kochi refinery

Kochi Refinery

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BPCL- KOCHI REFINERY

To the Hon. Jury membersTo the Hon. Jury membersofof

Safety Innovation Awards 2008-2009Safety Innovation Awards 2008-2009

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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 )

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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

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

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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.

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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

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• 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

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• 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

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• 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

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• 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


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Conducted joint programme on Industrial Safety and Fire Prevention with NSC (Kerala)


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• 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).


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• 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.


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• 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.


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• 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.


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• 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


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• 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 MANAGEMENT SYSTEMS

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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

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ROS RELATED TO SAFETY- A Few Samples

ROS No. DESCRIPTION11 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 Spaces63 Safety Guidelines for Excavation in Refinery

Premises. 90 Work Permit System

Refinery Operating System (ROS)

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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 446Total recommendations 5297Number of recommendations implemented 4085

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Process Safety

• Hazop study for– All new facilities – All modifications

• Risk analysis for– All new projects

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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.

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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)

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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

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SUPPORTING SYSTEMS TO ENHANCE SAFETY

Tool box meeting before critical hot works.

Safety briefing at turnaround sites / majorconstruction sitesMonthly Safety BulletinOff the job accident monitoring system

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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)

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SAFETY TRAINING - EMPLOYEES

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• 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

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

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SAFETY COMMITTEE

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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

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FIRE PROTECTION SYSTEMSFIRE PROTECTION SYSTEMS

FOAM TENDERS: 06

DCP TENDERS: 03

FOAM NURSER: 01

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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

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VIEW OF FIRE WATER RESERVOIRVIEW OF FIRE WATER RESERVOIR

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FIRE TENDERS

VOLVO FIRE TENDER

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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

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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

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Hydrocarbon TypePrimary block 34CDU II block 72FCCU block 33

CPP /Cooling tower 23LPG bottling plant 13Tank farm area 95PIBU /PRU 33DHDS block 81NHT/CCR 42

Total 352

H2S Type

CDU II SRU 09DHDS 14DHDS SRU 12

Total 35

Online Gas Monitors

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Fire Alarm System

Addressable analogue detection system.

Smoke detectors : 2032 Nos.

Manual Call points : 349 Nos.

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WATER SPRAY SYSTEMSFixed 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

FIRE PROTECTION SYSTEMS

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FIRE PROTECTION SYSTEMS

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WATER SPRAY SYSTEMS

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Automatic Fire Detection & Extinguishing Systems

CO2 System GT1 &GT2 enclosure.

NAF SIII System DHDS Control Room

FM 200 IT Centre

Argonite LPG T/L CR, SRR 1&2

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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.

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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…

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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 .

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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 :

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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

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MOCK DRILLS

Type of drill FrequencySurprise 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

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THANK YOU

kochi refinery

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