engineering department resolve the issues and close it.

226. Whether it is pressure vessel or not No pressure vessel.

227. Give storage vessels designation (exceeding threshold quantities specified in MSIHC, Rules 1989)

No storage vessels at site.

228. Give the names of storage materials in each of them. No storage vessels at site.

229. What are the vessel sizes (capacitytonnes)? Not Applicable.

230. What is the material of construction for each vessel and what standards followed in designing/fabricating the vessel?


231. What are the operating pressure and temperature? No storage vessels at site.

232. What are the vessels location? (Please indicate on-site plan or plot plan)


233. Indicate whether vessels are above ground/underground Not applicable

234. If any of the tanks storing flammable material, whether electrical installations are flameproof or not?

Not applicable

235. Are these storage vessels bunded/diked? Not applicable.

236. If yes, what is the capacity of the bunds/dikes? Not applicable

237. Are the vessels properly bonded and earthed and whether periodically checked and record maintained?

Not applicable

238. How are vessels isolated in the event of a mishap? Not applicable

239. Are the vessels fitted with remotely controlled isolation valves?

Not applicable

240. Are vessels provided with emergency vent, relief valve, bursting disc, level indicator, pressure gauge, overflow line?

Not applicable

241. Where do such vents discharge? Not applicable

242. Are the vessels provided with alarms for high level, high temperature and high pressure?


243. Are stand by empty tanks provided for emptying in case No storage vessels at site.



of emergencies?

244. What are the provisions made for fire fighting/tackling emergency situations around the storage vessels?


245. Has any consequence analysis been carried out for these vessels? (If yes, give details)


246. What periodical testingare carried out on the vessels to find out the integrity of the vessels?


247. Whether these tests are certified by the approved competent persons?


248. Whether log sheets are filled up on daily basis for recording the parameters of these vessels?


ON-SITE GAS CYLINDERS STORAGE AREA

249. What are the various gas cylinders used in the plant? (give details)

LPG cylinders in the plant.

250. What are the storage facilities? In a manifold and operating system approved by the PESO and all cylinders having tag of integrity with test date and filling date.

251. What are the measures taken for combating any emergency in the cylinders storage area?

Followed all safety systems as PESO recommended.

252. Are valid licenses available for storing all these cylinders?

Yes obtained the PESO approvals and license.

253. Whether integrity test certificates are obtained from the suppliers of the cylinders?

Yes, we are using gas cylinders at QC for GC HPLC, All cylinders having tag of integrity with test date and filling date.

COMMUNICATION SYSTEM ADOPTED IN PLANT

254. Are public address system available in all plant areas? Presently Mobile cell phones and land line phones are available.

255. Are public systems provided with uninterrupted power supply?

No,



256. Whether public address system is checked periodically for its proper functioning?

N A

257. Is there any hot line provided to fire station? Land line

258. What is the means of communicating emergency in the plants?

Cell and land line Phones,

TRANSPORTATION

259. What potentially hazardous materials are transported to or from the site (including wastes)?

All raw materials list is enclosed.

260. What modes of transport are used: By road trucks.

a) Road? For personnel movement, raw materials and finished products

b) Rail? No

c) Pipelines? No.

261. Does the company employ licensed vehicle of its own/ outside sources?

Outside sources

262. Are the loading/unloading procedures on-site and safety precautions displayed?

Not sufficient

263. Are loaded tankers or trucks parked in a specific area on-site?

Not applicable

264. Do all truck and tanker drivers carry TREM card or instruction booklet?

TREM cards are in place

265. Do all truck and tanker drivers get training in handling emergencies during transport?

They are of outside source. Not known about training.

RAIL

266. What hazardous materials are transported by rail? Not applicable

267. Does the company have a direct siding on site? Not applicable

268. Are tankers or others wagons used in transportation? Not applicable



PIPELINES

269. What materials are transported to and from the site by pipeline?

Not Applicable, No pipe lines in this unit.

270. Are the pipelines underground or over ground? Not Applicable, No pipe lines in this unit.

271. Are corrosion protection measures employed in pipelines?


272. Whether intermediate booster pumps are used? Not Applicable, No pipe lines in this unit.

273. What is the maximum, minimum and average transfer rates?


274. Are the pipelines extended in the public domain? Not Applicable, No pipe lines in this unit.

275. Are the pipelines dedicated for each type of chemicals? Not Applicable, No pipe lines in this unit.

276. Are the pipelines fitted with safety equipment such as leak detectors, automatic shut-off valves, etc.?


277. What is the frequency and method of testing of the pipeline?


278. Is there written procedure for tackling leakages in pipeline?



PROACTIONEERING CONSULTANTS-SAFETY Page 38

DETAILS OF DOCUMENTS EXAMINED AND MEETINGS HELD DURING OS&H

AUDIT AND ENCLOSED SOME OF THE COPIES IN THE ANNEXURE

DOCUMENTS/ MEETINGS Remarks & enclosed

1. Audit Opening meeting Photographs Enclosed

2. SAFETY Policy, Enclosed

3. Organization chart. Enclosed

4. Process flow charts Enclosed

5. Fire Extinguishers details Enclosed

6. Firefighting equipment third party inspections. Enclosed

7. Fire fighters list Enclosed

8. First Aiders list Enclosed

9. Mock drill specimen as per emergency plan Enclosed

10. Safety Committee members for the year 2015-2016 Enclosed.

11. Specimen copies of Competent persons test reports

of lifting equipment and pressure vessels.

Enclosed

12. Raw materials list Enclosed

13. Utility details Enclosed

14. Incident/accident/ near miss/ first information

report

Enclosed

15. Work place monitoring check list Enclosed.

16. Check list for fire extinguishers Enclosed

17. Plant safety inspection check list Enclosed

18. Check list for eye and body wash showers Enclosed

19. Check list for eye wash bottles Enclosed

20. Check list for fire hose boxes Enclosed

21. Hot work permit- copy. Enclosed

22. Govt. of AP. Payment treasury slip. Enclosed

23. Training plan for the year 2016-2017 Enclosed.

24. Training calendar for the year 2016-2017 Enclosed.

25. Ambient air quality test report. Enclosed.

26. Annual medical examination report- copy Enclosed.

27. National fire safety week celebrations report Enclosed.

28. National safety week celebrations report Enclosed.

29. Report of examination of pressure vessels, lifting

equipment and safety belts- copies.

Enclosed.

30. Earth resistance values of 2016-2017 Enclosed.

31. Factory plot plan copy Enclosed.

End

health audit 2020 - nacl industries limited

Documents