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Capacity Building Programme

Capacity Building Programme. New Techniques & Strategies in Prevention and Management of Industrial Disasters For Factory Inspectorate ORGANIZED BY   Karnataka State Safety Institute Department Of Factories, Boilers, Industrial Safety & Health, Bengaluru. Programme.

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Capacity Building Programme

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  1. Capacity Building Programme New Techniques & Strategies in Prevention and Management of Industrial Disasters For Factory Inspectorate ORGANIZED BY   Karnataka State Safety Institute Department Of Factories, Boilers, Industrial Safety & Health, Bengaluru

  2. Programme Prevention of Industrial Disasters - Techniques • Siting of Hazardous industries • Emergency Search & Rescue in Industrial Disasters • Safer Technology & Equipment • Green Chemistry Standard Codes followed in Hazardous industries • LPG Storage and Handling installations • POL storage and installation Emergency Plans and Mock Exercises • Emergency Search and Rescue in Industrial Disasters • Legal Liability for Industrial Accidents and Disasters • Preparation and updating of Off – Site Emergency Plans • Standardization and strengthening of inspection and compliance of hazardous industries

  3. Standard Codes followed in Hazardous industries POL Storage & Installation K.SureshBacon, Senior Manager, IndianOilCorporation Bengaluru Terminal

  4. Types of Standards / Codes are Man Made & God Made • Eg. Of God Made Laws • Science and scientific actions • Chemical reactions, Physics, Mathematics, • Heat Radiation Effect wrt Burning rate, Wind effect, …etc • Fire Equation CH4 + 2O2 = CO2 + 2H2O + HEAT In this session we shall cover Man Made Laws “framed” in the background of God Made Laws

  5. Standards / Codes are of 2 TypesMan Made & God Made • Eg. Of Man Made Laws • Person below age 18 should not be engaged in works related to hazardous industry … • Ladies should not be deployed in night shift.. • No exit door shall be less than 1mtr width.. • Factories Act & Rules, Petroleum Act (OISD), which are directly related to our session on Standards & codes for POL Storage & Installations

  6. God Made Laws - which form the basis for framing - Man Made Laws are • Flash Point of the product • Upper Explosive Limit & Lower Explosive Limit MS 1.3-7.6, HSD 0.7-5 SKO/ATF 1.3-8, • Auto Ignition Temperature of MS-257, HSD-256, & ATF-255 • Heat Radiation Effectwrt wind effect, release of vapors • Unconfined Vapour cloud Explosion : • Release of flammable vapour in atmosphere, Mixing with air • Totally within flammable range or the outer layer is within flammable range with Delayed ignition • Flash Fire of UVCE depending on quantity and mixing with air • High pressure lasts only fraction of a second. • Persons may not get killed due to blast, but secondary effects cause death and destruction

  7. Tank-Fire Clippings 25 seconds. Fire Spreading to Neighboring Tanks Even without Unconfined Vapour Cloud Explosion, since Inter Tank Distance is not maintained. Clipping goes to prove AUTO IGNITION effect which causes BLOW OUT – Explosion of CRVT Tank with Roof Flying away by failing in its weakest joint STITCH WELD at Curb Angle

  8. Factories Act Hazardous Processes First Schedule Sl.no.29 Highly Flammable Liquids & Gases Factories Act 1948 -Chapter IV • Section 36 : Precaution … vapors, use of FLP, … • Section 37 : Inflammable Dust Gas, Hot Work, Factories Act 1948 -Chapter IVA • Section 41A : Site Appraisal Committee • Section 41B : Disclosure of information ..handling ,usage, transportation, storage, waste, ..

  9. Karnataka Factories RulesChapter IV – Safety Rules • Rule 88 D: Site Appraisal Committee Form 41 • Rule 88 F: MSDS to be disseminated • Rule 88 G: Disclosure of information • Rule 88 N: Ambulance Van in hazardous indstr.

  10. Buncefield Location 5th largest terminal in UK Products handled Petrol, Diesel Jet Fuel & Heating fuel Buncefield Oil Depot 40 Kms from London Depot close to Maylands Industrial Estate, home to some businessmen employing about 16,500 people

  11. Incident involved overfilling of a large storage tank with petrol supplied through a pipeline. As the petrol flowed over the topside of the tank, it formed a large vapour cloud that subsequently ignited. Buncefield Oil DepotWhat happened 300 tons gasoline overflow in 30 minutes

  12. The main explosion centered on the car parks between the site and Fuji and North gate building

  13. Total foam : 786KL Total water: 68 million liters Environmental Issues: Surface/ground water pollution

  14. After 32 hours of tackling the ferocious blaze at the Buncefield depot, firefighters extinguished all 20 tank fires, although another broke out again on Wednesday.

  15. UK SATELLITE IMAGE 11 DECEMBER 2005, 1336 GMT

  16. Jaipur Fire was Similar to that of Bouncefeild UK Fire 2005

  17. Standard Codes followed in Hazardous industriesPOL Storage & Installation • Standards Codes deliberated in this session wrtDesign( Education), Construction( Engineering) & Operation( Enforcement) of POL Storage InstallationstoPREVENT FIREare : • Petroleum Act 1934 & Rules 2002 • OISD 118 • OISD 117 • Control of Major Accident Hazard (Karnataka) Rules

  18. PETROLEUM ACT Related Stds • Petroleum Act 1934 & Petroleum Rules 2002 • OISD 105 - Work Permit system 137 & 192 • OISD 116 - Fire protection for Refineries 142, 144, 154 & 173 • OISD 117 - Fire protection for POL locations 154, 169 • OISD 118 - Layouts for Oil & Gas Locations 106, 150, 163 • OISD 141 - Design & const of Cross Country P/L 138 • OISD 156 - Fire protection for Ports 113, GDN 115

  19. Petroleum Act & Rules 2002 wrt POL Storage Installations • Petroleum Act 1934 Amended 2002 under revision 2011 • Class-Aupto30 litsNo License • Up to 100 lits class-A can be stored if intended to be used to generate power for motor conveyance or engine but when it is more than 30 lits, it should be stored in an isolated place which does not communicate with any room where persons dwell. • Class-Bupto2500 litsNo License • Class-Cupto45000 litsNo License

  20. Petroleum Act & Rules 2002 wrt POL Storage Installations Licensing by District Authorities • Form XII : Import & Store Class A in Qty < than 300 lits - by DC • Form XIII : Import & Store Class B in Qty < 25000 lits – by DC PENALTIES & FINES Even if held under unauthorized POL products - Chapter III of Petroleum Act Clause 23 : Penalties & Procedures : up to 1 month imprisonment & Rs.1000/- fine and when repeated up to 3 months & fine Rs5000/- HOW MANY HAVE GOT ARRESTED UNDER THIS ACT TILL DATE ( unless accident has taken place … )

  21. Petroleum Act & Rules 2002 wrt POL Storage Installations • Rule 2 (xxvi) : Tank means any receptacle used to store more than 1000 lits • Rule (xx) : Protected area, area required to follow inter distances , ( Licensed area ) not = Hazardous area • Rule 3 : Restriction on Delivery & dispatch of Petroleum : No delivery shall take place to persons who do not posses proper license..etc BUT License is not required to dispatch upto 15000 lits if arrangements made at receiving end to store class B in qty less than 2500 lits on arrival of truck. ????? • Rule 9 : Prevention of escape of petroleum : all precautions to prevent escape of petroleum into drain, sewer, harbor, river or watercourse or any public road or railway line.

  22. Petroleum Act & Rules 2002 wrt POL Storage Installations • Rule 10 : Prohibition of employment of children and intoxicated persons : Person below 18 years & intoxicated should NOT be engaged in loading, transporting, unloading or any premises under petroleum rules. • Labor Laws do not prohibit children working above age 14 , but Factories Act & Petroleum Act do prohibit children above 18 years as workers in Hazardous industries but what document to believe for age proof ? Voter Id card ….. • Rule 73. …truck be attended by the driver and at least one more person both of What syllabus to train ? who shall certify ? who shall check ? .. refresher course under Rule 9 of MV Act …for transporattion of Hazardous Goods ? But even this act is not implemented till date by us ???????

  23. Petroleum Act & Rules 2002 wrt POL Storage Installations Chapter III – Part IV Transport on Land by Vehicles • Rule 64 : RLW & ULW : change in RC book 20,000 kg – 8000 kg = 16000 kg /0.85 = 20,000 lits • Rule 73 : …truck be attended by the driverand at least one more person both of whom shall be familiar with the rules in this part. ? • Rule 77: Prohibition of loading of leaky or defective tank vehicles or unlicensed tank vehicles • Rule 78 : Precaution against static charges. Loading rate is restricted / regulated with automated locations only. • Rule 83 : Precaution on loading and unloading of petroleum at night.

  24. Petroleum Act & Rules 2002 wrt POL Storage Installations Chapter V – Storage Of Petroleum requiring License • Rule 117 : Precaution against fire. No Smoking, No Fires, No Match Boxes, except in authorized places. Adequate no. of Portable DCP’s … Act mentions to have FFF as per OISD 117. • Rule 118: Supervision of operation by an experienced responsible person who is conversant with terms & condition of license for installation and shall have proper safety training. OISD 154 is not covered under this act, but followed by industry . • Rule 120 : Drainage. Enclosures with proper drainage no water is allowed to accumulate in enclosure and level of enclosure above surrounding level, dyke wall operational form outside the enclosure dyke wall, kept closed always, …

  25. Petroleum Act & Rules 2002 wrt POL Storage Installations • Rule 121 : Exclusion of un authorized persons : PROTECTED AREA surrounded by a fence of 1.8 meter height. • Rule 124 : Construction of Tanks [ OISD 118 ] … with vapor space minumm5% , height of tank wrt diameter … • Rule 126 : Testing of Tanks : Tanks tested only with water, pipes can be exemptedby competent authority to test using POL product . Certificate of Tank Testing to be issued to PESO • Rule 129 : Night Working : No installation shall be opened and no work shall be carried before sunrise & after sun set, unless PESO approved electrical fixtures used for lighting • Rule 130 : Certificate of Safety : To be issued before commencing the activity

  26. Petroleum Act & Rules 2002 wrt POL Storage Installations • Rule 104 : Classification of Hazardous Area under chapter IV – Electrical Installation • Forth Schedule - Extent of Hazardous Area in Installation conforming to conditions 10(b) of license Form XV and storage sheds. Relevant to BIS 5572 – use of electrical equipments in hazardous area ( not = to protected area ) • Zone 0 : vapors expected to present Continuously • Zone 1 : vapors LIKELY to be present under Normal Operating Conditions • Zone 2 : Likely to be present ONLY under Abnormal Operating Conditions or FAILURES

  27. Hazardous Area Classification

  28. Zone-1 & Zone-2 in POL Storage Installations as per Petroleum Rules Fourth Schedule No Zone-0 in POL Installations

  29. Petroleum Act & Rules 2002 wrt POL Storage Installations • Zone 0 : No Electric Apparatus to be used in Zone O area EXCEPT “IS”Intrinsically Safe apparatus of type approved by CCOE . Any electrical equipment which works with energy level of sparks at less than 5 mille joules. ( spark if at all is caused the heat energy will not be sufficient to ignite flammable vapors ) example : Radar Gauges fitted on to the top of the tank, VHF sets, Flow Meter Sensors, …etc • Zone 1: Intrinsically safe or Fame Proof type apvd by CCOE. Electrical apparatus purged, auto cut off, auto warning system, ..etc • Zone 2: Non sparking type apvd by CCOE or Any Other apparatus permitted by CCOE. Ie any electrical equipment in Zone 2 must also be of apvd type by CCOE . Better it can be Flame Proof.

  30. Petroleum Act & Rules 2002 wrt POL Storage Installations Form XX - Qualification & Experience of Competent person • Degree in any branch of engineering … minimum experience 10 years in testing, fabrication, operation & maintenance of POL tanks • Physically fit & Sound for carrying out tests & examination • Minimum of 10 years in testing & fabrication or mounting of POL tanks, operation & maintenance of tank vehicles .

  31. Petroleum Act & Rules 2002 wrt POL Storage Installations • Form XV : Import & Store Petroleum in Installation in Bulk [ Form mentions quantities class A, B & C licensed to store both in Bulk & Non Bulk together in a premises ] Conditions applicable are 1. Premises not used for any other purpose - lube storage ? • Embankment wall max 2mtr with walkway 1mtr width Capacity of Enclosure wall not less than LARGEST TANK in the dyke 3.(i) GL inside tank farm shall NOT be lower than GL outside tank farm 3.(ii) Drains controlled with a valve capable of being operated form outside 3.(iii)Drains connected to OWS 3.(iv) Capacity of not more than 60,000 kl for CRVT’s and 1,20,000 for FRVT’s fire break wall for spill control

  32. Petroleum Act & Rules 2002 wrt POL Storage Installations 4 . All tanks shall be fitted with vent pipes leading into the open air, the open end being covered with two layers of fine copper or other non corrodible metal wire gauze of not less than 11 meshes per linear centimeter and fitted with a hood of the tank shall be fitted with an approved relief valve of other approved means of preventing dangerous internal or external pressures. The vent pipe and the relief valve of one tank shall not be inter-connected with those of any other tank. Shortcomings wrt in this rule : No. of Vents in the tank according to capacity of tank, -Pumping rate, -Effective vent area available among mesh wires, -Hazards of mesh getting clogged, .….etc Do Oil Comps. Comply to this rule ?

  33. Petroleum Act & Rules 2002 wrt POL Storage Installations 5. Cast Iron valves are not permitted. 7. Storage sheds for Containers ( Packed ) should be in sump of at least 0.25 mtr deep and kept clean and dry. 8. Filling shed of Class A or B be adequately ventilated near the ground level immediately above the walls constructed to prevent leakage of petroleum. 9. Protected Area Fencing 12. No alteration without prior approval in licensed premises 14. Tank Entry NOT without PPE & compliance to OISD 105 examined by himself or competent person 15. When tank opened for cleaning, repair, ..etc Fans, torches,..of FLP or IS type approved by CCOE only to be used.

  34. Vapor Recovery System for Tank Entry

  35. Inlet & out let of Vapors

  36. Form XVI : Import & Store otherwise than in bulk NON BULK (a) Class A upto 2500 lits (b) Class B upto 25,000 lits (c) Class C upto 45,000 lits (d) Partly One Class & Partly two Classes of petroleum [ class A together with any other class of petroleum in quantities exceeding 300 lits ] using Drums or one or more underground tanks with gas tight conditions Inter distances between storage sheds : where more than one class of petroleum is stored together, the entire quantity of petroleum shall be for the purpose be deemed to be of the petroleum of the most flammable thereof

  37. Form XV Condition 10 License To Import & Store Petroleum in Installation in BulkTable-1, Table-2 to be followed for inter distances between facilities when storage is more than 5000 kl in bulk and Table-3 when storage isles than 5000kl.Table 2 is Given Below & Table 1 in the Next Slide

  38. Form XV : Import & Store Petroleum in Installation in Bulk

  39. Tank Farm Tanks in Rows

  40. Inter Tank Distance

  41. Tabl 3 & 4 of OISD 118 Rev 2004

  42. Inter Tank Distances & Fire Figting

  43. Petroleum Rules VsOISD • OISD derived power from Petroleum Rules but it Super Seeds Petroleum Rules. • All the inter distances mentioned in the above Petroleum rules is super Seeded by OISD 118 Revision Sep 2004, since Petroleum rules empowers OISD 118 as Part of it.

  44. OISD 118 ( Revision-II Sep 2004 ) Layout for Oil & Gas Installations • Facilities to be laid in blocks with arrangement following the route of raw material, process and finished goods. • Layout to be divided into suitable blocks with roads all around. Roads separate the blocks acting as ‘fire breaks’. • Road to be designed for maneuvering of largest Fire Tender. • Two road approaches from highway/major road to be provided – one for employees and other for material movement. • Rail spur to be located close to periphery.

  45. OISD 118 Information required for preparing Layout • Site topography including elevation, slope and drainage • Meteorological data • Seismic data • High flood level & high tide level • Aviation consideration risk from adjacent facilities • Statutory obligations • Environmental considerations

  46. OISD 118 General consideration for preparation of Layout • Tank farm, Filling sheds & ETP be located at high grounds. • Control room in non-hazardous area. • Power generation facilities near boundary walls. • No over head lines to pass the installations. • LT sub-stations located near the load centers'. • Storage tanks to be grouped according to classification. • TT loading/unloading close to the main gate with one-way traffic for entrance and exit. • Independent waste collection centers'/ETP • Smoking booths 60 meters away from Hydrocarbon source.

  47. OISD 118 General consideration for preparation of Layout • Fire Fighting Facilities say at a safe place away from the hazardous area. • Fire water pumps and tanks as per OISD 116 (Refineries) 117 (POL) & 144 (LPG).

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