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BPCL- KOCHI REFINERY

BPCL- KOCHI REFINERY . To the Hon. Jury members of Safety Innovation Awards 2008-2009. SAFETY RECORDS OF BPCL KR. SAFETY AWARDS 2011. 3. Safety Award- The Institution of Engineers (India), Delhi. SAFETY AWARDS. 6. Management System Certifications.

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BPCL- KOCHI REFINERY

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  1. BPCL- KOCHI REFINERY To the Hon. Jury members of Safety Innovation Awards 2008-2009

  2. SAFETY RECORDS OF BPCL KR

  3. SAFETY AWARDS 2011 3

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

  5. SAFETY AWARDS 6

  6. Management System Certifications OHSAS 18001 – Occupational Health & Safety Management Systems (Certified since January 2010) ISO 14001- Environmental Management Systems (Certifiedsince June 1999) ISO 9001 - Quality Management Systems (Certifiedsince August 2004) ISO 17025 – Certification for Quality control . (Certifiedsince August 2005) 7

  7. 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 8

  8. 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 9

  9. 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 10

  10. 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 Managementfor Chemical Emergency Training Trained 28 OHSAS Lead Auditors Safety Innovative Measures 11

  11. Conducted joint programme on Industrial Safety and Fire Prevention with NSC (Kerala) Safety Innovative Measures 12

  12. 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). Safety Innovative Measures 13

  13. 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. Safety Innovative Measures 14

  14. 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. Safety Innovative Measures 15

  15. 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. Safety Innovative Measures 16

  16. 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 Safety Innovative Measures 17

  17. Safety Innovative Measures

  18. 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 Innovative Measures 19

  19. SAFETY MANAGEMENT SYSTEMS

  20. 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

  21. Refinery Operating System (ROS) ROS RELATED TO SAFETY- A Few Samples

  22. 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

  23. Process Safety • Hazop study for • All new facilities • All modifications • Risk analysis for • All new projects

  24. 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.

  25. 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)

  26. 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 Preparednessprogramme for: • Local community

  27. SUPPORTING SYSTEMS TO ENHANCE SAFETY • Tool box meeting before critical hot works. • Safety briefing at turnaround sites / major construction sites • Monthly Safety Bulletin • Off the job accident monitoring system

  28. SAFETY TRAINING - EMPLOYEES

  29. SAFETY TRAINING - EMPLOYEES

  30. 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 31

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

  32. SAFETY COMMITTEE

  33. FOUR TIER SAFETY COMMITTEE SYSTEM

  34. FIRE PROTECTION SYSTEMS FOAM TENDERS: 06 DCP TENDERS : 03 FOAM NURSER: 01

  35. FIRE 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

  36. VIEW OF FIRE WATER RESERVOIR 37

  37. FIRE TENDERS VOLVO FIRE TENDER 38

  38. 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 39

  39. Fire Water Network

  40. FIRE PROTECTION SYSTEMS Online Gas Monitors

  41. FIRE PROTECTION SYSTEMS • Fire Alarm System • Addressable analogue detection system. • Smoke detectors : 2032 Nos. • Manual Call points : 349 Nos.

  42. FIRE PROTECTION SYSTEMS WATER SPRAY SYSTEMS Fixed water spray system. • For all Storage Tanks (Class A,B&C) • POL Wagon Loading and Truck Loading gantries • Critical Process Vessels & Hot oil pumps • Air fin exchangers Automatic water spray system • LPG Spheres, Bullets • LPG Wagon Loading and Truck Loading gantries • LPG Bottling Plant • Transformers

  43. FIRE PROTECTION SYSTEMS

  44. FIRE PROTECTION SYSTEMS 45

  45. FIRE PROTECTION SYSTEMS WATER SPRAY SYSTEMS

  46. FIRE PROTECTION SYSTEMS

  47. 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. 48

  48. 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… 49

  49. 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 . 50

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