Process Safety and Risk Management Nabha MANAGEMENT COMMITMENT

Process Safety and Risk Management @ Nabha MANAGEMENT COMMITMENT TECHNOLOGY PERSONNEL FACILITIES Nurturing Life …

Process Safety and Risk Management @ Nabha Process Technology / PSI Process Hazards Analysis (PHA) Safe Operating Procedures Management of Change PT / PSI Mechanical Integrity Quality Assurance Pre-start-up Safety Reviews MOC Facilities Nurturing Life … Training and Contractors Performance Incident Investigation MOC Personnel Emergency Auditin Planning g

Process Safety and Risk Management @ Nabha Process Safety Information (PSI) Hazards of Materials v MSDS available for all the materials handled at the site v All hazardous information is communicated to and made readily available to all affected employees Ø MSDS displayed in local language at all the relevant places Ø MSDS accessible to OHP and all the section in charges Ø Training imparted on chemical and sensitizing agents and methods of safe handling Nurturing Life …

Process Safety and Risk Management @ Nabha Process Safety Information Process design basis includes: Process flow diagrams u Description of the process u Inventory of hazardous substances. u Process steps, and limits including maximum, normal, and minimum conditions (temperatures, pressures, flows and/or compositions) u Process Safety Information (PSI) Process Design basis • • • Dust areas – 68 dust areas were identified – 42 areas were given RFI solutions – Remaing 26 areas will be completed by 2012 – Explosive vents provided for spray drier plant, cyclones , Malt mill, etc Electrical equipment – Most of the electrical equipment are IP 55 and Switches IP 65 – Earthing and bonding provided to all equipment for dissipating static electricity Flammable liquids and gases – Reduced the inventory of LPG gas cylinders – All the electrical fixtures @ LPG gas usage area are flame proof – Permit to work for diesel tank unloading Nurturing Life …

Process Safety and Risk Management @ Nabha Process Safety Information (PSI) Equipment Design basis v The equipment design basis is maintained upto date and communicated to the concerned employees u u u Piping and instrument diagrams (P&ID’s) Manufacturing data reports including design basis, data sheets, specifications, drawings, etc Equipment arrangement drawings Electrical diagrams Protective safety systems including emergency shutdowns, fire protections, etc Operating Manuals and Instructions Nurturing Life …

Process Safety and Risk Management @ Nabha Process Hazard Analysis (PHA & RM) Process Safety Information Process Hazards Analysis (PHA & RM) Nurturing Life … v The following risk assessments were carried out in the site u H&S risk assessments u HAZOP studies u Machinery safety risk assessments u Fire risk assessments u Ergonomics u Chemical risk assessment u Environment risk assessment u PPE Risk assessment

Process Safety and Risk Management @ Nabha Operating Procedures and Safe Work Practices Process Safety Information Process Hazards Analysis (PHA & RM) v Provided operating procedures for a clear understanding of safe operations in local language v Work instructions displayed at the relevant places Operating Procedures and v On the job training imparted Safe Work v Monitoring of work practices on Practices daily basis v Permit to work is in place and in use Nurturing Life …

Process Safety and Risk Management @ Nabha Management of Change - Technology Process Safety Hazards Information Analysis (PHA & RM) Operating Procedures and Safe Work Practices Management of Technology Change Nurturing Life … v Change control procedure is adopted for all the Changes to technology/facilities/personnel v To ensure that new process hazards are not created v Cross functional team formed to assess the EHS risks with a predetermined checklist

Process Safety and Risk Management @ Nabha Quality Assurance (QA) Quality Assurance v Pre-start-up Safety Reviews § Mechanical Integrity § MOC Facilities Nurturing Life … § QA efforts are focused to ensure that process equipment is: Manufactured and installed or assembled after maintenance in accordance with the design specifications and manufacturer’s recommendations Critical equipment inspections throughout the life cycle of a processes (fabrication, installation, operations and maintenance, etc) CAMMS in place

Process Safety and Risk Management @ Nabha Pre-Start-up Safety Reviews (PSSR) Quality Assurance v Pre-start-up Safety Reviews § Mechanical Integrity MOC Facilities Nurturing Life … § Pre-startup safety reviews done for new and modified equipment prior to startup To ensure that facilities are built or assembled in accordance with intended design specifications. To confirm that all appropriate elements of process safety have been addressed satisfactorily and the facility is safe for start up and operation

Process Safety and Risk Management @ Nabha Mechanical Integrity Program Ø Quality Assurance Ø Pre-start-up Ø Safety Reviews Mechanical Integrity MOC Facilities Ø Ø Nurturing Life … All the pressure vessels, lifting tools and tackles are tested at a certain frequency Maintenance procedures Training and performance of maintenance personnel Predictive and preventive maintenance programs (PPM) Quality control of maintenance parts and supplies Equipment tests and inspection procedures Work place inspections

Process Safety and Risk Management @ Nabha Training and Performance Emergency u Training given to all employees : Planning Auditing Ø E- modules on process safety MOC Ø SLT , EHS coordinators, and Personnel Engg team Incident Investigation Contractors Training and Performance Nurturing Life … Seven modules Ø Employees trained in hazards, procedures, SWPs, SOPs. Ø Start-up/shutdown/maintenance procedures and compliance Ø

Process Safety and Risk Management @ Nabha Contractors Ø Emergency Planning Auditing MOC Personnel Incident Investigation Contractors Training and Performance Nurturing Life … Ø Ø Ø Evaluated contractor’s EHS performance during selection All contractors are trained on EHS hazards, policies, rules, procedures, etc All contractors trained on emergency response plans Method statement and risk assessment Periodically evaluating contractor’s performance Daily pep talks and regular training on EHS

Process Safety and Risk Management @ Nabha Incident Reporting and Investigation Emergency Planning Auditing MOC Personnel Incident Investigation Contractors Training and Performance Nurturing Life … Ø Ø Near miss reporting is encouraged All the near misses, first aids and reportable injuries are investigated for root causes CAPA is written for each and every incident. All the actions are tracked in functional review

Process Safety and Risk Management @ Nabha Emergency Planning and Response Emergency Planning Auditing MOC Personnel Ø Incident Investigation Contractors Training and Performance Nurturing Life … Ø The plan addresses various types of potential emergency scenarios arising out of the risk assessments. Training given to all the employees at regular intervals

Process Safety and Risk Management @ Nabha Auditing Emergency Planning Auditing MOC Personnel Incident Investigation Ø Ø Ø Contractors Ø Training and Performance Nurturing Life … CEHS audit score: 85 Ø Leadership and management : 94 Flammable liquids/gases/dusts : 90 FM global Score: 75. 2 L-1 and L-2 audits are conducted on EHS standards CAPA is done for all the gaps identified All the actions are tracked in functional review

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