Kochi Refinery 1 BPCL- KOCHI REFINERY To the Hon. Jury members of Safety Innovation Awards...
-
Upload
noreen-ramsey -
Category
Documents
-
view
220 -
download
1
Transcript of Kochi Refinery 1 BPCL- KOCHI REFINERY To the Hon. Jury members of Safety Innovation Awards...
Kochi Refinery
1
BPCL- KOCHI REFINERY
To the Hon. Jury membersTo the Hon. Jury membersofof
Safety Innovation Awards 2008-2009Safety Innovation Awards 2008-2009
Kochi Refinery
2
SAFETY RECORDS OF BPCL KR
Accident Free Million Man-hours (as on 25th Sept 2012 ) : 28.22 (2462 days)
Previous best record : 21.29(From 06.08.1989 to 01.09.1997 )
Kochi Refinery
33
SAFETY AWARDS 2011
Sl.No NAME OF AWARD AWARDED BY
2011
Outstanding Safety performance award in Industrial Safety (Runner –Up)
National Safety Council, Kerala chapter.
2011
Certificate of Excellence (Second Prize) Large Factories (Chemical Petroleum & Petrochemical)
Department of Factories & Boilers, Govt. of Kerala
2011
Best Occupational Health Centre- 1st
Department of Factories & Boilers, Govt. of Kerala
2011
Safety Innovation Award The Institution of Engineers(India), Delhi
Kochi Refinery
66
SAFETY AWARDS
President of India Fire Service Medal for Gallantry
3 of our Fire and Safety officers have been awarded the Presidents Fire Service Medal for Gallantry during Republic Day 2011.
The award is for their daring efforts in effectively controlling a disastrous situation on public road arising from a profuse leakage of ammonia, by arresting the leak.
Liquid ammonia leaked through a failed 4” filling nozzle of a 15 MT ammonia tanker of FACT at Ambalamugal
The incident was at 0100 am on 11th Dec 2009.
Kochi Refinery
77
OHSAS 18001 – Occupational Health & Safety Management Systems (Certified since January 2010)
ISO 14001- Environmental Management Systems (Certified since June 1999)
ISO 9001 - Quality Management Systems (Certified since August 2004)
ISO 17025 – Certification for Quality control . (Certified since August 2005)
Management System Certifications
Kochi Refinery
88
• Intensive campaign to improve near miss reporting(118 Nos. in 2010-11). For the current year 89 Nos of near miss incidents reported.
• Canister masks replaced with light weight self contained breathing apparatus (SCBA).
• A scheme for Annual Safety Award among different departments for improving safety culture.
Recent Safety Innovative Measures
Kochi Refinery
99
• Commissioned LPG mounded bullets and new improved LPG loading gantry.
• Quarterly Self Audit of the operating departments by respective Department Safety Committee members.
• Safety Driving Licence system for drivers.
• Integration of Management Systems (ISO 9001, ISO14001 and OHSAS 18001)
Recent Safety Innovative Measures
Kochi Refinery
1010
• Comprehensive Internal Safety Audit inviting experts from group refineries.
• Conversion of floating roof tanks with double seals.
• Conducted comprehensive Industrial Hygiene Survey by CLI, Mumbai.
• Conducted one day intensive workshop on work permit system for officers and workmen
Safety Innovative Measures
Kochi Refinery
1111
• Procured breath analyser to deter people entering the refinery under the influence of alcohol.
• Intensive 2 day training on Handling of Chemical/ Petroleum Emergencies for officers of Fire & Rescue Services, Kerala state.
• Faculty support for Institute of Land and Disaster Management for Chemical Emergency Training
• Trained 28 OHSAS Lead Auditors
Safety Innovative Measures
Kochi Refinery
1212
Conducted joint programme on Industrial Safety and Fire Prevention with NSC (Kerala)
Safety Innovative Measures
Kochi Refinery
1313
• Safety walks of the operating areas by senior executives including GM’s and ED.
• Substitution of Chlorinator with Electro Chlorinator for cooling water system.
• The refinery got accredited as Approved Training Centre for conducting ‘Work Place Hazard Awareness’ course of British Safety Council for School children.
• BPCL-KR is an active member in the Chemical Emergency Response Centre (CHEMREC).
Safety Innovative Measures
Kochi Refinery
1414
• BPCL KR has taken key role in combating several emergencies in Kerala State.
• Dead man valves provided on water drain points of LPG
spheres to prevent accidental draining of LPG.
• QEHS Policy is being read through PA system every week (On every Thursday at 13.32 hrs).
• QEHS Policy is read at the beginning of every safety meeting.
Safety Innovative Measures
Kochi Refinery
1515
• Annual one day Fire and Safety training to all employees including the Unit Head.
• HSE training insisted as a prerequisite for entry inside the refinery for Contractors, Contract Supervisors and Contract Workers.
• Established financial deterrent scheme for violation of HSE norms by contractors.
• Provided retractable fall arresters for truck crew at the truck filling gantries.
Safety Innovative Measures
Kochi Refinery
1616
• Quick closing coupling valves provided for LPG truck loading bays
• Introduced counseling of injured and those violating safety norms.
• Additional high level alarm being provided for storage tanks.
• Safety audit of other industrial units.
Safety Innovative Measures
Kochi Refinery
1717
• Safety briefing at turnaround / construction sites.
• Issuing safety instructions through PA system at turnaround / major construction sites.
• Positive isolation of N2 lines at utility points in plant area.
• Scheme for awarding employees / contract employee for reporting high potential near miss incidents / unsafe conditions
Safety Innovative Measures
Kochi Refinery
1919
• Awards under Suggestion Scheme.
• Condition assessment of Cranes & Heavy Equipment
older than 10 years.
• Closed drainage system for storage tanks.
• Automatic rim seal fire detection and extinguishing
system for storage tanks.
Safety Innovative Measures
Kochi Refinery
21
Refinery Operating System (ROS)
Compilation of various operating practices, instructions and procedures.
ROS is meant for:
Improving safety of the refinery
Ensuring inter departmental coordination
Adhering to time schedules for key activities.
Defining roles and responsibilities.
Complying to statutory requirements
Enhancing independent decision making
Kochi Refinery
22
ROS RELATED TO SAFETY- A Few Samples
ROS No. DESCRIPTION
11 Accident/ Incident Enquiry & Analysis
23 Safety while draining water/ product from any container.
28 Procedure for carrying out changes in existing plant/ offsite facilities.
47 Working in Confined Spaces
63 Safety Guidelines for Excavation in Refinery Premises.
90 Work Permit System
Refinery Operating System (ROS)
Kochi Refinery
23
Action Taken Report (ATR)
Online monitoring and managing of ATRs Every incident including near-miss is investigated as
per ROS 11
Based on the enquiry findings/recommendations Action taken report (ATR) generated.
Responsibility and time frame is specified.
Status of implementation monitored by MHSSEC
NO: of ATR’s released 446
Total recommendations 5297
Number of recommendations implemented 4085
Kochi Refinery
24
Process Safety
• Hazop study for
– All new facilities – All modifications
• Risk analysis for– All new projects
Kochi Refinery
25
Safety Checks/ Inspections
Safety walk by senior officers.
Night visit by senior officials (Once in 2 days).
Safety checks by Safety Officers.
Planned Health & Hygiene Survey.
Kochi Refinery
26
Safety Audits
Multi-Disciplinary Internal Audit : Once a year Internal safety audit by Safety : Quarterly Committee members External Safety Audits by OISD : Once in three years
Surprise Safety Audit by OISD : Once a year
Statutory Safety Audits : Once in two year
Priority Inspection F&B : Once a year
Pre-Commissioning audit as per OISD guidelines for new facilities (prior to commissioning)
Kochi Refinery
27
Safety Promotions
Safety awareness programme for: Near by schools Housewives Truck drivers (Petroleum/LPG) Contract workers Loading / unloading workers
Nearby public
Workshop on Petroleum Safety for: Kerala Fire Force Kerala Police
Emergency Preparedness programme for: Local community
Kochi Refinery
28
SUPPORTING SYSTEMS TO ENHANCE SAFETY
Tool box meeting before critical hot works.
Safety briefing at turnaround sites / major
construction sites
Monthly Safety Bulletin
Off the job accident monitoring system
Kochi Refinery
29
SAFETY TRAINING - EMPLOYEES
1 One day Fire & Safety Training for all employees every year
(Achievement 100 %)
2 1 day intensive workshop on Work Permit System for Officers
(Trained- 413 Nos.)
3 1 day intensive workshop on Work Permit System for
Workmen (Trained- 200 Nos.)
4 Training on Chlorine Safety (141 employee attended)
5 2 Days First Aid Training ( 178 employees attended)
6 Training on Safety Aspects in Open field Radiography by
AERB ( 63 officers attended)
Kochi Refinery
3131
• On line gas /smoke /heat detectors
• Automatic fire detection and extinguishing system
• Advanced communication systems like MCP, VHF, Hot line PA system, CCTV etc
• Emergencies communicated to Sr. Executives by SMS.
SYSTEMS TO PREVENT/CONTROL EMERGENCIES
Kochi Refinery
34
FOUR TIER SAFETY COMMITTEE SYSTEM
Sl.No
Type of Committee Meeting Frequency
Chairman
1 DSC - 11 departments (With workmen representatives)
Once in two months
HOD
2 Joint HSSE Committee (With workmen representatives from different departments)
Once in two months
ED (Tech)
3 Management HSSE Committee
Once in a month
ED (KR)Occupier
4 Joint Safety Committee – Contract Labours
Once in two months
CM (Maint) Constituted in Dec 2011
Kochi Refinery
35
FIRE PROTECTION SYSTEMSFIRE PROTECTION SYSTEMS
FOAM TENDERS: 06
DCP TENDERS: 03
FOAM NURSER: 01
Kochi Refinery
36
FIRE WATER PONDSFIRE WATER PONDS
FIRE WATER POND I : 80, 000 M3
FIRE WATER POND II : 100,000 M3
ACTP PONDS : 45, 375 M3
DHDS PONDS : 15, 500 M3
Kochi Refinery
3939
Modern fire tenders
VOLVO Foam tenders - 3 Nos.
Bronto Sky lift Foam tender - 1 No.
DCP tenders - 3 Nos.
Foam Nurser - 1 No.
FIRE TENDERS
Kochi Refinery
40
Total Length Approx 60 km.
Fire water header pressure 12 kg/cm2Header Size 12” to 24”
Fire Water Network
Drive Capacity (m3/hr) Nos.
Engine 410-616 20Motor 410-616 06
(Motor) Jockey Pumps
66 04
Total 30
Kochi Refinery
41
FIRE PROTECTION SYSTEMSFIRE PROTECTION SYSTEMS
Hydrocarbon Type
Primary block 34
CDU II block 72
FCCU block 33
CPP /Cooling tower 23
LPG bottling plant 13
Tank farm area 95
PIBU /PRU 33
DHDS block 81
NHT/CCR 42
Total 352
H2S Type
CDU II SRU 09
DHDS 14
DHDS SRU 12
Total 35
Online Gas Monitors
Kochi Refinery
42
FIRE PROTECTION SYSTEMSFIRE PROTECTION SYSTEMS
Fire Alarm System
Addressable analogue detection system.
Smoke detectors : 2032 Nos.
Manual Call points : 349 Nos.
Kochi Refinery
43
FIRE PROTECTION SYSTEMSFIRE PROTECTION SYSTEMS
WATER SPRAY SYSTEMS
Fixed water spray system.
For all Storage Tanks (Class A,B&C)POL Wagon Loading and Truck Loading gantriesCritical Process Vessels & Hot oil pumpsAir fin exchangers
Automatic water spray system LPG Spheres, BulletsLPG Wagon Loading and Truck Loading gantries LPG Bottling PlantTransformers
Kochi Refinery
47
FIRE PROTECTION SYSTEMSFIRE PROTECTION SYSTEMS
Automatic Fire Detection & Extinguishing Systems
CO2 System GT1 >2 enclosure.
NAF SIII System DHDS Control Room
FM 200 IT Centre
Argonite LPG T/L CR, SRR 1&2
Kochi Refinery
4848
FIXED FIRE FIGHTING SYSTEMS
Fixed foam pourer system on storage tanks
Automatic rim seal fire protection on storage tanks
2000 Nos. of Portable fire extinguishers of different capacity placed at different locations.
Kochi Refinery
4949
ADVANCED RESCUE EQUIPMENTS
Pneumatic lifting bag (68 ton, 2.5 cm gap,52 cm lift)
Smoke extractor fan
Vetter leak sealing lance (for tanks)
Vetter leak sealing bandage ( for pipes)
Liquid leak arresting pad for arresting and contain the
leak.
Lukas Hydraulic metallic cutter (Spreading distance-36
cm)Contd…
Kochi Refinery
5050
ADVANCED RESCUE EQUIPMENTS
Fall arrester for rescue in confined space
Fire entry suits/Fire proximity suits/ Fully body chemical
splash suit
Trolley mounted breathing apparatus
Inflatable lighting tower (10000 Lux)
Chain saw for wood cutting and Power saw for concrete /
metal cutting .
Kochi Refinery
51
Column Fire
Pump Seal Failure
Tank Fire
Wagon Fire
Open Pit Fire
Vertical / Horizontal flange leak
Fire Fighting Training Facilities
State of art fire fighting training ground with simulating models of :
Kochi Refinery
60
EMERGENCY PREPAREDNESS PLANS
Fire Emergency Procedure
Onsite Emergency Plan
Mutual Aid Plan with neighboring industries since 1991 (FACT & HOC)
Active involvement in District Crisis Management Plan / CHEMREC
Kochi Refinery
61
MOCK DRILLS
Type of drill Frequency
Surprise Fire emergency mock drill Once in a month
Surprise Mutual aid mock drill Once in 3 months(On rotation)
Onsite emergency mock drill Once in 6 months