Safety - Index - KPP OCT

Safety Index Assessment
Study
For
Petronet LNG Limited

DAHEJ LNG TERMINAL
By
APRIL 2016
JOGI SAFETECH SOLUTIONS

An ISO 9001:2008 Certified Organization
207, Pramukh Chambers, Rander Road,
JOGI SAFETECH SOLUTIONS

An ISO 9001:2008 Certified Organization
207, Pramukh Chambers, Rander Road,

Tadwadi, SURAT (GUJ.)
Ph.: 0261-6451411 M: +91-9825656499
safety@jogisafetech.comIIwww.jogisafetech.com
Safety Index Assessment Report Petronet LNG

Document ID
Revision Number
Sr.
No.
1
2
Document Identification
Revision
No
Date
Final Report
Prepared By
Reviewed and Approved By
Ms. Disha Jethva
Mr. Nilesh Jogal
DISCLAIMER
This report is for the sole use by the Client for the purpose for which they have claimed it is required to us. We are not
responsible to any other person/party for any decision of such person/party based on this report. It is hereby notified
that reproduction, copying or otherwise quoting of our report or any part thereof other than the aforementioned purpose,
can be done only with our prior permission.
The report cannot be used or relied by the Client for any other purpose or any other third party for any purpose
whatsoever and we will not be liable which the client may incur on this account including in tort (including but not
limited to negligence) arising out of or in connection with this Report. This Report is not intended to identify all hazards
which may exist nor is it intended to be an exhaustive review of all possible eventualities. The recommendations for risk
improvement contained in the report are purely advisory and the decision and responsibility for implementation rests
with the Client.
Page 3
ex Assessment Report Petronet LNG

SIA/SR/PLL/15-16/11
0
Comments / Nature of Changes
Reviewed and Approved By
Mr. Nilesh Jogal
hich they have claimed it is required to us. We are not

erson/party based on this report. It is hereby notified
ny part thereof other than the aforementioned purpose,
er purpose or any other third party for any purpose

r on this account including in tort (including but not
port. This Report is not intended to identify all hazards
ll possible eventualities. The recommendations for risk
e decision and responsibility for implementation rests
Page 4
1.0 Executive Summary

Safety Index Assessment Study
Date of
study :
30.07.2016
Plant:
M/s. Petronet LNG Ltd, Plot No 7/A, GIDC Ind Estate, Dahej.
1) Mr. Kailash Pandey
M/s. Petronet LNG Ltd., Dahej.
Area of
study:
Auditor (s):
1) Mr. Japan Shah
2) Mr. Sunil Dharaiya

Cordinator (s):
2) Mr. Dhruv Khudkhudia
3) Mr. Dilip Chand

30.07.201
OHC
A. 6
30.07.201
Process Safety Performance
6
30.07.201 Asset Integrity
6
(Instrumentation)
30.07.201
Asset Integrity (Electrical)
6
30.07.201
Asset Integrity (Mechanical)
Auditee (s):
6
30.07.201
Fire Department
6
30.07.201 Emergency Management
6
System
Dr. Virendra Patel

Mr. Sailesh Shrivastava
Mr.Kamlesh Patel
Mr. Vipul Modi & Mr. Bhavesh Patel
Mr. Anil Patel
Mr. Manoj Chautale
Mr. Japan shah
30.07.201 Health and Safety

Mr. Gnanadesigan. N & Mr. Japan Shah
6
Management -Training Details
M/s. Petronet LNG Limited, Dahej
Safety Performance Ranking Score Graph
Safety Performance Ranking Score

Health and Safety Management
4.655.00
Environment Management System
5.00
4.00
3.00
4.46
2.00
1.00
1.03
Emergency Management System
5.00
Asset Integrity - Mechanical
4.00
5.00
Asset Integrity - Instrumentation
Asset Integrity - Electrical
Page 5
2.0 INTRODUCTION
The management of Petronet LNG Limited (hereinafter referred to as PLL) had approache
M/s. JOGI SafeTech Solutions to carry out periodic Safety Index Assessment at its Natur
Gas receiving, storage and regasification plant located at Dahej. Team from M/s. JO
SafeTech Solutions had carried out the site study for Safety Index Assessment for the mon
of April 2016 on 29th April 2016.
2.1 ABOUT PETRONET LNG LIMITED
Petronet LNG Limited, is one of the fastest growing world-class companies in the India
energy sector, has set up the country's first LNG receiving and re-gasification terminal
Dahej, Gujarat, and another terminal at Kochi, Kerala. The Dahej terminal has a nomin
capacity of 10 MMTPA [equivalent to 40 MMSCMD of natural gas], the Kochi terminal has
capacity of 5 MMTPA [equivalent to 20 MMSCMD of natural gas].
Petronet LNG is at the forefront of India's all-out national drive to ensure the country
energy security in the years to come. To bridge the natural gas demand-supply gap in th
country, Petronet LNG Limited imports LNG from various parts of globe on long term
short/ spot term basis.
The company has formed as a Joint Venture by the Government of India to import LNG an
set up LNG terminals in the country, it involves India's leading oil and natural gas indust
players. Promoters are GAIL (India) Limited (GAIL), Oil & Natural Gas Corporation Limite
(ONGC), Indian Oil Corporation Limited (IOCL) and Bharat Petroleum Corporation Limite
(BPCL).
2.2 ABOUT THE CONSULTANTS
JOGI SafeTech is an Industrial Safety Consultant based in Surat (Gujarat State, Indi
providing safety consultancy and safety training for PHA, HAZOP Study, Risk Assessme
Services, Hazardous Area Classification, Process Safety Management, Behaviour Base
Safety and EHS Training.
With his extensive experience, the founder, Mr. Nilesh Jogal; leads the organization wi
quality, processes and commitments that are commensurate with the highest internation
standards. Under his stewardship, JOGI has developed methods and procedures f
excellence in HSE services, while cultivating a high level of professionalism in tea
members.
2.3 OBJECTIVES OF THE STUDY
To study the existing operations of PLL and the existing safety systems and to develop safety ind
for PLL.
2.4 SCOPE OF SAFETY INDEX ASSESSMENT STUDY
Page 6
Page 7
M/s. Petronet LNG Limited, Dahej has appointed M/s. JOGI SafeTech Solutions, Surat to car
out an Assignment on SAFETY INDEX AUDIT (CRITICAL), of their plant.
The detailed scope of work is as follow:
a) Carry out Monthly audit in the last week of every month as per mutual planning.
b) Minimum Two man days audit for evaluating safety index by experienced auditors wi
engineering background (Minimum 15 year industrial experience in field of Oil and Ga
operation, maintenance and HSE practices).
c) Evaluate the various items identified for Safety Index (Critical) every month.
d) Prepare and submit two copies of final report after approval of draft report of month
safety index (critical) within One week of audit.
2.5 SAFETY INDEX ASSESSMENT METHODOLOGY
The study was carried out in following broad steps:
Study of existing safety management system of PLL

Review of written policies and procedures
Interviews with a cross-section of facility staff, reviews of records an
documentation, and field observation of work practices and plant equipment.
Safety Index Assessment report Preparation.
The overall study methodology is represented in graphical form as follows:
Page 8
2.6 STANDARDS / REFERENCES ADOPTED FOR THE STUDY

IS 14489, Code of Practice of Occupational Health & Safety Audits
The Factories Act, 1948/The Kerala Factories Rules
Petroleum Act 1934 and Petroleum Rules 2002
The Static and Mobile Pressure Vessels (Unfired) Rules, 1981
The Manufacture, Storage and Import of Hazardous Chemical Rules, 1989
Central Electricity Authority Regulations, 2010
The Motor Vehicles Act, 1988 / The Central Motor Vehicles Rules, 1989
Applicable OISD Standards / Guidelines 116, 117, 118, 129, 130, 194 and etc.,
Applicable BIS Standards for Fire Protection
Other applicable safety standards (National & International NFPA 59 A etc.,)
Good Engineering Practices followed in similar industries.
2.7 ACKNOWLEDGEMENT
JOGI SafeTech Solutions expresses its sincere thanks for the entire team at Petronet LN
Limited for the whole hearted co-operation in successful completion of the study.
particular we would like to thank Mr. Gnanadesigan Navaneethan, Mr. Japan Shah and th
team members for their support and help throughout the study and efforts in making th
study a success.
Page 9
LIST OF ABBREVIATIONS
CP
DCS
ECC
ELCB
ESD
FGS
LNG
LTI
MOC
MTC
MTTR
PLL
PM
PPE
PSV
PTW
SCBA
SMP
TIFR
TSV
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
Cathodic Protection
Distributed Control System
Emergency Control Centre
Earth Leakage Circuit Breaker
Emergency Shutdown System
Fire and Gas Detection System
Liquefied Natural Gas
Lost Time Injury
Management of Change
Medical Treatment Case
Mean Time To Repair
Petronet LNG Limited
Preventive Maintenance
Personal Protective Equipment
Pressure Safety Valve
Permit To Work System
Self Contained Breathing Apparatus
Standard Maintenance Procedure
Total injury Frequency Rate
Thermal Safety Valve
Page 10
) had approached
ent at its Natural
m from M/s. JOGI
ent for the month
nies in the Indian

cation terminal at
al has a nominal
chi terminal has a
ure the country's

supply gap in the
e on long term &
o import LNG and

tural gas industry
rporation Limited
rporation Limited
arat State, India)

Risk Assessment
Behaviour Based
organization with
hest international
d procedures for
onalism in team
evelop safety index
Page 11
Page 12
ns, Surat to carry
lanning.
ced auditors with
d of Oil and Gas
nth.
report of monthly
s of records and
ent.
Page 13
etc.,
c.,)
at Petronet LNG
of the study. In
pan Shah and the
rts in making this
Page 14
Page 15
5.0 Safety Index - Petronet LNG - Dahej

Month: October 2016
S.
No
Performance Criteria
Description
Section I: Health and Safety Management
Points Basic
Actual
Plan %
Score Score
%
d
Points
59.5
64.0
No of walkthrough safety
Senior Management site
inspection conducted as per
walkthrough/safety audit
plan for the month
100
90
4.5
Safety performance
review by Top
management
100
100
5.0
Quarterly review of safety

performance by top
management
Page 16
Month: October 2016

S.
No
Total injury Frequency

Rate (TIFR)*
Description
Plan Vs Actual
Page 17
Points Basic
Actual
Plan %
Score Score
%
d
Points
3.0
Month: October 2016

S.
No
Incident Reporting and

Investigation
Description
(1) Process compliance of

Incident Reporting and
Investigation system during
review period (50%)
(2) CAPA Compliance (50%)
Page 18
Points Basic
Actual
Plan %
Score Score
%
d
Points
100
40.00
2.0
Month: October 2016

S.
No
Description
Safety Committee
Frequency compliance
meeting and
(30%) / percentage of
implementation status of action points
recommendation
implementation (70%)
Closure of Audit
recommendations
Internal and External safety

audits/studies
recommendation
implementation status (15
days from the issue of the
report)
Page 19
Points Basic
Actual
Plan %
Score Score
%
d
Points
100
100.00
5.0
100
100.00
5.0
Month: October 2016

S.
No
Description
Points Basic
Actual
Plan %
Score Score
%
d
Points
Safety Training
Conducted
Plan vs. Actual for the

month based safety training
calendar
100
100.00
3.0
Effectiveness of Safety
Training*
Plan vs. Actual - Average

score to be fixed for the
company
100
100.00
3.0
Calibration of personal
gas monitors*
Plan vs. Actual - 100%

compliance
100
100
5.0
Page 20
Month: October 2016

S.
No
Description
Plan vs. Actual based on the

periodical medical
Occupational Health Preexamination schedule for
10 medical and/or Periodical
the month and 100% premedical examination
medical examination for
new employees
Page 21
Points Basic
Actual
Plan %
Score Score
%
d
Points
100
100
3.0
Month: October 2016

S.
No
Description
Points Basic
Actual
Plan %
Score Score
%
d
Points
Occupational Health
11 facility and infrastructure inspection/ calibration
compliance
schedule for the month
100
100
2.0
Sample based review of the

Number of job executed
12
work activity list and
without PTW
Permits
100
100
5.0
Page 22
Month: October 2016

S.
No
Contractor's Safety
13
Performance
14
Statutory and legal

compliance
Description
Points Basic
Actual
Plan %
Score Score
%
d
Points
Plan vs. actual based on the

contractor safety activity
schedule for the month
100
80.00
4.0

compliance
100
100
5.0
Page 23
Month: October 2016

S.
No
15
At Risk Behaviour
Reporting in Month.
Description

compliance
Points Basic
Actual
Plan %
Score Score
%
d
Points
100
100.0
Section II: Process Safety Performance
Demands on FGS
16
Systems
Number of times FGS

system activated for the
month
Page 24
5.0
87.5
98.0
5.0
Month: October 2016

S.
No
Description
Points Basic
Actual
Plan %
Score Score
%
d
Points
Demands on Fire alarm

17
Systems
Number of times Fire alarm

system activated for the
month
3.0
18 Availability of FGS
Percentage of availability of
FGS
100
100.00
10.0
10
19 Availability of Fire alarm
Fire alarm
100
100
10.0
10
Availability of Pump
20 (Running hours of Jockey
Fire pump
pump & in auto mode)
100
100.00
10.0
10
Page 25
Month: October 2016

S.
No
21
Effectiveness of MOC
System.
Releasing the process

22
equipment for PM*
Description
Points Basic
Actual
Plan %
Score Score
%
d
Points
Based on sample review of

MOC process adhered
i) Robust conduction of PHA
ii) Implementation of the
recommendations
iii) Record management
100
95.00
9.5
10

inspection schedule for the
month
100
100
10.0
10
Page 26
Month: October 2016

S.
No
Pre-startup Safety
23 Review (PSSR)
Compliance*
Description
Plan vs. Actual based on

PSSR schedule for the
month
Page 27
Points Basic
Actual
Plan %
Score Score
%
d
Points
NA
NA
NA
NA
Month: October 2016

S.
No
Description
Points Basic
Actual
Plan %
Score Score
%
d
Points
24 By pass register
Process Compliance based

on sample audit
100
100
5.0
Percentage compliance
25 of Equipment
changeover Schedule
Plan vs. actual based on

equipment changeover
Schedule
100
100.0
5.0
10.0
10
26
Failures of Basic Process Process Compliance based

Control System
on sample audit
Page 28
Month: October 2016

S.
No
Description
27
Errors in Executing
Operational Procedures
Based on sample audit of

incident investigation
reports for the month and
field observation
28
Effectiveness of PTW
system*
Sample based audit/review

of the PTW
Page 29
Points Basic
Actual
Plan %
Score Score
%
d
Points
100
100.00
10.0
10
100
0.00
0.0
10
Month: October 2016

S.
No
Description
Points Basic
Actual
Plan %
Score Score
%
d
Points
Section III: Asset Integrity

a) Mechanical
153.5 225.0
Safety critical equipment Plan vs. Actual based on the

29 (PSV) PM due for the
month
month
100
100
15.0
15
Static Equipment - Legal Plan vs. Actual based on the

30 Requirement Inspection inspection schedule for the
due for the month*
month
100
100
10.0
10

month
100
100
10.0
10

Pipeline Integrity PM due
32
for the month*
month
NA
NA
NA
NA
Static Equipment - PM
31
due for the month
Page 30
Month: October 2016

S.
No
Rotary Equipment
33 (Condition monitoring)
PM due for the month
Description
Points Basic
Actual
Plan %
Score Score
%
d
Points

month
100
100
10.0
10
Safety critical equipment Plan vs. Actual based on the

34 (TSV) PM due for the
month
month
100
100
15.0
15
Closure of Corrective
action from the PM
35
inspection for the
month*

month
100
100
5.0
SMP effectiveness and

followed during PM
36
inspection for the
month*

month
100
100
10.0
10
Page 31
Month: October 2016

S.
No
Description
Points Basic
Actual
Plan %
Score Score
%
d
Points
Lifting tools appliances

37 and hand tools PM due
for the month

month
100
100
5.0
Mean Time to Repair

38
Safety Systems
MTTR plan vs. actual for M2

and M3 maintenance
activities
NA
NA
NA
NA
PM for Contractor
39
equipment*

month
NA
NA
NA
NA
Page 32
Month: October 2016

S.
No
Description

SAP: Auto generation of inspection schedule for the
40 PM notification and
month (50% for PM
updation in SAP system* generation & 50% for
Updation of the same)
Points Basic
Actual
Plan %
Score Score
%
d
Points
100
100.00
5.0
Preventive Maintenance
for critical Electrical
41
equipments (Motors,
month
Transformer, relays, etc)
100
89
0.0
10
PM schedule for FLP

equipment (those not
42
covered in the other PM
month
schedule)*
100
89
0.0
15
b) Electrical
Page 33
Month: October 2016

S.
No
Description
Points Basic
Actual
Plan %
Score Score
%
d
Points
43 ELCB Inspection

month
100
89
0.0
10
44 Earth continuity test

month
100
89
0.0
10
Page 34
Month: October 2016

S.
No
Description
Points Basic
Actual
Plan %
Score Score
%
d
Points

Cathodic Protection - CP
45
(Piping & building piling)
month
100
0.0
10

46 PM of Fire alarm system inspection schedule for the
month
100
89
0.0
15
action from the PM
47
inspection for the
month*
100
100
5.0

month
Page 35
Month: October 2016

S.
No

followed during PM
48
inspection for the
month*
Description
Points Basic
Actual
Plan %
Score Score
%
d
Points

month
100
85
8.5
10

month (50% for PM
100
100
5.0

and M3 maintenance
activities
NA
NA
NA
NA
Mean Time to Repair

50
Safety Systems
Page 36
Month: October 2016

S.
No
Description
Points Basic
Actual
Plan %
Score Score
%
d
Points
c) Instrumentation
Calibration of process
51
instruments / gauges

month
100
100
10.0
10
Calibration of FGS
52
instruments / gauges

month
100
100
20.0
20
Proof Tests of Safety

53 critical Systems
conducted

month
NA
NA
NA
NA
action from the PM
54
inspection for the
month*

month
100
100
5.0
Page 37
Month: October 2016

S.
No

followed during PM
55
inspection for the
month*
Description
Points Basic
Actual
Plan %
Score Score
%
d
Points

month
100
100
10.0
10

month (50% for PM
100
100.00
5.0

and M3 maintenance
activities
NA
NA
NA
NA
Mean Time to Repair

57
Safety Systems
Page 38
Month: October 2016

S.
No
Description
Points Basic
Actual
Plan %
Score Score
%
d
Points
Section IV: Emergency Management System
80.0
100.0

the emergency mock drill
schedule
100
100
5.0
Total recommendations
Implementation of mock open vs. closed based on
59
drill recommendation*
conducted.
100
100
5.0
89
0.0
10
Number of emergency
58
mock drill conducted
PM for Emergency
Facilities (Fire Tender,
60 SCBA (PPE), Fire
hydrant/hose &
accessories, etc)*
Plan vs. actual based on PM

schedule for emergency
100
facility (70% for compliance
& 30% for Field verification)
Page 39
Month: October 2016

S.
No
Description
Points Basic
Actual
Plan %
Score Score
%
d
Points

schedule / periodical testing
records
100
100
10.0
10

62 Availability of Fire tender
records
100
100
10.0
10

records
100
100
10.0
10

records
100
100
10.0
10
61
63
ECC infrastructure and

availability*
Availability of Fire crew

with PPE (SCBA, etc)
Availability of Fire
64 hydrant / hose &
accessories, etc
Page 40
Month: October 2016

S.
No
Description
Points Basic
Actual
Plan %
Score Score
%
d
Points
Number of emergency
Based on the sample audit
systems not functional
65
and emergency equipments
during real emergency /
periodical testing records
mock drill.
100
10.0
10
Defects notification of
Fire and Emergency
66
system (M8) in SAP
system*
100
100
10.0
10
EDG availability and PM

and testing

schedule for EDG
availability and PM & testing 100
(70% for availability & 30%
for PM and testing)
99.00
0.0
10
Emergency
68 communication system
PM and working status

schedule for emergency
100
facility (70% for compliance
& 30% for Field verification)
100.00
10.0
10
20.0
20.0
67
Based on the sample audit,

periodical testing records
and SAP system
Section V: Environment Management System

Page 41
Month: October 2016

S.
No
Description
Points Basic
Actual
Plan %
Score Score
%
d
Points

Enviornment Monitoring
schedule (70% for following
69 (Ambient, Stack, Ground
100
schedule & 30% for data
water, Marine water etc.)
under the perscribed limit.)
HW, E-waste, /Biomedical Waste, Used

70
Batteries handling
(storage & disposal)
Updated data of generation

and disposal for the month
(30%).
Collection of HW from
source to HW collecion area
in the month of generation
(40%).
Disposal within 90 days of
generation (30%).
Page 42
100
100
5.0
100
5.0
Month: October 2016

S.
No
71
Envionment pollution
Incident (Demand)
Description
No environment pollution
incident in Month.
Points Basic
Actual
Plan %
Score Score
%
d
Points
0
10.0
10
Score will be "Zero" if Actual is 1; Score will

Score will be "Zero" if Actual is less than 90%
Direct score will be taken based on the Actu
Score will be "Zero" if Actual is less than 100
Score will be "Zero" if Actual is less than 100
Page 43
Remarks
Assessment Criteria
Assessor shall check the number of walkthrough/safety

REMARK: No Plan for Senior Management walk through
audits carried out by the Senior Management as per PLL
audit could be found for the month of July 2016 but two
practice.
walkthrough audit was done by the team of HSE Head, HRRecords to be checked:
GM and GM-Port Operations.
a) Monthly audit reports
Actual percentage of compliance = (Actual/Plan)*100
Score = Actual percentage of compliance x Basic Score
REMARK: Last Quarterly performance review was
conducted on 16th July 2016, safety performance review is Assessor shall check if the safety performance review by
the top management has been carried out as per PLL's
done quarterly.
frequency (Once a 3 months).
Records to be checked:
Note:
a) Minutes of meetings
1st Quarter - Safety Performance Review
b) Action plan/tracking sheet
2nd Quarter - Operations Performance Review (includes
safety)
3rd Quarter - Safety Performance Review
4th Quarter - Operations Performance Review (includes
safety)
Page 44
Remarks
Assessment Criteria
REMARK: TIFR was Zero, but injury classification by doctor

was not done, it would have been pertinent that procedure
should address that, the injury classification to be done by
the doctor immediately after giving the medical
treatment .
Assessor shall check the actual TIFR cumulative value

till date.
a) Monthly safety statistics report
The target is not more than 2 for the month.

If actual TIFR is <= 2, score will be 3.
If actual TIFR is > 2, score will be 0.
Page 45
Remarks
Assessment Criteria
REMARK: Total 6 incidents are reported and four

investigation are pending. Other than that, there was one
more incident recorded in the fire dept., for an emergency
call received in the fire department. The incident was of
8th july wherein the person was stuck up in the lift. But
the same incident was not recorded in the HSE dept.
Incident where emergency call is made for rescue should
also be recorded and investigated, at least as a near miss.
Assessor shall check the Incident Reporting and

Investigation system for the month.
a) Incident investigation reports
Out of total 109 recommendations 43 are

pending fro compliance.
Actual percentage of compliance = Investigation of the
Incident + Compliance of the CAPA recomandation till
month date/Total No. of incidents occurred during the
month + CAPA due for compliance)*100 .
Page 46
Remarks
Assessment Criteria
REMARK: Safety committee meeting was conducted 29th Assessor shall check if Safety Committee meetings are
July 2016 .Three recommendations are pending for
conducted as per PLL's frequency. Assessor shall also
compliance but the action for the same has been initiated. check the implementation of the recommendations
arising from these meetings.
Actual percentage of compliance shall be calculated based Records to be checked:
on the weightage given.
a) Safety committee - Minutes of meetings
Score = Actual percentage of compliance x Basic Score.
If the percentage of compliance is less than 80% (for
safety system related parameters) then the score obtained
shall be "Zero".
REMARK: National Safety Council (NSC) has conducted the
audit from 12th to 14th July, report for the same is
awaited.
Actual percentage of compliance = (No. of
recommendations implemented / Total No. of
recommendations from the audits & studies)*100.
safety system related parameters) then the score obtained
shall be "Zero".
Assessor shall check the implementation status of

Internal and External safety audits/studies
recommendations (15 days from the issue of the report).
a) Internal / External audit & Studies
b) Implementation status report
Page 47
Remarks
Assessment Criteria
REMARK: Three training programs have been conducted

for the month, on BBS, ERDMP and on life saving rules.
Score will be given if trainings are conducted as per Plan.
Score will be on prorata basis.
Actual percentage of compliance = (No. of safety trainings
conducted / Total No. of safety trainings planned for the
month)*100.
REMARK: All candidates has passed the test as per the
evaluation criteria & the same has been validated.
Score will be awarded if an evaluation criteria for training
effectiveness is developed and rolled out for all Safety
Trainings, i.e. Objective Question paper for all HSE training.
Score will be on prorata basis.
Assessor shall check the safety training records for the

month.
a) Safety Training attendance sheet
b) Monthly safety statistics report
Assessor shall check the safety training post test

records for the month.
a) Post Test records
Assessor shall check the calibration and test certificate

of personal gas monitors for the month.
Score will be "Zero" if Actual is less than 100% compliance. a) Calibration certificate
REMARK: There are 37 LEL cum Oxygen detectors, all are
calibrated
Page 48
Remarks
Assessment Criteria
Assessor shall check the medical examination report for

REMARK: Medical check up found to be done in accordance the month.
to the plan.
a) Pre-medical and/or Periodical medical examination
Score will be given if PME are conducted as per Plan. Score report
will be "Zero" if Actual is less than 100% compliance.
b) New employee list for the month
c) Induction Training attendance
Page 49
Remarks
Assessment Criteria
REMARK: All equipments are calibrated as per the

schedule, calibaration certificates are avaiable with OHC.
But, OHC team needs to look into the matter, if Blood
pressure measuring instrument needs calibration or not.
Score will be given if OHC facilities are
inspected/calibrated as per Plan. Score will be on prorata
basis.
Assessor shall check the Occupational Health facility

and infrastructure compliance report for the month.
a) Equipment daily inspection report
b) PM schedule and inspection report
Assessor shall check work permits are issued for non

REMARK: Checked from job planing and filed permits and it routine activities which are carried out during the
was validated that no job was done without permit.
month.
Score will be "Zero" if Actual is less than 100% compliance. a) Work permits
b) Job list for the month
Page 50
Remarks
Assessment Criteria
REMARK Contractors safety performance report could not Assessor shall check the contractor safety performance
against the plan for the month.
be found. Induction is in order but 34 violations were
recorded.
a) Contractor safety performance report
Score will be given based on compliance of all the point on b) Contractor's safety performance will be measured on
six parameters:
prorata basis.
1st: Contractor Safety Induction(weightage : 10%)
2nd: Contractor Monthly Safety Review(weightage: 20%)
1st: Contractor Safety Induction (weight age: 10%)
2nd: Contractor periodic Safety Review (weight age: 20%) 3rd: Contractor Safety Training (2 Trg/Month)
3rd: Contractor Safety Training (2 Trg/Month) (weight age: (weightage: 15%)
4th: Site Safety Inspection (weightage: 25%)
15%)
5th: Zero MTC & LTI (weightage: 20%)
4th: Site Safety Inspection (weight age: 25%)
6th: No violation (weightage: 10%)
5th: Zero MTC & LTI (weight age: 20%)
6th: No violation (weight age: 10%)
Licence status , any notice from government agency
during the month
REMARK: No non confirmance was found.

Score will be "Zero" if Actual is less than 100% compliance
of HSE and Legal fire protection system.
Page 51
Remarks
Assessment Criteria
REMARK: Planned was 19 but conducted was 25.
BBS module in suraksha setu
Actual percentage of compliance = (No. of BBS

Observations actual/No. of BBS Observations Planed )
*100.
REMARK:In order
Score will be "Zero" if Actual is 1; Score will be negative if
Actual is 2 and above.
Assessor shall check the number of times the FGS

system was activated in a month.
a) DCS trend of detection system
b) Intimation to Fire Safety Department
c) Incident Reports
Page 52
Remarks
Assessment Criteria
REMARK: In order
Score will be "Zero" if Actual is 1; Score will be negative if
Assessor shall check the number of times the buildings

Fire alarm system was activated in a month.
b) Intimation report to Fire Safety Dept
c) Incident Reports
Assessor shall ascertain the availability and integrity of

the FGS and other detection system as a group through
a site evaluation.
Score will be "Zero" if Actual is less than 100% compliance a) Maintenance Records
of the any one of parameters in Fire Detection system.
REMARK: 100% avaiable during the month.
Assessor shall check the availability of the fire alarm

Score will be "Zero" if Actual is less than 100% compliance a) Records of the schedule of fire alarm testing
in Fire Detection and Alarm system.
REMARK: 100% avaiable during the month.
REMARK: In Order.
Assessor shall through a site evaluation ascertain the

availability of the fire water pump.
Score will be "Zero" if Actual is less than 100% compliance Records to be checked:
a) Maintenance Records of the pump
b) Daily testing records of the pump
Page 53
Remarks
Assessment Criteria
Assessor shall check the MOCs raised in that month.

REMARK: MOC procedure was reviwed in the procedure
PLL/TECH/SOP/05 , there are sentence which are not clear a) MOCs
to the technical person, safety and operation for example b) Documents related to the MOCs which need to be
updated
Approval authority: defined on Page 4 of 11 of the
c) Robust conduction of PHA
procedure, It is recommended that procedure should be
d) Implementation of the recommendations.
revisited and corrected . This is essentailly needed for
effective implementation of the procedure. One closed
MOC was reviewed, wherein it was mentioned about
HAZOP sheet, attached as an Annexure no.: 4 but the
same could not be found as an annexure - FCO/PLL/MC/85
Process hardware related parameters) then the score
obtained shall be "Zero".
Assessor shall check the PM schedule & records for the
month.
Score will be "Zero" if Actual is less than 90% compliance - Records to be checked:
a) PM schedule
for Process hardware related parameters.
b) PM inspection records
REMARK: In Order
Page 54
Remarks
Assessment Criteria
REMARK: Not Applicable

Actual percentage of compliance = (No. of PSSR conducted
/ Total number of PSSR scheduled for the month)*100
Assessor shall check the PSSR schedule for the month.

a) PSSR schedule
Page 55
Remarks
Assessment Criteria
REMARK: In Order- no trips were bypassed.

Actual percentage of compliance = (No. Of times Bypasses
have been recorded/Total number of Bypasses)*100
Assessor shall check the process compliance based on a

sample audit at the site.
a) DCS by-pass page
b) By-Pass Register
Assessor shall check if the changeover schedule is being

adhered to through a site check.
REMARK: In order- equiment change over shedule

complied.
a) Equipment Changeover schedule
Actual percentage of compliance = (No. of Equipment

running as per changeover schedule/Total no. of
equipment that need to be changed over)*100
REMARK: NIL failure in the month
The score obtained shall be "Zero" if the basic process
control system was failed once.
The score obtained shall be Negative if the basic process
control system was failed more than once.
Assessor shall evaluate failures records of basic process

control system.
a) Failures records of basic control system
b) Incident reports
c) By-pass register
Page 56
Remarks
Assessment Criteria
Assessor shall through sample audit of incident

investigation reports (50% weightage) and site
evaluation (50% weightage) ascertain the SOP
Actual percentage of compliance = (No. of SOP complied /
compliance.
Total sample size) *100
Score will be "Zero" if Actual compliance is less than 80% a) Incident investigation reports for the month
for safety system related parameters.
b) Training records
c) List of SOPs
REMARK: 1- Paitning job in nitrogen plant was being
Assessor shall perform sample based work permit audit
without appropriate permit, basic PPE were not being used review the work permits for the month.
by M/s Toyo persons doing job.
2-Phase one HP pump
a) Work permit records
area permit number 9709 mettalic grinder was used
without earth connection.
3- Permit number- 6895 scaffold erection work
supervisors working without googles, area not barricaded,
ladder not used.
Actual percentage of compliance = (No. of work permits
without deficiencies / Total No. of work permits audited
(sample size))*100.
Score will be "Zero" if Actual is less than 80% compliance for safety system related parameters.
REMARK: In order
Page 57
Remarks
Assessment Criteria
REMARK: All Planned Scheduled done.
Assessor shall check the actual PM conducted for the

safety critical equipment.
a) PM Schedule
b) PM Records
static equipment.
Score will be "Zero" if Actual is less than 100% compliance a) PM Schedule
b) PM Records
of emergency / legal / fire protection system.
REMARK: In Order. Certificate no. PLNG/V-705/2016
verified.

static equipment.
Score will be "Zero" if Actual is less than 90% compliance - a) PM Schedule
b) PM Records
REMARK: Complies.
REMARK: LNG line is under insulation hence inspection

done as and when insulation open for any kind of
pipelines
maintenance job.
b) PM Records
Page 58
Remarks
Assessment Criteria

rotary equipment.
b) PM Records
REMARK: Order NO. PM01-00034999 was verified.
Assessor shall check the actual PM for the safety critical

equipment for the month
b) PM Records
REMARK: Document for PSV-1620 dtd. 27.07.2016,
verified.

b) PM Records
REMARK: Complies.

REMARK: NO incident investigated for the month. For
training records, document dtd.25.07.2016 to 29.07.2016 investigation reports and site evaluation ascertain the
verified. List of SOPs, doc. No.: PLL/MECH/SOP/12 verified SMP compliance.
Score will be "Zero" if Actual is less than 80% compliance - a) Incident investigation reports for the month
b) Training records
c) List of SOPs
Page 59
Remarks
Assessment Criteria

lifting tools and hand tools.
b) PM Records
REMARK: Complies. Next Due in Jan 2017.
REMARK:It was conveyed by auditee there is 100 % standby for all equipments. So MTTR concept is not applicable
for this site. Also, the MTTR calculation method is not
being implemented. Even SAP is having automatic
generation of MTTR/MTBF(mean time before failure) using
specific code.
Assessor shall check actual MTTR of M2 and M3

activities for the month.
a) Maintenance Records
b) Operations Log Book
Actual percentage of compliance = (No. Of times MTTR

was within accepted time period/Total No. Of M2 and M3
activities)*100

REMARK:No equipments belongs to Contractors.
contractor equipment.
b) PM Records
Page 60
Remarks
Assessment Criteria
Assessor shall check the SAP system on M1
notifications.
a) PM Schedule
b) PM Records
c) M1 notfication in SAP system
REMARK: In order. Auto Generation Doc. Checked.

Note: The SAP system is not fully automated and hence
the manual schedule is also checked in parallel.
REMARK: Criticality assessment under progress through

criticality matrix. Plant level critical equipment list is
available. Procedure for Ex-d motors preventive
maintenance not avaliable, considering flammiblity hazard
of site this is essentially needed
Assessor shall check the actual PM for critical Electrical

equipment
a) OEM Specifications
b) Inspection records of FLP
Score will be "Zero" if Actual is less than 90% compliance for Process hardware related parameters.
REMARK: As there is no procedure for Ex-d motor
preventive maintenance, there is total failure of the
system under this element
Assessor shall check the actual PM for flame proof

equipment.
c) FLP PM schedule
Page 61
Remarks
Assessment Criteria
REMARK: There is no procedure for ELCB inspection and

testing
Assessor shall check the actual PM for ELCB

Score will be "Zero" if Actual is less than 90% compliance - b) Inspection records of FLP
REMARK: There is no procedure for earthing contuity test Assessor shall check the testing records of the earth
continuity
Page 62
Remarks
Assessment Criteria
Assessor shall check the inspection records of the
cathodic protection
REMARK:Phase 1: 10 out of 10 Anodes are Fail.

LNG Tank 3 & 4 all 192 Anodes are Fail.
North Jetty: 30 out of 90 are Fail.
South Jetty: All Anodes are OK.
Score will be "Zero" if Actual is less than 90% compliance for Process hardware related parameters.
Assessor shall check the actual PM for the Fire Alarm

System
Score will be "Zero" if Actual is less than 90% compliance - a) OEM Specifications
b) Inspection records of Fire Alarm System
REMARK: PM periocity is not defined, same has to be
defined in accordance with NFPA/ BIS standatd

REMARK -In order
a) PM Schedule
b) PM Records
Page 63
Remarks
Assessment Criteria

investigation reports and site evaluation ascertain the
REMARK: in order
SMP compliance.
a) Incident investigation reports for the month
b) Training records
c) List of SOPs
REMARK:Documents verified, the same is Auto Generated
notifications.
on 25th of every Month.
a) PM Schedule
percentage of compliance = (Actual PM (M1) notification
b) PM Records
generated & updated in SAP system/Planned PM)*100
Weightage 50% for PM generation & 50% for Updation.
REMARK:Not Maintained, because having enough Stand-by Assessor shall check actual MTTR of M2 and M3
Equipments. Please refer comment in Sr. No.38. CP TRs
are not standby)
Actual Compliance Percentage = (No. Of times MTTR was b) Operations Log Book
within accepted time period/Total No. Of M2 and M3
activities)*100
Page 64
Remarks
Assessment Criteria
REMARK: PM records verified , tag no.: PV-2001 dtd.:

04.07.2016.
Assessor shall check the actual PM (Calibration) of

process instruments/gauges conducted.
b) PM Records
REMARK: PM records verified , tag no.: GSD-611 dtd.:
23.07.2016.
Assessor shall check the actual PM (Calibration) of FGS

instruments/gauges conducted.
Score will be "Zero" if Actual is less than 90% compliance. a) PM Schedule
b) PM Records
REMARK:The Instrument manager told that it is not
Assessor shall check records to see if actual Proof Tests
fissible. TO BE REVIEWED. For scoring purpose, it has been of safety critical systems have been conducted
marked as NA.
a) PM Schedule
Score will be "Zero" if Actual is less than 90% compliance. b) PM Records
REMARK: In order. Verified. Tag no.: GSD - 604 dtd.
12.07.2016

b) PM Records
Page 65
Remarks
Assessment Criteria
REMARK: Document Verified. List of SOP, SOP no.:

PLL/Inst/SOP/26 dtd.: 21.012.2014 found Ok.

investigation reports and site evaluation ascertain the
SMP compliance.
a) Incident investigation reports for the month
b) Training records
c) List of SOPs
REMARK: In order. Doc. no.: PM05-5000007223 dtd.:
01.07.2016 Verified.
notifications.
percentage of compliance = (Actual PM (M1) notification
a) PM Schedule
generated & updated in SAP system/Planned PM)*100
b) PM Records
Weightage 50% for PM generation & 50% for Updation.
REMARK: Concept not relevant for this site. Please refer
comments in Sr. No. 38 & 50.
Actual percentage of compliance = (No. Of times MTTR
was within accepted time period/Total No. Of M2 and M3
activities)*100
Assessor shall check actual MTTR of M2 and M3

Page 66
Remarks
Assessment Criteria
REMARK: Mock drill conducted on 25th october 2016.

Actual percentage of compliance = (Actual/Planned)*100
If the Actual percentage of compliance is less than 90%
(for Process hardware related parameters) then the score
Assessor shall check if the number of Emergency mock

drills conducted is as per PLL's frequency.
a) Mock drill records
Assessor shall check if the number of Emergency mock

drills conducted is as per PLL's frequency.
Score will be "Zero" if Actual is less than 90% compliance - b) Implementation status report
REMARK: one recommendations out of five is pending,
compliance procedure for the same is in progress. Target
dated extended to 31/12/2016
REMARK: SCBA set air quality certificate for CO was

being given in 2015 but in 2016 new vendor does not give
certificate for CO. Same has been discussed in Closing
meeting in detail
Assessor shall check the actual PM of Emergency

Facilities (Fire Tender, SCBA (PPE), Fire hydrant/hose &
accessories, etc) conducted.
a) PM Schedule
Score will be "Zero" if Actual is less than 90% compliance - b) PM Records
Page 67
Remarks
Assessment Criteria
Assessor shall check the actual availability of emegency

equipmemets in the ECC.
REMARK: In order.
a) Min ECC requirements
b) ECC Inspection Records
REMARK: In order.
availability of the fire tender.
Score will be "Zero" if Actual is less than 100% compliance b) Inspection records
c) Emergency Mock drill records
Assessor shall ascertain through a site evaluation the
REMARK: In order.
availability of the fire crew and check their adherence to
usage of PPE.
of emergency / fire protection system.
a) Emergency Mock drill records
availability of the fire hydrant/hose & accessories.
REMARK: In order.
Score will be "Zero" if Actual is less than 100% compliance a) Maintenance Records
b) Inspection records
of emergency / fire protection system.
Page 68
Remarks
Assessment Criteria
Assessor shall check the functionality of the emergency

system by simulating an emergency situation during the
site visit.
Score will be "Zero" if Actual is 1; Score will be negative if Records to be checked:
REMARK: In order.
Assessor shall check actual M8 notification generated in
SAP system for the month.
Actual percentage of compliance = (No. of M8 notifications Records to be checked:
generated in SAP system / Total No. of M8
a) PM Records
notifications)*100
b) SAP system M8 notifications
REMARK: The level indicator for diesel feed tank to DG
Assessor shall check
set is having totally opeque glass tube hance level can
a) PM Records
not be seen, there is no indication anywhere to know the b) Weekly trial run records
level.
C) availability of EDG
REMARK: In order.

- for Process hardware related parameters.
REMARK: In order.
Plan vs. actual based on PM schedule for emergency

facility like telephone, paging system (70% for
compliance & 30% for Field verification)
- for Process hardware related parameters.
Page 69
Remarks
Assessment Criteria
REMARK: In order
Actual percentage of compliance = (No. of planned
montioring / Total No. monitoring done)*100
Plan vs. actual based on schedule (70% for following

schedule & 30% for data under the perscribed limit.)
.Monthly third party report to be check
REMARK: In order
Actual percentage of compliance is b ased on Sample audit
of the documentation and based on all three points criteria
HW record to be check, Manifest Documents to be
actual percentage of compliance will be decided on
check
prorata basis .
Page 70
Remarks
Assessment Criteria
REMARK: In order
Score will be "Zero" if Actual 1, score will be given only if
there is no any Envioronment related Incident.
Incident record
ual is 1; Score will be negative if Actual is 2 and above

ual is less than 90% compliance - for Process hardware related parameters
ual is less than 80% compliance - for safety system related parameters
based on the Actual - Pro rata basis
ual is less than 100% compliance of emergency / legal / fire protection system.
ual is less than 100% compliance of the any one of parameters in fire detection system
Page 71
Index Assessment Criteria - Petronet LNG

Performance
Criteria
Section I: Health and
1 Senior
Management site
walkthrough/safe
ty audit
SNo
Assessment Criteria
Safety Management
Assessor shall check the number of
walkthrough/safety audits carried
out by the Senior Management as
per PLL practice.
a) Monthly audit reports
Safety
performance
review by Top
management
Assessor shall check if the safety

performance review by the top
management has been carried out
as per PLL's frequency (Once a 3
months).
a) Minutes of meetings
Total injury
Frequency Rate
(TIFR)
Assessor shall check the actual TIFR

cumulative value till date.
a) Monthly safety statistics report
Incident
Reporting and
Investigation
Assessor shall check the Incident

Reporting and Investigation system
for the month.
a) Incident investigation reports
Safety
Committee
meeting and
implementation
status of
recommendation
Assessor shall check if Safety

Committee meetings are conducted
as per PLL's frequency. Assessor
shall also check the implementation
of the recommendations arising from
these meetings.
a) Safety committee - Minutes of
meetings
Closure of Audit Assessor shall check the

recommendation implementation status of Internal
s
and External safety audits/studies
recommendations (15 days from the
issue of the report).
a) Internal / External audit & Studies
Safety Training
Assessor shall check the safety

training records for the month.
a) Safety Training attendance sheet
b) Monthly safety statistics report
Effectiveness of
Safety Training
Assessor shall check the safety

training post test records for the
month.
a) Post Test records
Calibration of
personal gas
monitors
Assessor shall check the calibration

and test certificate of personal gas
monitors for the month.
a) Calibration certificate
10 Occupational
Health Premedical and/or
Periodical
medical
examination
Assessor shall check the medical

examination report for the month.
a) Pre-medical and/or Periodical
medical examination report
b) New employee list for the month
c) Induction Training attendance
11 Occupational
Assessor shall check the
Health facility
Occupational Health facility and
and infrastructure infrastructure compliance report for
compliance
the month.
a) Equipment daily inspection report
b) PM schedule and inspection report
12 Number of job
Assessor shall check work permits
executed without are issued for non routine activities
PTW
which are carried out during the
month.
a) Work permits
b) Job list for the month
13 Contractor's
Safety
Performance
Assessor shall check the contractor

safety performance against the plan
for the month.
a) Contractor safety performance
report
b) Contractor's safety performance
will be measured on six parameters:
14 Statutory and
Licence
status ,Safety
any notice from
1st: Contractor
legal compliance government
agency
Induction(weightage during
: 10%) the
month
2nd: Contractor Monthly Safety
Review(weightage: 20%)
3rd:
Contractor
Safety Training
15 At Risk
BBS module
in suraksha
setu (2
Trg/Month) (weightage: 15%)
Behaviour
4th: Site Safety Inspection
Reporting in
(weightage: 25%)
Month.
5th: Zero
MTC & LTI (weightage:
Section II: Process Safety
Performance
20%)
16 Demands on FGS Assessor shall check the number of
6th: No violation (weightage: 10%)
Systems
times the FGS system was activated
in a month.
b) Intimation to Fire Safety
Department
c) Incident Reports
17 Demands on Fire Assessor shall check the number of
alarm Systems
times the Fire alarm system was
activated in a month.
b) Intimation report to Fire Safety
Dept
c) Incident Reports
18 Availability of FGS Assessor shall ascertain the
availability and integrity of the FGS
and other detection system as a
group through a site evaluation.
19 Availability of Fire Assessor shall check the availability

alarm
of the fire alarm
a) Records of the schedule of fire
alarm testing
20 Availability of
Pump (Running
hours of Jockey
pump & in auto
mode)
Assessor shall through a site

evaluation ascertain the availability
of the fire water pump.
a) Maintenance Records of the pump
b) Daily testing records of the pump
21 Effectiveness of
MOC System.
Assessor shall check the MOCs

raised in that month.
a) MOCs
b) Documents related to the MOCs
which need to be updated
c) Robust conduction of PHA
d) Implementation of the
recommendations.
22 Releasing the
Assessor shall check the PM
process
schedule & records for the month.
equipment for PM Records to be checked:
a) PM schedule
b) PM inspection records
23 Pre-startup
Safety Review
(PSSR)
Compliance
Assessor shall check the PSSR

schedule for the month.
a) PSSR schedule
24 By pass register
Assessor shall check the process

compliance based on a sample audit
at the site.
a) DCS by-pass page
b) By-Pass Register
25 Percentage
compliance of
Equipment
changeover
Schedule
Assessor shall check if the

changeover schedule is being
adhered to through a site check.
26 Failures of Basic
Process Control
System
Assessor shall evaluate failures

records of basic process control
system.
a) Failures records of basic control
system
b) Incident reports
c) By-pass register
27 Errors in
Executing
Operational
Procedures
Assessor shall through sample audit

of incident investigation reports
(50% weightage) and site evaluation
(50% weightage) ascertain the SOP
compliance.
a) Incident investigation reports for
the month
b) Training records
c) List of SOPs
a) Equipment Changeover schedule
28 Effectiveness of
PTW system
Assessor shall perform sample based

work permit audit review the work
permits for the month.
a) Work permit records
Section III: Asset Integrity

a) Mechanical
29 Safety critical
Assessor shall check the actual PM
equipment (PSV) conducted for the safety critical
PM due for the
equipment.
month
a) PM Schedule
b) PM Records
30 Static Equipment
- Legal
Requirement
Inspection due
for the month

conducted for the static equipment.
a) PM Schedule
b) PM Records
31 Static Equipment Assessor shall check the actual PM

- PM due for the conducted for the static equipment.
month
a) PM Schedule
b) PM Records
32 Pipeline Integrity Assessor shall check the actual PM

PM due for the
conducted for the pipelines
month
a) PM Schedule
b) PM Records
33 Rotary Equipment Assessor shall check the actual PM

PM (Condition
conducted for the rotary equipment.
monitoring) due Records to be checked:
for the month
a) PM Schedule
b) PM Records
34 Safety critical
equipment (TSV)
PM due for the
month

for the safety critical equipment for
the month
a) PM Schedule
b) PM Records
35 Closure of
Corrective action
from the PM
inspection for the
month

the month
a) PM Schedule
b) PM Records
36 SMP
effectiveness and
followed during
PM inspection for
the month

of incident investigation reports and
site evaluation ascertain the SMP
compliance.
the month
b) Training records
c) List of SOPs
37 Lifting tools
appliances and
hand tools

conducted for the lifting tools and
hand tools.
a) PM Schedule
b) PM Records
38 Mean Time to
Repair Safety
Systems
Assessor shall check actual MTTR of

M2 and M3 activities for the month.
39 PM for Contractor Assessor shall check the actual PM

equipment
conducted for the contractor
equipment.
a) PM Schedule
b) PM Records
40 SAP: Auto
generation of PM
notification and
updation in SAP
system.
b) Electrical
41 Preventive
Maintenance for
critical Electrical
equipments
(Motors,
Transformer,
relays, etc)
Assessor shall check the SAP system

on M1 notifications.
a) PM Schedule
b) PM Records

for critical Electrical equipment
42 PM schedule for
FLP equipment
(those not
covered in the
other PM
schedule)

for flame proof equipment.
c) FLP PM schedule
43 ELCB Inspection

for ELCB
44 Earth continuity
test
Assessor shall check the testing

records of the earth continuity
45 Cathodic
Protection - CP
(Piping & building
piling)
Assessor shall check the inspection

records of the cathodic protection
46 PM of Fire alarm
system

for the Fire Alarm System
b) Inspection records of Fire Alarm
System
47 Closure of
Corrective action
from the PM
inspection for the
month

the month
a) PM Schedule
b) PM Records
48 SMP
effectiveness and
followed during
PM inspection for
the month

compliance.
the month
b) Training records
c) List of SOPs
49 SAP: Auto
generation of PM
notification and
updation in SAP
system.

a) PM Schedule
b) PM Records
50 Mean Time to
Repair Safety
Systems

c) Instrumentation
51 Calibration of
process
instruments /
gauges

(Calibration) of process
a) PM Schedule
b) PM Records
52 Calibration of FGS Assessor shall check the actual PM

instruments /
(Calibration) of FGS
gauges
a) PM Schedule
b) PM Records
53 Proof Tests of
Safety critical
Systems
conducted
Assessor shall check records to see if

actual Proof Tests of safety critical
systems have been conducted
a) PM Schedule
b) PM Records
54 Closure of
Corrective action
from the PM
inspection for the
month

the month
a) PM Schedule
b) PM Records
55 SMP
effectiveness and
followed during
PM inspection for
the month

compliance.
the month
b) Training records
c) List of SOPs
56 SAP: Auto
generation of PM
notification and
updation in SAP
system.

a) PM Schedule
b) PM Records
57 Mean Time to
Repair Safety
Systems


58 Number of
Assessor shall check if the number
emergency mock of Emergency mock drills conducted
drill conducted
is as per PLL's frequency.
59 Implementation Assessor shall check if the number

of mock drill
of Emergency mock drills conducted
recommendation. is as per PLL's frequency.
60 PM for
Emergency
Facilities (Fire
Tender, SCBA
(PPE), Fire
hydrant/hose &
accessories, etc)

of Emergency Facilities (Fire Tender,
SCBA (PPE), Fire hydrant/hose &
accessories, etc) conducted.
a) PM Schedule
b) PM Records
61 ECC
Assessor shall check the actual
infrastructure and availability of emegency
availability
equipmemets in the ECC.
a) Min ECC requirements
b) ECC Inspection Records
62 Availability of Fire Assessor shall through a site

tender
evaluation ascertain the availability
of the fire tender.
63 Availability of Fire Assessor shall ascertain through a
crew with PPE
site evaluation the availability of the
(SCBA, etc)
fire crew and check their adherence
to usage of PPE.
64 Availability of Fire Assessor shall through a site
hydrant / hose & evaluation ascertain the availability
accessories, etc of the fire hydrant/hose &
accessories.
65 Number of
emergency
systems not
functional during
real emergency /
mock drill.
Assessor shall check the

functionality of the emergency
system by simulating an emergency
situation during the site visit.
66 Defects
Assessor shall check actual M8
notification of Fire notification generated in SAP system
and Emergency for the month.
system (M8) in
SAP system
a) PM Records
b) SAP system M8 notifications
67
68
69
70
71
Assessor shall check

EDG availability and PM a) PM Records
b) Weekly trial run records
and testing
C) availability of EDG

Emergency
schedule for emergency facility
communication
like telephone, paging system
system PM and
(70% for compliance & 30% for
working status
Field verification)
Enviornment
Monitoring
schedule (70% for following
(Ambient, Stack, schedule & 30% for data under
Ground water, the perscribed limit.)
Marine water
Monthly third party report to be
etc.) E-waste,
check
HW,
/Bio-medical
Waste, Used
HW reord to be check, Manifest
Batteries
Documents to be check
handling
(storage &
disposal)
Envionment
pollution
Incident (Demand)
Incident record
Scoring Criteria
Score = Actual percentage of compliance x Basic
Score

Score
If actual TIFR is <= 2, score will be 3.

If actual TIFR is > 2, score will be 0.
Actual percentage of compliance = (No. of incidents

reported and investigated as per PLL procedure/Total
No. of incidents occurred during the month)*100.
Score
Weightage for conducting Safety Committee meetings

shall be 30%.
Weightage for status of the implementation of
recommendations shall be 70%.
Actual percentage of compliance shall be calculated
based on the weightage given.
Score.
safety system related parameters) then the score

recommendations from the audits & studies)*100.
Score
safety system related parameters) then the score
Actual percentage of compliance = (No. of safety

trainings conducted / Total No. of safety trainings
planned for the month)*100.
Score
Actual percentage of compliance = Average score
obtained out of 100 from the post test.
Score
Actual percentage of compliance = (No. of monitors

calibirated / Total No. of gas monitors planned for
calibiration for the month)*100.
emergency / legal / fire protection system) then the
score obtained shall be "Zero".
Score
Actual percentage of compliance = (No. of personnel
examined / Total No. personnel planned for the
month)*100.
Score
Actual percentage of compliance = (No. of inspection

[PM & calibration] conducted / Total No. of inspection
[PM & calibration] planned for the month)*100.
Score
Actual percentage of compliance = (No. of non routine

activities carried out with work permits / Total No. of
non routine activities carried out during the
month)*100.
Score
Actual percentage of compliance = (No. of contractor
safety activity completed / Total No. of safety activity
planned for contractor for the month)*100.
Score

compliance of HSE and Legal fire protection system.
Actual percentage of compliance = (No. of BBS
Observations actual/No. of BBS Observations Planed )
*100.
Score
The score obtained shall be "Zero" if the FGS system
was activated even once.
The score obtained shall be Negative if the FGS
system was activated more than once.
The score obtained shall be "Zero" if the Fire Alarm

system was activated once.
The score obtained shall be Negative if the Fire alarm
system was activated more than once.
If the percentage availability is less than 100% (for

any parameters in Fire Detection system - FGS & Fire
alarm system) then the score obtained shall be "Zero"
for whole detection system.
Score
Actual Percentage Availability = (No. of times the fire

alarm has worked and was audible throughout the
plant/No. of times the fire alarm has been tested)*100
If the percentage availability is less than 100% (for
any parameters in Fire Detection system - FGS & Fire
alarm system) then the score obtained shall be "Zero"
for whole detection system.
Score

Actual percentage of compliance = (No. of MOCs that

followed all aspects of MOC procedure/Total number of
MOCs raised)*100
Score
Actual percentage of compliance = (No. of Process

equipments released for PM / Total number of
equipments in the PM schedule for the month)*100
Score
Actual percentage of compliance = (No. of PSSR

conducted / Total number of PSSR scheduled for the
month)*100
Score
Actual percentage of compliance = (No. Of times

Bypasses have been recorded/Total number of
Bypasses)*100
Score
Actual percentage of compliance = (No. of Equipment

running as per changeover schedule/Total no. of
equipment that need to be changed over)*100
Score
The score obtained shall be "Zero" if the basic process

control system was failed once.
The score obtained shall be Negative if the basic
process control system was failed more than once.
Actual percentage of compliance = (No. of SOP

complied / Total sample size) *100
Score will be "Zero" if Actual compliance is less than
80% - for safety system related parameters.
Score
Actual percentage of compliance = (No. of work

permits without deficiencies / Total No. of work
permits audited (sample size))*100.
compliance - for safety system related parameters.
Score
percentage of compliance = (Actual PM

conducted/Planned PM)*100
Score
Actual percentage of compliance = (Actual PM
Score
Score
percentage of compliance = (Actual PM conducted /
Planned PM)*100
Score

Score
If the Actual percentage of compliance is less than
90% (for Process hardware related parameters) then
the score obtained shall be "Zero".
Score

recommendations closed / Total no. of PM
recommendations from PM inspection)*100
Score
Actual percentage of compliance = (No. of SMP
Score

conducted/Planned PM)*100.
Score

MTTR was within accepted time period/Total No. Of M2
and M3 activities)*100
Score

Score
percentage of compliance = (Actual PM (M1)
notification generated & updated in SAP
system/Planned PM)*100
Weightage 50% for PM generation & 50% for
Updation.
Score

Score
Actual Percentage of compliance = (Actual PM
Score

Score

Score
Score
Score
Score
Score

Updation.
Score
Actual Compliance Percentage = (No. Of times MTTR

was within accepted time period/Total No. Of M2 and
M3 activities)*100
Score

Score
Score
Score
Score

Score

Updation.
Score
MTTR was within accepted time period/Total No. Of M2
and M3 activities)*100
Score
Actual percentage of compliance =

(Actual/Planned)*100
Score

recommendations from the drills)*100.
Score

conducted/Planned)*100
Weightage70% for compliance & 30% for Field
verification.
Score
Actual percentage of compliance = (Actual

availability of emegency equipmemets / Min
requirements defined)*100
Score
Score = Availability % x Basic Score


The score obtained shall be "Zero" if there has been a

single emergency system failure during a real
emergency/mock drill. The score obtained shall be
Negative if more than one emergency system has
failed.
Actual percentage of compliance = (No. of M8

notifications generated in SAP system / Total No. of M8
notifications)*100
Score
Score will be "Zero" if Actual is less than 100% compliance - for Process
hardware related parameters.
Score will be "Zero" if Actual is less than 100% compliance - for Process
hardware related parameters.
Actual percentage of compliance = (No. of planned montioring / Total No.

monitoring done)*100
Actual percentage of compliance is b ased on Sample audit of the

documentation and based on all three points criteria actual percentage of
compliance will be decided on prorata basis .
Score will be "Zero" if Actual 1, score will be given only if there is no any
Envioronment related Incident.
2.0 Scorecard
Sec
Category
Score as per the

Applicable
Parameters
Sec I
64
59.50
98
87.50
225
153.50
100
80.00
20
20.00
507
400.50
Score as per the

Applicable Parameters
Score Achieved
64
98
85
90
50
100
20
507
59.50
87.50
85.00
18.50
50.00
80.00
20.00
400.50
Sec II Process Safety Performance

Sec III Asset Integrity
Emergency Management
System
Environment Management
Sec V
System
Sec IV
Total
Sec
Sec
Sec
Sec
Sec
Sec
Sec
Sec
Category
I
II
III (aAsset Integrity - Mechanical
III (bAsset Integrity - Electrical
Asset Integrity III (c
Instrumentation
Emergency Management
IV
System
Environment Management
V
System
Total
Score
Achieved
Safety Performance Ranking Score Graph
Safety Performance Ranking Score

4.655.00
Environment Management System5.00
4.00
Process Safety Perform

4.46
3.00
2.00
1.03
1.00
4.00
5.00
Asset Integrity - Me
5.00
Asset Integrity - Instrumentation
Page 111
Scoring Criteria
All Not Applicable points will be eliminated from the scoring criteria and the Maximum score wil
the Applicable safety parameters only.
Safety Performance Ranking Scoring is done based on the following criteria:
Score
Rank
> 90
Excellent
71 to 90
Good
51 to 70
Average
< 50
Below Average
Action Required
Excellent, efforts required to sustain good practices.

Scope for improvement exists.
Attention is required to address the existing hazards

Immediate attention of management is required.
Page 112
Terminal Safety Weightage

Score
Given (%)
13.95
15
26.79
30
20.47
30
12.00
15
10.00
10
83.20
100
Safety Performance Ranking

Score
4.65
4.46
5.00
1.03
5.00
4.00
5.00
3.95
ormance Ranking Score Graph
formance Ranking Score

4.655.00
m5.00
4.00

4.46
3.00
2.00
1.03
1.00
4.00
5.00
Asset Integrity - Mechanical
5.00
entation
Page 113
m the scoring criteria and the Maximum score will be derived based on
Action Required
ellent, efforts required to sustain good practices.
pe for improvement exists.
ention is required to address the existing hazards.
mediate attention of management is required.
Page 114

Safety - Index - KPP OCT

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Safety Index Assessment

Petronet LNG Limited

JOGI SAFETECH SOLUTIONS

207, Pramukh Chambers, Rander Road,

JOGI SAFETECH SOLUTIONS

207, Pramukh Chambers, Rander Road,

Safety Index Assessment Report Petronet LNG

Reviewed and Approved By

Ms. Disha Jethva

Mr. Nilesh Jogal

ex Assessment Report Petronet LNG

Comments / Nature of Changes

Reviewed and Approved By

Mr. Nilesh Jogal

hich they have claimed it is required to us. We are not

er purpose or any other third party for any purpose

1.0 Executive Summary

1) Mr. Japan Shah

2) Mr. Sunil Dharaiya

2) Mr. Dhruv Khudkhudia

3) Mr. Dilip Chand

Dr. Virendra Patel

30.07.201 Health and Safety

Safety Performance Ranking Score Graph

Safety Performance Ranking Score

Process Safety Performance

Asset Integrity - Electrical

2.4 SCOPE OF SAFETY INDEX ASSESSMENT STUDY

2.5 SAFETY INDEX ASSESSMENT METHODOLOGY

The study was carried out in following broad steps:

Study of existing safety management system of PLL

2.6 STANDARDS / REFERENCES ADOPTED FOR THE STUDY

nies in the Indian

ure the country's

o import LNG and

arat State, India)

evelop safety index

ns, Surat to carry

5.0 Safety Index - Petronet LNG - Dahej

Section I: Health and Safety Management

Quarterly review of safety

Month: October 2016

Total injury Frequency

Month: October 2016

Incident Reporting and

(1) Process compliance of

Month: October 2016

Internal and External safety

Month: October 2016

Plan vs. Actual for the

Plan vs. Actual - Average

Plan vs. Actual - 100%

Month: October 2016

Plan vs. Actual based on the

Month: October 2016

Sample based review of the

Month: October 2016

Statutory and legal

Plan vs. actual based on the

Plan vs. Actual - 100%

Month: October 2016

Plan vs. Actual - 100%

Section II: Process Safety Performance