erdmp & best practices at nrl - hrdp-idrm.in
TRANSCRIPT
NUMALIGARH REFINERY LIMITED
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. “Numaligarh Refinery Limited” 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
SRefinery 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 OAS
FH S DV
C
DD
DCU
CPP
DM P
LANT
N2 Plant
Compressorhouse
MEDICAL CENTRE
FIRE STATION
STOREOPEN
STORAGEYARD
WAR
E
HOUS
E
CENTRAL WORKSHOP
LABNR
L
SITEEIL
CANTEEN
Admbldg
CTCP&T
PO
BANK
OPE
N S
TOR
AG
E YA
RD
ETP
SCRAP
YARD
FLARECRUDE TANKS CRUDE TANKS
VR
RCO
DRY SLOP
WET
SLO
P
FO
NAPHTHA
CENTRAL CONTROL
ROOM
CPC
WA
RE
HO
USE
HO
RTO
N S
PHER
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 F
OR
BO
TTL
ING
PLA
NT
Pum
p ho
use
(Whi
te o
il.)
CIS
F C
OM
PLE
X
NRMT MAIN GATE
RA
iL
LOA
DIN
G
GA
NTR
Y
GREEN B
ELT
GREE
N B
ELT
GREEN BELT
GREEN BELT
CISF MAIN GATE
RW RESERVOIR
FW RESERVOIR
SRU
CONT
ROL
ROOM
PANKA GAON
NRL PLOT PLAN
STORM WATER OUTLET
CRUDE PIPE LINE IN
101A
101B
101C
101D
61.6512.35
26
BPCL GOA OIL
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)
CAPACITY RESERVOIR-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 terminalHydrants 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 SystemCO2 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.)
ParticularsLocation
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 374ETP Control Room 54Administrative Building 220Warehouse 128NRMT 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 OFFSITEEMMERGENCYCO-ORDINATOR
DEPUTY COMMISSIONERTel. : 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, BokakhatTel : 268382 (O), 268387 ( R) 94351-54221(M)
Civil Supply Officer Tel : 280532 (O)
Dist. Transport OfficerTel : 282181 (O)
Ex. Engineer, PWD (Road)Tel : 280226 (O), 280426 (R)
Asst. Ex. Engineer, PWD (Bldg)Tel : 280365 (O),
Ex. Engineer, PHEDTel:284763(O) 94350-90808(M)
Inspector of Factories Mob :9435160729
Divisional engg. TelMob :9435000384
Railway AuthorityDiv. Rly. Engineer, TSKTel : 0374 -2333570 (O)
Fire Service Co- ordinatorGolaghat Fire Brigade : 280300
Bokakhat Fire Brigade : 269733(O)
NRL Authority,D(T) : 265401 (O), 266425 (R)
GM(O) : 265529(O), 266423(R)
OIL Co-ordinatorSupdt. 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 NHTel : 280319(O)
CO Marangi Tel : 9401088312 (M)
Panchayat VDPMob:9854872854
DIPROMob: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