BPCL- KOCHI REFINERY
Kochi Refinery
To the Hon. Jury members
of
Safety Innovation Awards 2008-2009
1
SAFETY RECORDS OF BPCL KR
Kochi Refinery
Accident Free Million Man-hours
(as on 25th Sept 2012 )
Previous best record
(From 06.08.1989 to 01.09.1997 )
: 28.22 (2462 days)
:
21.29
2
SAFETY AWARDS 2011
Kochi Refinery
Sl.No
NAME OF AWARD
AWARDED BY
Outstanding
Safety
2011 performance
award
in
Industrial Safety (Runner –Up)
2011 Certificate of Excellence
(Second Prize)
Large Factories (Chemical
Petroleum & Petrochemical)
2011 Best Occupational Health
Centre- 1st
National
Safety
Council,
Kerala
chapter.
Department of
Factories & Boilers,
Govt. of Kerala
2011 Safety Innovation Award
The Institution of
Engineers(India), Delhi
Department of
Factories & Boilers,
Govt. of Kerala
3
Kochi Refinery
4
Safety Award- The Institution of
Engineers (India), Delhi
Kochi Refinery
5
SAFETY AWARDS
Kochi Refinery
President of India Fire Service Medal for Gallantry
3 of our Fire and Safety officers have been awarded the
Presidents Fire Service Medal for Gallantry during Republic
Day 2011.
The award is for their daring efforts in effectively controlling
a disastrous situation on public road arising from a profuse
leakage of ammonia, by arresting the leak.
Liquid ammonia leaked through a failed 4” filling nozzle of a
15 MT ammonia tanker of FACT at Ambalamugal
The incident was at 0100 am on 11th Dec 2009.
6
Management System Certifications
Kochi Refinery
OHSAS 18001 – Occupational Health & Safety
Management Systems (Certified since January
2010)
ISO 14001- Environmental Management Systems
(Certified since June 1999)
ISO 9001 - Quality Management Systems
(Certified since August 2004)
ISO 17025 – Certification for Quality control .
(Certified since August 2005)
7
7
Recent Safety Innovative Measures
Kochi Refinery
• 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.
8
8
Recent Safety Innovative Measures
Kochi Refinery
• 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)
9
9
Safety Innovative Measures
Kochi Refinery
• 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
10
10
Safety Innovative Measures
Kochi Refinery
• 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
Management for Chemical Emergency Training
• Trained 28 OHSAS Lead Auditors
11
11
Safety Innovative Measures
Kochi Refinery
Conducted joint programme on Industrial Safety and Fire
Prevention with NSC (Kerala)
12
12
Safety Innovative Measures
Kochi Refinery
• 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).
13
13
Safety Innovative Measures
Kochi Refinery
• 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.
14
14
Safety Innovative Measures
Kochi Refinery
• 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.
15
15
Safety Innovative Measures
Kochi Refinery
•
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.
16
16
Safety Innovative Measures
Kochi Refinery
•
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
17
17
Safety Innovative Measures
Kochi Refinery
18
Safety Innovative Measures
Kochi Refinery
• 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.
19
19
SAFETY MANAGEMENT
SYSTEMS
Refinery Operating System (ROS)
Kochi Refinery
 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)
Kochi Refinery
ROS RELATED TO SAFETY- A Few Samples
ROS No.
DESCRIPTION
11
Accident/ Incident Enquiry & Analysis
23
Safety while draining water/ product from any
container.
28
Procedure for carrying out changes in existing
plant/ offsite facilities.
Working in Confined Spaces
47
63
Safety Guidelines for Excavation in Refinery
Premises.
90
Work Permit System
22
Action Taken Report (ATR)
Kochi Refinery
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
NO: of ATR’s released
Total recommendations
Number of recommendations implemented
446
5297
4085
23
Process Safety
Kochi Refinery
• Hazop study for
– All new facilities
– All modifications
• Risk analysis for
– All new projects
24
Safety Checks/ Inspections
Kochi Refinery

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
Kochi Refinery

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
Kochi Refinery
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 Preparedness programme for:
 Local community
27
SUPPORTING SYSTEMS TO ENHANCE
SAFETY
Kochi Refinery
 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
Kochi Refinery
1
One day Fire & Safety Training for all employees every year
(Achievement 100 %)
2
1 day intensive workshop on Work Permit System for Officers
(Trained- 413 Nos.)
3
1 day intensive workshop on Work Permit System for
Workmen (Trained- 200 Nos.)
4
Training on Chlorine Safety (141 employee attended)
5
2 Days First Aid Training ( 178 employees attended)
6
Training on Safety Aspects in Open field Radiography by
AERB ( 63 officers attended)
29
SAFETY TRAINING - EMPLOYEES
Kochi Refinery
30
SYSTEMS TO PREVENT/CONTROL
EMERGENCIES
Kochi Refinery
• 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.
31
31
Oil spill response mock drill at
Single point Mooring (SPM)
Kochi Refinery
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SAFETY COMMITTEE
Kochi Refinery
33
FOUR TIER SAFETY COMMITTEE
SYSTEM
Sl. Type of Committee
No
Meeting
Frequency
Chairman
1
DSC - 11 departments
(With workmen
representatives)
Once in two
months
HOD
2
Joint HSSE Committee
(With workmen
representatives from
different departments)
Once in two
months
ED (Tech)
3
Management HSSE
Committee
Once in a
month
ED (KR)
Occupier
4
Joint Safety Committee
– Contract Labours
Once in two
months
CM (Maint)
Kochi Refinery
Constituted
in Dec 2011
34
FIRE PROTECTION SYSTEMS
Kochi Refinery
FOAM TENDERS: 06
DCP TENDERS: 03
FOAM NURSER: 01
35
FIRE WATER PONDS
Kochi Refinery
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
Kochi Refinery
37
37
FIRE TENDERS
Kochi Refinery
VOLVO FIRE TENDER
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FIRE TENDERS
Kochi Refinery
Modern fire tenders
VOLVO Foam tenders
- 3 Nos.
Bronto Sky lift Foam tender
- 1 No.
DCP tenders
- 3 Nos.
Foam Nurser
- 1 No.
39
Fire Water Network
Kochi Refinery
Total Length
Approx 60 km.
Fire water header pressure
Header Size
12 kg/cm2
12” to 24”
Drive
Capacity (m3/hr)
Nos.
Engine
Motor
410-616
410-616
(Motor) Jockey
Pumps
66
20
06
04
Total
30
40
FIRE PROTECTION SYSTEMS
Kochi Refinery
Online Gas Monitors
Hydrocarbon Type
H2S Type
Primary block
34
CDU II block
72
FCCU block
33
CPP /Cooling tower
23
LPG bottling plant
13
Tank farm area
95
PIBU /PRU
33
DHDS block
81
NHT/CCR
42
Total
352
CDU II SRU
09
DHDS
14
DHDS SRU
12
Total 35
41
FIRE PROTECTION SYSTEMS
Kochi Refinery
Fire Alarm System
Addressable analogue detection system.
Smoke detectors
: 2032 Nos.
Manual Call points
: 349 Nos.
42
FIRE PROTECTION SYSTEMS
Kochi Refinery
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
FIRE PROTECTION SYSTEMS
Kochi Refinery
45
FIRE PROTECTION SYSTEMS
Kochi Refinery
WATER SPRAY SYSTEMS
46
FIRE PROTECTION SYSTEMS
Kochi Refinery
Automatic Fire Detection & Extinguishing Systems
CO2 System
GT1 &GT2 enclosure.
NAF SIII System
DHDS Control Room
FM 200
IT Centre
Argonite
LPG T/L CR, SRR 1&2
47
FIXED FIRE FIGHTING SYSTEMS
Kochi Refinery
 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
ADVANCED RESCUE EQUIPMENTS
Kochi Refinery
 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
ADVANCED RESCUE EQUIPMENTS
Kochi Refinery
 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
Fire Fighting Training Facilities
Kochi Refinery
State of art fire fighting training ground
with simulating models of :
 Column Fire
 Pump Seal Failure
 Tank Fire
 Wagon Fire
 Open Pit Fire
 Vertical / Horizontal flange leak
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EMERGENCY PREPAREDNESS PLANS
Kochi Refinery
 Fire Emergency Procedure
 Onsite Emergency Plan
 Mutual Aid Plan with neighboring
industries since 1991 (FACT & HOC)
 Active involvement in District Crisis
Management Plan / CHEMREC
60
MOCK DRILLS
Kochi Refinery
Type of drill
Frequency
Surprise Fire emergency mock drill
Once in a month
Surprise Mutual aid mock drill
Once in 3 months
(On rotation)
Once in 6 months
Onsite emergency mock drill
61
THANK YOU
Kochi Refinery
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