Emergency Response & Disaster Management Plan

and Best Practices at NRL

2

THE GENESIS

1. Proposal for Refinery included in “Assam Accord” : August 15, 1985

2. “” incorporated : April 22, 1993

3. Commercial Production commenced : Oct. 1, 2000

4. NRL became subsidiary of BPCL : March 31, 2001

4

OUR LOCATION- IN THE STATE OF ASSAM

BRPL

IOC,GHY

AOD

NH-37NH-52

NH-39

EW

N

S

Refinery Capacity DST. from (MMTPA) NRL (Km)

IOCL, Ghy 1.00 260

AOD, Digboi 0.65 310

BRPL 2.35 460

NRL 3.00 ----

NRL

CDU/VDUHCU

H2U

CCU

CRUDE TANKS(FUTURE)

S RU

LPG LOADING

GANTRY

COOLING TOWER

RWTP

T

K OA

SF

H S DV

C

D

D

DCU

CPP

DM

PLA

NT

N2 Plant

Compressorhouse

MEDICAL CENTRE

FIRE STATION

STOREOPEN

STORAGEYARD

WA

RE

HO

USE

CENTRAL WORKSHOP

LABNR

L

SITE

EIL

CANTEEN

Admbldg

CTCP&T

PO

BANK

OP

EN

ST

OR

AG

E Y

AR

D

ETP

SCR

AP

YA

RD

FLARECRUDE TANKS CRUDE TANKS

VR

RCO

DRY SLOP

WET

SLO

P

FO

NAPHTHA

CENTRAL CONTROL

ROOM

CPC

WA

RE

HO

USE

HO

RT

ON

SPH

ER

E

<--- NH - 39---> /

CISF MATERIAL GATE

ADM.BLDG.

CONTROL ROOM

Black oilGantry A

White oilGantry B

Scaling platform

250 KV DG set

Oil loading gantry

AR

EA

FO

R B

OT

TL

ING

PL

AN

T

Pum

p ho

use

(W

hite

oil

.)

CIS

F C

OM

PLE

X

NRMT MAIN GATE

RA

iL

LOA

DIN

G

GA

NT

RY

GREEN B

ELT

GR

EEN

BEL

T

GREEN BELT

GREEN BELT

CISF MAIN GATE

RW RESERVOIR

FW RESERVOIR

SRU

C

ON

TRO

L R

OO

M

PANKA GAON

NRL PLOT PLAN

STORM WATER OUTLET

CRUDE PIPE LINE IN

101A

101B

101C

101D

OUR PROMOTERS

Share holding pattern of the refinery

7

THE PROJECT AT A GLANCE

Installed Capacity : 3 MMTPA

Area : Refinery - 750 Acres Township - 250 Acres

Approved Project Cost : Refinery - Rs. 2489.12 Crores

Marketing Terminal - Rs. 235.52 Crores ---------------------------------------------------------

Total - Rs. 2724.64 Crores

Both Refinery and Marketing Terminal completed within approved Project Cost Annual turn over Rs.7874CroreGross Profit for the financial year 2009-10 is Rs. 521CroreProfit After Tax Rs.232Crore

8

HIGHLIGHTS

Eco-friendly Refinery

First Sulfur Recovery Unit

for processing Assam

Crude

Installation of Ground Flare

Clean & Green Environment

9

MILESTONES

Management Systems:

•IMC Ramakrishna Bajaj National Quality awards for 2009.•Jawaharlal Nehru Centenary Awards for Energy Performance of Refineries for the year 2004-05 and for 2007-08. •National Energy Conservation Award consecutively for 2007(2nd Prize in refinery sector) and 2008 by Bureau of Energy Efficiency.•Oil & Gas Conservation Award in 2008 by Centre of High Technology.•TERI Corporate Environmental excellence Award consecutively for 2007 and 2008.

Safety Management:

•Oil Industry Safety Awards for the year 2005-06 and for 2008 by OISD.•National Safety Award in 2008.•Shrestha Suraksha Puraskar consecutively for 2006 and 2007 by National safety council.•Green Tech Safety Gold Award for 2005-06 by Greentech Foundation, Hyderabad and for 2007-08 by Greentech Foundation, Delhi.

MILESTONES (Contd.)

Environment Management:

• Best green Location: Refinery in 2009 by BPC Mumbai Refinery

• Chairman's award for Excellence in Green (Refinery) in 2007-08 by Corporate HSE& S award , BPCL

Information Technology:

• Awarded Best Industry Status in IT Agency National Petroleum Management Programme for year 2001-02.

• Fastest implementation of SAP

11

Achieved 15.96 Million LTA free man-hours (3292 days).

Regular study of water quality of Dhansiri river

Continuous monitoring of the status of ambient air quality.

Waste Management System

- Solid Waste Disposal Yard- Secured Land Fill- Melting Pit

Post commissioning Environment Audit by NEERI.

Use of sweet fuel for internal consumption

HSE – Our Primary Concern

SAFETY MANAGEMENT SYSTEM OF NRL

• NRL is certified by DNV for OHSAS 18001 since 2002 along with ISO 9001 & 14001 for Quality & Environment

also. NRL also achieved ISRS level -9 1) Safety points covered under internal and external management system audit.2) Safety points are discussed everyday in the morning meeting.3) Quarterly the status of various safety points implementation are reviewed at the level of Director (Technical) in Apex safety Committee Meeting.4) Every month, in Functional Co ordination meeting, Managing Director takes monthly report on safety performance.

5) Safety Audit by OISD

• Status of OISD related points are regularly sent to OISD every three months.

• The DGFASLI audit compliance report are also sent to

RLI, Kolkata periodically.

SAFETY COMMITTEES

Sectional safety Committee

- Conducted monthly by Shift In Charges’ of the various units

Area Safety Committee

- Conducted quarterly with equal participation of

management and Non-management staff

Apex Loss Control Committee

- Conducted quarterly with all unit heads,VKNRL & non-

management staff and convened by Director (T)

NRL has 3-tier safety committees:

FIRE PROTECTION FACILITIES AT NRL

• Fire water system I. Fire water pumps and Reservoir. II. Fire Water Network (As per OISD 116 , other relevant codes & IS standards) Fire water network of length 55 km is laid in closed loop multidirectional flow.

It includes: * Hydrants * Monitors * Water spray system * Deluge system

• Foam Protection System * Fixed Foam System & * Semi fixed Foam System

• CO2 Total Flooding System• First Aid fire fighting Appliances• Mobile fire fighting equipments• Gas Detection & Alarm system

I. Fire Water Pumps:

LEGEND3 JOCKEY PUMPS 65 M3/Hr. 11kg/cm2(Electric Driven)

4 MAIN FW PUMPS 700 M3/Hr. 10.5 kg/cm2(Electric Driven)

4 MAIN FW PUMPS 700 M3/Hr. 10.5 kg/cm2 (Diesel Driven)

CAPACITYRESERVOIR-7000 M3

RESERVOIR-7000 M3

PA-101

PA-104

PA-103

PA-107

PA-106

PA-108

PA-109

PA-102

PA-102A

PA-109

PA-110

PA-105

Pump Head

•Second Source of Fire water : Raw water reservoir of capacity (2 x 12000) m3

FIRE PROTECTION FACILITIES

•100% back up with 4 Diesel driven pumps

FIRE PROTECTION FACILITIES (Contd.)

II. Fire Water Network

Particulars Location

Refinery Marketing terminal

Hydrants 445 nos. 170 nos.

Medium range Monitors

145 nos. 131 nos.

Long range Monitors

22 nos. 1 no.

Water Spray System Storage Tanks , Hot & light H/C pumps, Loading gantries

Deluge System CPP fuel Day Tanks,

CPP Transformer Area

LPG sphere, LPG bottling Plant

FIRE PROTECTION FACILITIES (Contd.)

Particulars Location

Refinery Marketing terminal

Semi fixed Foam system

In all the storage tanks except FO tank

-

Fixed Foam System Storage tank of Co-Generation Plant

In all the storage tanks except FO Tank

III. Foam System

IV. CO2 System

CO2 Total flooding System

In the GTG , cable cellar room of Co-Generation Plant

V. FM200 (Compound of Carbon, Fluorine & Hydrogen) System

FM200 flooding system

ERP Server room

Particulars Nos.

Foam cum water Tender 4 nos.

DCP Tender 1 no.

Mobile Oil Spill Recovery Unit 1 no.

Foam Trailer 4 nos.

Mobile Foam Units 4 nos.

Trailer Pump 2 nos.

VI. Mobile Fire Fighting Units

FIRE PROTECTION FACILITIES (Contd.)

VII. First Aid Fire Fighting Equipments (Approx 1200 nos.)

Particulars

Location

Refinery Marketing terminal

Offices , Buildings

DCP extinguisher

10 kg 643 141 41

75 kg 72 29 -

Cleaning Agent

6 kg 4 1 8

CO2 extinguisher

6.5 kg 73 04 11

9 kg 64 18 12

VII. Gas Detection & Alarm System The Fire Detection and alarm system is micro-processor based

and covers the entire refinery and NRMT. The system consists

of Fire detecting sensors & manual call points

LOCATION Total No of Fire Detecting Sensor (Ionization, Smoke, Heat & Optical photo detector)

Main Control Room 374

ETP Control Room 54

Administrative Building 220

Warehouse 128

NRMT Control Room 239

Total 279 nos. of Manual Call points are installed in around the road

network. A separate Fire Detection ,Alarm & Suppression System is installed in

CPP (Captive Power Plant)

SOME SAFETY EQUIPMENTS

• Safety Kit box located at strategic locations containing:

• Canister Mask: SO2, Cl2, NH3, H2S• Hand Gloves: Chemical, Lather, Kelver, Cotton, Electrical• Face Shield: Chemical, Furnace• Goggles: Bocal Blue, Safety Goggles• Ear Protection: Muff, Plug• Safety Torch• Dust Musk• Water Gel

• Compressed Air Breathing Equipment• Articulated Boom• Mobile Oil Spillage Recovery Unit

Mobile Fire Fighting Units

Mobile Fire Fighting Units

DCP TENDER

Mobile Fire Fighting Units

EQUIPMENTS

ARTICULATOR

MOBILE OIL SPILLAGE RECOVERY UNIT

1. Intercom / BSNL / Fax 2. LAN / Internet / VSAT.3. Group Dialing System4. Public Address System5. Siren at 9 locations including 2 at township.6. Multi channel VHF sets with eleven Base stations Range - Base Station : 25 Km, Hand sets :5 km7. Fire alarm & Detection system.

Remarks : All the above facilities have UPS or emergency power.

COMMUNICATION FACILITIES

• CONSTRUCTION SAFETY MANUAL (ENGLISH / ASSAMESE)• SAFETY MANUAL• FIRE MANUAL• ONSITE DISASTER MAMAGEMENT PLAN• OFFSITE DISASTER MANAGEMENT PLAN• FIRE ORDER• MATERIAL SAFETY DATA SHEET• CONTRACTOR SAFETY MANUAL• FIRE PROTECTION & SAFETY POCKET MANUAL• VISITOR’S FAMILIARISATION & SAFETY CARD• LEAFLET ON LPG SAFETY

MANUALS & DOCUMENTS

Onsite & Offsite Disaster Management Plan

CHIEF OFFSITE

EMMERGENCY

CO-ORDINATOR

DEPUTY COMMISSIONER

Tel. : 280222 (O),280221 (R)

94350-95420 (M)

alternate

ADDL. DY. COMMISSIONER (R&R)

Tel. : 280261(O),281019(R)

94350-54474 (M)

CONTROL ROOM

AT OFFICE OF

DC / ADC

SDO Office, Bokakhat

Tel : 268382 (O), 268387 ( R) 94351-54221(M)

Civil Supply Officer Tel : 280532 (O)

Dist. Transport Officer

Tel : 282181 (O)

Ex. Engineer, PWD (Road)

Tel : 280226 (O), 280426 (R)

Asst. Ex. Engineer, PWD (Bldg)

Tel : 280365 (O),

Ex. Engineer, PHED

Tel:284763(O) 94350-90808(M)

Inspector of Factories

Mob :9435160729

Divisional engg. Tel

Mob :9435000384

Railway Authority

Div. Rly. Engineer, TSK

Tel : 0374 -2333570 (O)

Fire Service Co- ordinator

Golaghat Fire Brigade : 280300

Bokakhat Fire Brigade : 269733(O)

NRL Authority,

D(T) : 265401 (O), 266425 (R)

GM(O) : 265529(O), 266423(R)

OIL Co-ordinator

Supdt. Engg. : 265561(O) 4429 (R)

Hospital Co- ordinator

Tel : 280505/ 280373

Supdt Of Police

Tel. : 285233 (O),

284234 (R) Jt. Director Health Service

Tel : 282438 (O), 280397(R)

Ex. Engineer ASEB

Tel : 280312 (O),

94350-54337(M)

Ex. Engineer NH

Tel : 280319(O)

CO Marangi

Tel : 9401088312 (M)

Panchayat VDP

Mob:9854872854

DIPRO

Mob:9435002199

ORGANOGRAM FOR OFFSITE EMERGENCY PREPARDNESS PLAN

ORGANOGRAM FOR ONSITE EMERGENCY PREPARDNESS PLAN

FIRE & SAFETY TRAINING

TRAINING FACILITIES:

• TRAINING HALL AT FIRE STATION

• FIRE TRAINING GROUND AS PER OISD 116

• TRAINING POLICY AS PER OISD - 154

TYPES OF TRAINING:

• FRESHER TRAINING FOR NEW EMPLOYEES

• RE-FRESHER TRAINING FOR ALL EMPLOYEES

OTHERS

• CONTRACTOR’S SUPERVISORS / WORKMEN

• CISF & OTHER SECURITY STAFF

• POL DRIVERS

Fire Fighting Training

Fire Fighting Training to CISF Jawans Fire Fighting demonstration in public

1) MINOR FIRE

• DRILLS ARE CONDUCTED ONCE A MONTH

2) MAJOR FIRE

• DRILLS ARE CONDUCTED ONCE IN A QUARTER

3) ONSITE DISASTER

• DRILLS ARE CONDUCTED HALF-YEARLY

4) OFFSITE DISASTER

• CONDUCTED ON ONCE A YEAR

MOCK DRILLS

MOCK DRILL REPORT

GLIMPSES OF MOCK DRILL

Rescue operation by NDRF persons

GLIMPSES OF MOCK DRILL

High Expansion Foam Generator

GLIMPSES OF MOCK DRILL

Rescue OperationRelief Camp during off site disaster mock drill

Review Meeting after Mock Drill

SAFETY INCENTIVE SCHEMES

• INCENTIVE LINKED WITH MILLION LTA FREE MAN HRS.

• OUTSTANDING SAFETY PERFORMANCE AWARD.

• HOUSEKEEPING AWARD (FOR UNITS).

• SECTIONAL SAFETY AWARDS.

• SAFETY AWARD FOR CONTRACTORS.

• TURN AROUND SAFETY AWRAD

• BEST SAFETY AWARD FOR NRL EMPLOYEES

• BEST SAFETY AWARD FOR CONTRACTS EMPLOYEES (AMC/PROJECT)

RECENT PROJECTS

COMPLETED PROJECTS

• Motor Spirit Unit

• Utilization of Natural Gas

• Diesel Quality Up gradation Project

• 12 MW Steam Turbine Generator

• Pipeline Dispatch & Receipt Terminal

FUTURE PERSPECTIVE

• Naphtha Splitter Project

• Wax Project

• Production of Needle Coke

Key Tasks Adopted in NRL for Improvement of Health & Fire

1. Health Hazard Survey for Employees:• As a good corporate citizen among oil industries in India, NRL has

under taken the health hazard survey for critical tasks and high hazard areas in plants and other areas

2. On the site Safety training for employees:• A specific training programme adopted for training of employees at the

site. 3. Contractor Safety Evaluation for Turn Around Jobs:

• NRL was having a full-fledged contractor safety evaluation during turn • The system of evaluation for contractors is very elusive considering all

aspects of HSE.

4. Survey of fire fighting and safety equipments: • The fire fighting and safety items in refinery are surveyed by a

multidisciplinary team of operation, Maint and F&S to exactly evaluate the correct equipments for fire fighting and safety. All required actions are taken by F&S for the same.

5. Internal Safety Audit by members from group companies: • The system of Internal Safety Audit is being prevailed in NRL as per

OISD guidelines.

EXAMPLES OF POSITIVE ACTION TAKEN

• From last year onwards, NRL’s all meetings starts with a “safety moment” where safety points are discussed.

• NRL is always meeting MOU target of Training of NRL personnel, workers of contractors, CISF & security guards etc on safety.

• General Loss Control Rules/Dos/Don’ts • Hazard Communication:

– Contractor must familiarize himself from NRL EICs about all known potential fire, explosion or toxic release hazards related to his contract. He in turn will ensure that same information has been passed to his supervisors and workmen.

• Contractors Penalty clause

– In order to improve and maintain safe working environment we are planning to introduce a special conditions of contracts for HSE (Health Safety and Environment) regulation for contractors.

• Note: Generally we do counseling to the workers if they are found practicing unsafe acts or work in unsafe condition before imposing the above penalty clauses.

• PPE: NRL has adopted colour code for PPEs to improve safety culture at NRL with effect from 1st January, 2011.

Thank You