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PRESENTATION

NUMALIGARH REFINERY LIMITED. PRESENTATION. ON. Emergency Response & Disaster Management Plan and Best Practices at NRL. FIRE & SAFETY DEPARTMENT OF NRL. Numaligarh Refinery Limited. . THE GENESIS. 1. Proposal for Refinery included in “Assam Accord” : August 15, 1985

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PRESENTATION

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  1. NUMALIGARH REFINERY LIMITED PRESENTATION ON Emergency Response & Disaster Management Plan and Best Practices at NRL FIRE & SAFETY DEPARTMENT OF NRL

  2. Numaligarh Refinery Limited . 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

  3. Numaligarh Refinery Limited .

  4. Numaligarh Refinery Limited Offsite Diaster Mock Drill 24/02/2009 OUR LOCATION- IN THE STATE OF ASSAM AOD BRPL NH-52 NH-37 NH-39 IOC,GHY NRL N E W Refinery CapacityDST. from (MMTPA) NRL (Km) IOCL, Ghy 1.00 260 AOD, Digboi 0.65 310 BRPL 2.35 460 NRL 3.00 ---- S

  5. Numaligarh Refinery Limited Offsite Diaster Mock Drill 24/02/2009 NRL PLOT PLAN PANKA GAON CRUDE PIPE LINE IN STORM WATER OUTLET GREEN BELT 101D 101C 101B 101A CRUDE TANKS (FUTURE) CRUDE TANKS CRUDE TANKS FLARE S K O 250 KV R V D V DG set H S D DRY SLOP C NAPHTHA WET SLOP FO R A F T D C O DCU C CDU/VDU (White oil.) Pump house HCU C GREEN BELT CPC WARE HOUSE SCRAP YARD Black oil White oil CISF COMPLEX U Gantry A Gantry B CENTRAL CONTROL PLANT AREA FOR BOTTLING Oil loading gantry ETP ROOM LOADING GANTRY H2U Scaling platform N2 Compressor HOUSE WARE house Plant HORTON SPHERE RWTP SRU CONTROL ROOM RAiL STORE DM PLANT CPP OPEN COOLING CENTRAL STORAGE WORKSHOP TOWER YARD GREEN BELT OPEN STORAGE YARD CONTROL ROOM S S CTC RW P&T MEDICAL I LPG NRL LAB CENTRE ADM. CANTEEN RESERVOIR T R LOADING E BLDG. GANTRY Adm FW U EIL PO FIRE STATION RESERVOIR bldg CISF MATERIAL GATE NRMT MAIN GATE BANK CISF MAIN GATE GREEN BELT <--- NH - 39---> /

  6. OUR PROMOTERS Numaligarh Refinery Limited . Share holding pattern of the refinery

  7. Numaligarh Refinery Limited . 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.7874Crore • Gross Profit for the financial year 2009-10 is Rs. 521Crore • Profit After Tax Rs.232Crore

  8. Numaligarh Refinery Limited . HIGHLIGHTS • Eco-friendly Refinery • First Sulfur Recovery Unit for processing Assam Crude • Installation of Ground Flare Clean & Green Environment

  9. Numaligarh Refinery Limited . 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.

  10. Numaligarh Refinery Limited . 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. Numaligarh Refinery Limited . HSE – Our Primary Concern • 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

  12. Numaligarh Refinery Limited . 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.

  13. Numaligarh Refinery Limited . SAFETY COMMITTEES NRL has 3-tier 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)

  14. Numaligarh Refinery Limited . 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

  15. FIRE PROTECTION FACILITIES I. Fire Water Pumps: • 100% back up with 4 Diesel driven pumps • Second Source of Fire water : Raw water reservoir of capacity (2 x 12000) m3 PA-101 PA-102 PA-102A PA-103 PA-104 PA-105 RESERVOIR-7000 M3 PA-106 LEGEND PA-107 CAPACITY Pump Head 3 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) PA-108 PA-109 PA-109 RESERVOIR-7000 M3 PA-110

  16. Numaligarh Refinery Limited . FIRE PROTECTION FACILITIES (Contd.) II. Fire Water Network

  17. Numaligarh Refinery Limited . FIRE PROTECTION FACILITIES (Contd.) III. Foam System IV. CO2 System V. FM200 (Compound of Carbon, Fluorine & Hydrogen) System

  18. FIRE PROTECTION FACILITIES (Contd.) VI. Mobile Fire Fighting Units VII. First Aid Fire Fighting Equipments (Approx 1200 nos.)

  19. Numaligarh Refinery Limited . 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 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)

  20. Numaligarh Refinery Limited . 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

  21. Numaligarh Refinery Limited . Mobile Fire Fighting Units

  22. Numaligarh Refinery Limited . Mobile Fire Fighting Units DCP TENDER

  23. Numaligarh Refinery Limited . Mobile Fire Fighting Units

  24. Numaligarh Refinery Limited . EQUIPMENTS MOBILE OIL SPILLAGE RECOVERY UNIT ARTICULATOR

  25. Numaligarh Refinery Limited . COMMUNICATION FACILITIES • 1. Intercom / BSNL / Fax • LAN / Internet / VSAT. • Group Dialing System • 4. Public Address System • 5. 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 km • 7. Fire alarm & Detection system. • Remarks : All the above facilities have UPS or • emergency power.

  26. Numaligarh Refinery Limited . MANUALS & DOCUMENTS • 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

  27. Onsite & Offsite Disaster Management Plan Numaligarh Refinery Limited .

  28. ORGANOGRAM FOR OFFSITE EMERGENCY PREPARDNESS PLAN SDO Office, Bokakhat Tel : 268382 (O), 268387 ( R) 94351-54221(M) Supdt Of Police Tel. : 285233 (O), 284234 (R) Hospital Co- ordinator Tel : 280505/ 280373 Jt. Director Health Service Tel : 282438 (O), 280397(R) OIL Co-ordinator Supdt. Engg. : 265561(O) 4429 (R) Civil Supply Officer Tel : 280532 (O) NRL Authority, D(T) : 265401 (O), 266425 (R) GM(O) : 265529(O), 266423(R) 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 Dist. Transport Officer Tel : 282181 (O) Fire Service Co- ordinator Golaghat Fire Brigade : 280300 Bokakhat Fire Brigade : 269733(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) Railway Authority Div. Rly. Engineer, TSK Tel : 0374 -2333570 (O) Divisional engg. Tel Mob :9435000384 CO Marangi Tel : 9401088312 (M) Ex. Engineer ASEB Tel : 280312 (O), 94350-54337(M) Ex. Engineer NH Tel : 280319(O) Inspector of Factories Mob :9435160729 Panchayat VDP Mob:9854872854 DIPRO Mob:9435002199

  29. Numaligarh Refinery Limited . ORGANOGRAM FOR ONSITE EMERGENCY PREPARDNESS PLAN

  30. Numaligarh Refinery Limited . 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

  31. Numaligarh Refinery Limited . Fire Fighting Training Fire Fighting Training to CISF Jawans Fire Fighting demonstration in public

  32. Numaligarh Refinery Limited . MOCK DRILLS • 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

  33. Numaligarh Refinery Limited . MOCK DRILL REPORT

  34. Numaligarh Refinery Limited . GLIMPSES OF MOCK DRILL Rescue operation by NDRF persons

  35. Numaligarh Refinery Limited . GLIMPSES OF MOCK DRILL HighExpansionFoam Generator

  36. Numaligarh Refinery Limited . GLIMPSES OF MOCK DRILL Relief Camp during off site disaster mock drill Rescue Operation Review Meeting after Mock Drill

  37. Numaligarh Refinery Limited . 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)

  38. Numaligarh Refinery Limited . 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

  39. Numaligarh Refinery Limited . Key Tasks Adopted in NRL for Improvement of Health & Fire • 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 • On the site Safety training for employees: • A specific training programme adopted for training of employees at the site. • 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. • 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. • Internal Safety Audit by members from group companies: • The system of Internal Safety Audit is being prevailed in NRL as per OISD guidelines.

  40. Numaligarh Refinery Limited . 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.

  41. Numaligarh Refinery Limited . Thank You

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