vehicle inspection protocol

Revision: 0

Page 1 of 17 Date Prepared: Aug 30, 2009 Date Revised:

Vehicle Inspection Protocol Revision: 0


1.0 Purpose:

The Purpose of this procedure is to ensure that all Heavy Vehicles entering the EPCL site must meet the minimum accepted fitness level defined through this procedure.

2.0 Scope:

All Vehicles transporting hazardous chemicals, hazardous materials, Finished products, Raw materials, waste (any type), scrap and warehouse material will be inspected and checked through this procedure.

3.0 Definitions: 3.1 Class A Vehicles:

All vehicles transporting EDC, 50% Caustic, HYPO, HCL, H2SO4, Spent Acid regardless of the quantity will come under this category.

3.2 Class B Vehicles:

All vehicles transporting PVC, Salt, Waste disposal, Scrap removal, warehouse deliveries, sewerage collection will come under this category.

3.3 Transporter

Owner of the Vehicle will be termed as Transporter, he may be direct owner, or may be arranging the vehicle through some other company.

Sr. # Chemical Transported

Transporter Company

Traker YES / NO

EPCL Focal Point

1 EDC Shakoor Yes MI 2 Caustic Shakoor

Tri Star Yes Yes

MI

3 HYPO Shoaib Trader No Zaki Shareef 4 PVC New Malik

BSL Capital Agility Faisal

No No No No No

MI

5 Salt Hub Salt No YAS 6 HCL Shoaib Trader No Zaki Shareef 7 H2SO4 Shoaib Trader No Zaki Shareef 8 Spent Acid Shoaib Trader No Zaki Shareef



9 CA Waste Different No AZ 10 Ware house Misc.

Chemicals Different No HMA

11 EDC /VCM Waster water

Govt. No FA

12 Domestic Sewerage waste

Different No FA

4.0 Procedure: Vehicles that come under the umbrella of this procedure has been divided into two groups, Group A and Group B, refer to section 3 for definition.

4.1. Vehicle Fitness certificate by Transporter

4.1.1. This clause is applicable for Class A vehicles only. 4.1.2. It is the responsibility of transporter to provide EPCL with Vehicle

fitness certificate issued from Vehicles Department, Government of Pakistan.

4.1.3. This certificate shall be provided to EPCL Supply Chain

department, and after checking its validity a sticker will be issued having information about the vehicle, and expiry date of the sticker.

4.1.4. Security guard will ensure that this sticker (See Attachment-1) is

present on the Vehicle and only then he will allow Class A vehicles to enter the site.

4.1.5. For all vehicles having this sticker will exempt them from Safety

checking at the main EPCL gate. 4.1.6. For Class A vehicles having this valid sticker, Security guard will

not be required to fill the standard vehicle inspection checklist (See Attachment-2), this will only be required for Class B vehicles, however for some Class B vehicles Admin is authorize to issue stickers after Safety inspection.

4.2. Truck Monthly Inspection Program by Transporter

4.2.1. This clause is applicable for Class A vehicles only. 4.2.2. Detailed Monthly inspection checklist (See Attachment-3) prepared

by EPCL shall be used by the Transporter.

4.2.3. Monthly Inspection checklist shall be filled for each vehicle separately, and will be submitted to EPCL Supply chain



Department by 7th of each month. A signed copy will be kept inside the truck by Transporter all the time. Any Auditor may check this checklist.

4.2.4. If there are any deficiencies, Supply chain will communicate it to the

Transporter and may disallow truck entry to EPCL Site.

4.2.5. If Monthly truck inspection checklist is not filled, or is not made available then entry to site will be restricted, this will be audited by HSE, Supply chain or during any MSA Audit.

4.2.6. A financial Penalty up to Rs 10,000/- may be exercised on false

filling of the checklist, or not filling it at all. This will be done by EPCL Supply Chain Department.

4.2.7. Random checks on 10% vehicles will be carried out by EPCL thru

their MSA Audit program.

4.2.8. Record keeping and tracking of the Monthly inspection checklists will be done by EPCL Supply chain, and non-compliances will be notified to Transporter and to EPCL Management.

4.2.9. EDC, Caustic, HYPO and HCL Tankers will also be required to fill

the Tanker inspection checklist (See Attachment- 5)

4.3. Truck Inspection at EPCL Gate# 6

4.3.1. This clause is applicable for Class B vehicles only 4.3.2. EPCL will provide vehicle inspection checklist at gate 9See

Attachment-2)

4.3.3. EPCL Security guard will fill truck inspection checklist at gate.

4.3.4. In case of any doubts about the safety condition of the vehicle, Security guard many seek help from EPCL Shipment officer or HSE.

4.3.5. All vehicle having valid Vehicle inspection Sticker (See Attachment-

1) will not require safety check at EPCL gate. Class B vehicles can also be provided with the Vehicle Inspection sticker upon approval of Shipment Advisor.

5.0 Drivers Safety 5.1.1. For all Class A vehicles it is the responsibility of Transporter to provide the

driver / Helper information to EPCL Supply chain.



5.1.2. Driver / Helper information sheet (See Attachment-4) will be filled and

submitted for all drivers and Helpers of Class A. 5.1.3. Drivers / Helpers Safety orientation will be conducted by Transporter,

however they will special Safety session conducted or them by HSE.

6.0 Training 6.1.1. It is the responsibility of Transporter of Class A vehicles to conduct

training of drivers and Helpers on hazards associated with the vehicle, including Defensive driving training. Attachment-6 will be used to guide the drivers about the hazards associated with the vehicle.

6.1.2. HSE of EPCL will conduct safety trainings of these drivers on the

following subject;

6.1.2.1. HAZCOM 6.1.2.2. Spill Control 6.1.2.3. Emergency Response Plan 6.1.2.4. First Aid 6.1.2.5. Plant HSE rules and regulations

7.0 Attachments:

7.1. Attachment 1 Class A Vehicle Sticker 7.2. Attachment 2 Vehicle Inspection checklist at Gate

7.3. Attachment 3 Monthly Vehicle Inspection Checklist

7.4. Attachment 4 Driver / Helper information

7.5. Attachment 5 EDC / Caustic / HYPO / HCL Tanker Safety

Checklist



ATTACHMENT-1

ENGRO POLYMER AND CHEMICAL LTD

Class A / B Vehicle Sticker #________

Transporter Name Vehicle Registration #

Chemical Transported Vehicle Fitness Certificate #

Detail Safety Inspection Date

This Vehicle has been inspected and is fit for use,

Sticker is valid for 06 Months. Sticker Expiry Date:

Requested BY; Approved BY: Transporter ____________ Logistics Section Head________________



ATTACHMENT-2

VEHICLE INSPECTION CHECKLIST AT EPCL PLANT GATE

Date & Time: Product :

Vehicle Reg. #:

Note: 1. Check all items and write "D" in status column if it is working correctly. Write "U" if it is faulty. If item is marked "U" provide explanation.

2. If an item is not related to your vehicle than write "NA"

Sr # Items Status

1.1 Horns

1.2 Light

1.3 Tyre Condition OK

1.4 No Mobile

1.5 Oil Leaks

1.6 Hanging Electrical Cables

Remarks

Security Guard Security Supervisor



ATTACHMENT-3

Monthly Vehicle Inspection Checklist ONLY APPLICABLE FOR CLASS A VEHICLES

Date & Time: Product :

Origion/Destination: Vehicle Reg. #:

Company : Vehicle Make and Model:

Driver-1 Name & Code: Vehicle Capacity :

Driver-2 Name & Code:

Note: 1. Check all items and write "D" in status column if it is working correctly. Write "U" if it is faulty. If item

is marked "U" provide explanation. 2. If an item is not related to your vehicle than write "NA"

1.00 In Cabin Checks 1.14 Clean cabin Interior

1.1 Ease in starting 1.15 Dash Board Switches

1.2 Abnormal Noises/Misfiring/Knocking 1.16 Door Glass Operation / condition

1.3 Engine Oil Pressure 1.17 Wind Shield Condition/Visibility

1.4 Alternator/Generator Charging 1.18 No Loose object in cabin

1.5 Horns

1.6 Head Light ON (Low/Dipper/High)

2.00 Top Checks

1.7 Indicators-Hazard /Left/Right

2.1 Clear top

1.8 Parking Light 2.2 Man hole Lids, Locks & Seals

1.9 Brake Light 3.00 General Checks

1.10 Function of Brakes 3.1 Rear View Mirrors Outer Left

1.11 Low air pressure warning/buzzer

3.2 Rear View Mirrors Outer Right

1.12 Pressure Brake 3.3 Jack & Jack Rod

1.13 Reverse Light & Buzzer 3.4 Pliers & Screw Drivers



3.5 Clutch & Gear Change Operation

6.2 Wheel Spanner

3.6 Speedometer 6.3 Wooden Hammer

3.7 Windshield wiper operation

6.4 Valid License & Valid Explosive Certificate

3.8 Parking Brake Function 6.5 Splash/Mud Guards

3.9 Valid Cabin Fire extinguisher 6.6 Fuel tank Lid & Lock

3.10 Seat belts All- Locking at Jerk 7.00 Oil Levels & Belts

7.01 Brake Fluid Level and Leaks

4.00 Tyre Checking 7.02 Coolant Level & Leaks

4.01 Front Left Tyre Condition / Pressure

7.03 Engine Oil Level & Leaks

4.02 Front Right Tyre Condition / Pressure

7.04 Clutch Fluid level & leaks

4.03 Rear Right Tyre Condition / Pressure

7.05 Air compressor belt condition & tension

4.04 Rear Left Tyre Condition / Pressure

7.06 Alternator belt condition & tension

4.05 Rims (All for damage) 7.07 Water pump belt condition & tension

4.06 Wheel Bolts Tightness Missing

8.00 Safety Checks

5.00 Electrical 8.01 Both Fire Extinguisher

5.01 Electrical Connectors 8.02 Reflective Cones / Red Flag

5.02 Battery Isolation Cover 8.03 Emergency Light / Torch Light

5.03 Battery in Secure position 8.04 TREM Card/MSDS

5.04 Battery Water Level 8.05 PPE's (Helmets / Safety Shoes / Gloves / Glasses/ Chemical Resistant Clothing/Face Mask)

5.05 Bonding Cables 8.06 First Aid Box

5.06 Bonding strip 8.07 Uniform

6.00 Tank, Valve & Hoses 8.08 Driver knows the usage of Mobile

6.01 Tanker correctly attached 8.09 Hazard Plates Available & Clean



6.02 Outlet valves Leaks 8.10 Trakker Switches

6.03 Tanker outlet Valve Dust caps

8.11 Shovel & Rope/ Hammer / Spill kit

6.04 Fuel Tank leaks 8.12 Gerry Can Filled with water

6.05 Outlet valves Operation 8.13 Non Reactive drums

6.06 Discharge Valve Sealed 8.14 Quick Steel metal repair Kit

6.07 Manhole & Vapor Balance line Sealed 8.15 Stoppers

Remarks:

ATC Opertation Manager Signature Driver's Signature



ATTACHMENT-4

Driver / Helper Information Sheet

Driver Helper Name Age Literacy Licence CNIC No. Experience

Medical Test Details Drug Test Chest X Ray Physical Examination

Training Details Initial Training Basic Training Specialized Training Driver Testing & Audit Mock Drill

Documents Required Copy of driver License & CNIC S&C. Employee History Report Medical Test Reports Training Attendance Report



ATTACHMENT-5

EDC / CAUSTIC / HYPO / HCL Truck Audit Checklist

Vehicle 1 Vehicle 2 Remarks

Registration No. Year of Registration Fitness Certificate Route Permit Calibration Chart Insurance Vehicle Maintenance Record Hydrotesting Certificate Vehicle Tax

Safety Signage UNFPA Diamond ( 3 sides) Hazard Signs (3 Sides) Emergency No. including S&C,ATC, EPCL, EDHI,Police & brigade (3 Sides)

Reflective tapes on tanker

Fittings & Fixtures Safety relief valves Dicharge valve connection Reverse alarm system, headlights and indicators

Handrail on top of the roof Tanker Filling vapor balance line Monkey Ladders for the climbing to the roof of the vehicle.

Gasket Material Teflon/PTFE 2 Manholes 2 Compartments Antistatic Chain Earthing Connections Bottom Discharge Filling Line Trakker Monitoring System

Equipment On Board Driver file with MSDS & ERP for EDC First Aid Box 2 Torches with spare batteries



4 Traffic Cones Wooden Hammer Quick Steel metal repair kit Twenty litres Gerry can filled with fresh water 4 Stoppers 2 Non reactive drums 2 Shovels 2 Danger / Caution signs 2 Dry powder fire extinguisher of 9kg 1 Incabin Fire extinguisher 1 Spill Kit Trem Card 2 Cordon off Tapes of 100m each 2 Safety Helmets 2 Chemical Splash Goggles 2 Full face masks 2 Rubber Gloves 2 Rubber Boots 2 Chemical Resistant Clothing

Content of First Aid Box Pocket Mask Bandage 2 and 4 Band Aid Cotton Dettol (large bottle) Elastoplast Furacin Cream Gauze Mercurochrome Scissors (small size) Soap Tissue Paper box Tourniquet Zincocid Drop Syringe 3ml Syringe 5 ml Panadol Gravinate Dermazine



ATTACHMENT-6

Pre-Trip Vehicle Inspection Sheet Desired Status : a - It shows that the checked item is operating correctly or it is in proper working condition. Malfunction : r - It shows that the checked item is out of order / malfunctioning.

Guideline Action / Cushion Time 1.00 In Cabin Checks 1.03 Engine Oil Pressure Start the engine. The engine oil warning light

must go OFF with in few seconds after starting the engine. If it is shown by a dial gauge, it should read as per specification in the operators manual. Normally three quarters or more.

To be repaired with in fifteen days.

1.04 Alternator/Generator Charging Start engine. Battery charging light must go OFF immediately after starting the engine. If it is shown by a dial gauge, the needle must show a positive value above zero.

Stop vehicle. To be repaired immediately.

1.05 Horns Switch ON ignition and operate horn. It should sound.

Primary next trip, Secondary 01 day

1.06 Head Light ON (Low/Dipper/High) Switch ON ignition and then switch ON head lights. Check all bulbs lighting in three positions Low beam, Dipper and High beam.


1.07 Indicators-Hazard /Left/Right Switch ON ignition and turn on indicators. Check for all indicators blinking in right turn, left turn and hazard (all indicators at the same time). Hazard should also work with ignition OFF.


1.08 Parking Light Switch ON ignition and then switch ON head lights. Check all bulbs lighting in three positions Low beam, Dipper and High beam.


1.09 Brake Light Switch ON ignition and depress brake pedal. Brake lights should go ON.


1.10 Function of Brakes Apply brakes to check their function. Stop vehicle. To be repaired immediately.

1.13 Clutch & Gear ChangeOperation Depress Clutch pedal and engage all gears one by one with engine start to check clutch function. All gears should engage without any problem or any significant rpm drop.

To be repaired with in fifteen days.

1.14 Reverse Light & Buzzer Engage reverse gear and check that reverse lights and buzzer go ON.


1.15 Speedometer Check attachment of tanker to prime-mover/Chassis and confirm that it is properly attached and there is no risk of tanker to detach accidentally.




1.16 Windshield wiper operation Switch ON ignition and operate wipers. They should wipe the screen with and without water spray at all wiping speeds available.


1.18 Fire extinguisher These should be available at the designated spots. Check for easy removal, type and expiry date.


1.19 Seat belts All- Locking at Jerk Check all seat belts for condition and locking by applying sudden forceful jerks.


1.20 U bolts - Right & Left Side Visually inspect U Bolts for damage or any portion missing.


1.21 Master Switch operation Operate master switch to OFF position. All electrical circuits should go dead. This means no electrical accessory should work and ignition switch is dead.


1.24 Door Glass operation/condition Roll up and down all door glasses and check for smooth operation, sealing and cracks.


3.00 General Checks 3.06 Wooden Hammer Confirm presence. Tool kit immediate,

Wooden hammer: Primary next trip, secondary 01 day.

3.08 Splash/Mud Guards Inspect guards for rigid fitting and clearance from tyres and road.

Primary next trip, secondary 01 day.

4.00 Tyre Checking 4.05 Rims (All for damage) Check all rims for damage and deformation.

Inspect all wheel bolts. To be installed immediately.

5.00 Electrical 5.01 Electrical Connectors Check electrical connectors for damage, loose

hanging and proper coupling. Stop vehicle. To be repaired immediately.

5.02 Battery Isolation Cover Check battery isolation cover for insulating lining inside and proper seating on battery top.


5.03 Battery in Secure position Check battery isolation cover for insulating lining inside and proper seating on battery top.


5.04 Battery Water Level Inspect fuel lines for leakage. Stop vehicle. To be repaired immediately.

5.05 Bonding Cables Bonding strip should be rigidly fixed at the designated spot with conducting connection of suitable cross-section to vehicle.




5.06 Bonding strip Bonding strip should be rigidly fixed at the designated spot with conducting connection of suitable cross-section to vehicle.


6.00 Tank, Valve & Hoses 6.01 Tanker correctly attached Check attachment of tanker to prime-

mover/Chassis and confirm that it is properly attached and there is no risk of tanker to detach accidentally.


6.02 Outlet valves Leaks No naked wiring or cracked insulation to be accepted.

6.03 Tanker outlet Valve Dust caps Confirm availability of dust caps to prevent contamination and clogging of valves.


6.04 Fuel Tank leaks Inspect fuel tank for any leaks of fuel. Stop vehicle. To be repaired immediately.

6.05 Outlet valves Operation Check outlet valves for leaks. No dripping of product should be there.

Stop vehicle. To be repaired Immediately.

6.07 Fuel tank Lid & Lock Inspect fuel tank filling cap for sealing and locking (if available).

7.00 Oil Levels & Belts 7.01 Brake Fluid Level and Leaks Check brake oil level. It should be between

minimum and maximum marking on the reservoir near maximum value.


7.02 Coolant Level & Leaks Check coolant level. It should be filled to maximum capacity.


7.03 Engine Oil Level & Leaks Check engine oil level. It should be filled to a level lower than maximum mark but more than centre of filling capacity.

Replenish if required. Leaks to be repaired with in one day.

7.04 Clutch Fluid level & leaks Inspect clutch fluid level, if it has a separate filling arrangement.

Replenish if required. Leaks to be repaired with in one day.

7.05 Air compressor belt condition & tension Check condition and tightness of all belts for any cut marks, worn out belt plies, alignment of pulleys.


7.06 Alternator belt condition & tension Check condition and tightness of all belts for any cut marks, worn out belt plies, alignment of pulleys.


7.07 Water pump belt condition & tension Check condition and tightness of all belts for any cut marks, worn out belt plies, alignment of pulleys.


8.00 Safety Checks



8.01 Both Fire Extinguisher Visually inspect all tyres for cuts, bulges, and low air pressure.

To be repaired within seven days.

8.02 Reflective Cones Confirm availability of reflective cones, stored securely at a proper place.

Immediate.

8.03 Emergency Light / Torch Light Check for availability. Immediate. 8.04 TREM Card Check for availability. Immediate. 8.05 Helmets Check for availability. Immediate. 8.06 Safety Shoes Check for availability. Immediate. 8.07 Uniform Check for availability. Immediate. 8.08 Driver knows the usage of Mobile 8.09 Hazard Plates Available & Clean Check for availability. Immediate. 8.10 Trakker Switches 1.01 Ease in starting 1.02 Abnormal Noises/Misfiring/Knocking Check the manhole lids are properly closed and

latched. Primary next trip, Secondary 01 day

1.11 Low air pressure warning/buzzer 1.12 Pressure Brake 1.21 Clean cabin Interior 1.22 Dash Board Switches 4.06 Wheel Bolts Tightness / Missing 4.01 Front Left Tyre Condition / Pressure 4.02 Front Right TyreCondition / Pressure 4.03 Rear Right TyreCondition / Pressure 4.04 Rear Left Tyre Condition / Pressure 3.03 Jack & Jack Rod 3.04 Pliers & Screw Drivers 3.05 Wheel Spanner 1.25 Wind Shield Condition/Visibility 1.26 No Loose object in cabin 1.17 Parking Brake Function 2.00 Top Checks 2.01 Luggage Free T/L top 2.02 Man hole Lids, Locks & Seals 3.01 Rear View Mirrors Outer Left 3.02 Rear View Mirrors Outer Right Check bonding cables for proper clamps at both ends. Cable should be of

uniform cross-section with proper insulation cover without any joints. No loose strands of wire to be present.