BPCL KOCHI REFINERY Kochi Refinery To the Hon

BPCL- KOCHI REFINERY Kochi Refinery To the Hon. Jury members of Safety Innovation Awards 2008 -2009 1

SAFETY RECORDS OF BPCL KR Kochi Refinery Accident Free Million Man-hours (as on 25 th Sept 2012 ) Previous best record (From 06. 08. 1989 to 01. 09. 1997 ) : 28. 22 (2462 days) : 21. 29 2

SAFETY AWARDS 2011 Kochi Refinery Sl. No NAME OF AWARDED BY Outstanding Safety National 2011 performance award in Council, Industrial Safety (Runner –Up) chapter. Safety Kerala 2011 Certificate of Excellence (Second Prize) Large Factories (Chemical Petroleum & Petrochemical) 2011 Best Occupational Health Centre- 1 st Department of Factories & Boilers, Govt. of Kerala 2011 Safety Innovation Award The Institution of Engineers(India), Delhi Department of Factories & Boilers, Govt. of Kerala 3

Kochi Refinery 4

Safety Award- The Institution of Engineers (India), Delhi Kochi Refinery 5

SAFETY AWARDS Kochi Refinery 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 11 th Dec 2009. 6

Management System Certifications Kochi Refinery 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) 7 7

Recent Safety Innovative Measures Kochi Refinery • 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. 8 8

Recent Safety Innovative Measures Kochi Refinery • 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, ISO 14001 and OHSAS 18001) 9 9

Safety Innovative Measures Kochi Refinery • 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 10 10

Safety Innovative Measures Kochi Refinery • 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 Disaster Management for Chemical Emergency Training • Trained 28 OHSAS Lead Auditors 11 11

Safety Innovative Measures Kochi Refinery Conducted joint programme on Industrial Safety and Fire Prevention with NSC (Kerala) 12 12

Safety Innovative Measures Kochi Refinery • 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). 13 13

Safety Innovative Measures Kochi Refinery • 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. 14 14

Safety Innovative Measures Kochi Refinery • 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. 15 15

Safety Innovative Measures Kochi Refinery • 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. 16 16

Safety Innovative Measures Kochi Refinery • Safety briefing at turnaround / construction sites. • Issuing safety instructions through PA system at turnaround / major construction sites. • Positive isolation of N 2 lines at utility points in plant area. • Scheme for awarding employees / contract employee for reporting high potential near miss incidents / unsafe conditions 17 17

Safety Innovative Measures Kochi Refinery 18

Safety Innovative Measures Kochi Refinery • 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. 19 19

SAFETY MANAGEMENT SYSTEMS

Refinery Operating System (ROS) Kochi Refinery Ø Compilation of various operating practices, instructions and procedures. Ø 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 21

Refinery Operating System (ROS) Kochi Refinery 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. Working in Confined Spaces 47 63 90 Safety Guidelines for Excavation in Refinery Premises. Work Permit System 22

Action Taken Report (ATR) Kochi Refinery Online monitoring and managing of ATRs Ø Every incident including near-miss is investigated as per ROS 11 Ø Based on the enquiry findings/recommendations Action taken report (ATR) generated. Ø Responsibility and time frame is specified. Ø Status of implementation monitored by MHSSEC NO: of ATR’s released Total recommendations Number of recommendations implemented 446 5297 4085 23

Process Safety Kochi Refinery • Hazop study for – All new facilities – All modifications • Risk analysis for – All new projects 24

Safety Checks/ Inspections Kochi Refinery Ø Safety walk by senior officers. Ø Night visit by senior officials (Once in 2 days). Ø Safety checks by Safety Officers. Ø Planned Health & Hygiene Survey. 25

Safety Audits Kochi Refinery Ø Multi-Disciplinary Internal Audit : Once a year Internal safety audit by Safety : Quarterly Committee members External Safety Audits by OISD : Once in three years Ø Surprise Safety Audit by OISD : Once a year Ø Statutory Safety Audits : Once in two year Ø Priority Inspection F&B : Once a year Ø Pre-Commissioning audit as per OISD guidelines for new facilities (prior to commissioning) Ø Ø 26

Safety Promotions Kochi Refinery ØSafety awareness programme for: § Near by schools § Housewives § Truck drivers (Petroleum/LPG) § Contract workers § Loading / unloading workers § Nearby public ØWorkshop on Petroleum Safety for: § Kerala Fire Force § Kerala Police ØEmergency Preparedness programme for: § Local community 27

SUPPORTING SYSTEMS TO ENHANCE SAFETY Kochi Refinery § Tool box meeting before critical hot works. § Safety briefing at turnaround sites / major construction sites § Monthly Safety Bulletin § Off the job accident monitoring system 28

SAFETY TRAINING - EMPLOYEES Kochi Refinery 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) 29

SAFETY TRAINING - EMPLOYEES Kochi Refinery 30

SYSTEMS TO PREVENT/CONTROL EMERGENCIES Kochi Refinery • 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. 31 31

Oil spill response mock drill at Single point Mooring (SPM) Kochi Refinery 32

SAFETY COMMITTEE Kochi Refinery 33

FOUR TIER SAFETY COMMITTEE SYSTEM Sl. Type of Committee No 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) Kochi Refinery Constituted in Dec 2011 34

FIRE PROTECTION SYSTEMS Kochi Refinery FOAM TENDERS: 06 DCP TENDERS: 03 FOAM NURSER: 01 35

FIRE WATER PONDS Kochi Refinery FIRE WATER POND I : 80, 000 M 3 FIRE WATER POND II : 100, 000 M 3 ACTP PONDS : 45, 375 M 3 DHDS PONDS : 15, 500 M 3 36

VIEW OF FIRE WATER RESERVOIR Kochi Refinery 37 37

FIRE TENDERS Kochi Refinery VOLVO FIRE TENDER 38

FIRE TENDERS Kochi Refinery Modern fire tenders VOLVO Foam tenders - 3 Nos. Bronto Sky lift Foam tender - 1 No. DCP tenders - 3 Nos. Foam Nurser - 1 No. 39

Fire Water Network Kochi Refinery Total Length Fire water header pressure Header Size Approx 60 km. 12 kg/cm 2 12” to 24” Drive Capacity (m 3/hr) Nos. Engine Motor 410 -616 (Motor) Jockey Pumps 66 20 06 04 Total 30 40

FIRE PROTECTION SYSTEMS Kochi Refinery Online Gas Monitors Hydrocarbon Type H 2 S 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 CDU II SRU 09 DHDS 14 DHDS SRU 12 Total 35 41

FIRE PROTECTION SYSTEMS Kochi Refinery Fire Alarm System Addressable analogue detection system. Smoke detectors : 2032 Nos. Manual Call points : 349 Nos. 42

FIRE PROTECTION SYSTEMS Kochi Refinery WATER SPRAY SYSTEMS Fixed water spray system. ØFor all Storage Tanks (Class A, B&C) ØPOL Wagon Loading and Truck Loading gantries ØCritical Process Vessels & Hot oil pumps ØAir fin exchangers Automatic water spray system ØLPG Spheres, Bullets ØLPG Wagon Loading and Truck Loading gantries ØLPG Bottling Plant ØTransformers 43

FIRE PROTECTION SYSTEMS

FIRE PROTECTION SYSTEMS Kochi Refinery 45

FIRE PROTECTION SYSTEMS Kochi Refinery WATER SPRAY SYSTEMS 46

FIRE PROTECTION SYSTEMS Kochi Refinery Automatic Fire Detection & Extinguishing Systems CO 2 System GT 1 &GT 2 enclosure. NAF SIII System DHDS Control Room FM 200 IT Centre Argonite LPG T/L CR, SRR 1&2 47

FIXED FIRE FIGHTING SYSTEMS Kochi Refinery Ø Fixed foam pourer system on storage tanks Ø Automatic rim seal fire protection on storage tanks Ø 2000 Nos. of Portable fire extinguishers of different capacity placed at different locations. 48

ADVANCED RESCUE EQUIPMENTS Kochi Refinery Ø Pneumatic lifting bag (68 ton, 2. 5 cm gap, 52 cm lift) Ø Smoke extractor fan Ø Vetter leak sealing lance (for tanks) Ø Vetter leak sealing bandage ( for pipes) Ø Liquid leak arresting pad for arresting and contain the leak. Ø Lukas Hydraulic metallic cutter (Spreading distance-36 cm) Contd… 49

ADVANCED RESCUE EQUIPMENTS Kochi Refinery Ø Fall arrester for rescue in confined space Ø Fire entry suits/Fire proximity suits/ Fully body chemical splash suit Ø Trolley mounted breathing apparatus Ø Inflatable lighting tower (10000 Lux) Ø Chain saw for wood cutting and Power saw for concrete / metal cutting. 50

Fire Fighting Training Facilities Kochi Refinery State of art fire fighting training ground with simulating models of : Ø Column Fire Ø Pump Seal Failure Ø Tank Fire Ø Wagon Fire Ø Open Pit Fire Ø Vertical / Horizontal flange leak 51

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EMERGENCY PREPAREDNESS PLANS Kochi Refinery Ø Fire Emergency Procedure Ø Onsite Emergency Plan Ø Mutual Aid Plan with neighboring industries since 1991 (FACT & HOC) Ø Active involvement in District Crisis Management Plan / CHEMREC 60

MOCK DRILLS Kochi Refinery 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 61

THANK YOU Kochi Refinery 62