OIL INDUSTRY SAFETY DIRECTORATEoisd.nic.in/PDF/NOTICE/Group1Refineries.pdf · oil industry safety...

OIL INDUSTRY SAFETY DIRECTORATE Form No.: OISD-101/A

2013-14

OIL INDUSTRY SAFETY AWARDS

Input Data Sheet

Group - 1 : REFINERIES

Data to be furnished on Refinery basis (Read Notes on Sheet 4 of 21 before filling in the format)

1) Year (1st April to 31st March ) : 2013-14

2) Name of the Organisation /Installation :

4) Crude through put ( in MMT) :

5) Man hours worked during the year - in millions :

(Refer Note 1of Sheet 4 of 21)

Note: Project manhours will include those for manpower used in only Grass root project within Refinery premises.

6) Products loaded in bulk in wagons & trucks : (in million tonnes)

6.1 LPG :

6.2 Other Products (Total) :

7) Products dispatched through pipelines: (in million tonnes) 7.1 LPG :

7.2 Other products :

8) LPG filled in cylinders- in thousand tonnes :

9) Bitumen filled in drums in thousand tonnes :

Man hours in Refinery Operation

Project Manhours

Employees

Contractors's Employees

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10) Total lost time due to injuries in man-hours :

(Refer Note 2 of Sheet 4 of 21)

11) Fatalities - Nos. :

(including those due to incidents taken place outside the Property Wall in project related work of the installation)

(To be filled in table provided in Sheet 8 of 21)

12) Major Fires- Nos. : (To be filled in table provided in Sheet 9 of 21)

13) Material Losses - in Rs. Lakhs : (Direct losses) (Refer Note 3 of Sheet 5 of 20)

(To be filled in table provided in Sheet 9 of 21) 14) Production/Handling Loss on account of interruptions caused by Fire(s) &

accident(s) in ₹ Million : (Refer Note 4 of Sheet 5 of 20)


Incident-1

Incident-2

Date Caused by Units /Facilities affected Duration of S/Down Products affected Potential Production/ Handling loss ( Rs Million)

15) Detailed Analysis of Incidents in 2013-14 :


Man hours lost in accidents related to refinery operation

Man hours lost in accidents in Project area

Employees


Fatalities in Refinery operation

Fatalities in Projects

Employees


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16) Questionnaire on Safety Management System :

(To be filled in table provided in Sheet 12 of 21))

17) Details of the Installations : (To be filled in Sheets 5 & 6 of 21)

18) Furnish clause wise compliance/ Deviation to OISD standards : (Details to be filled in separate Sheet for standards mentioned in Annexure-IV)

19) The nomination for ‘Individual Award category’ should be submitted in the prescribed format attached as Annexure-II.

20) Furnish information of Sulphur Recovery Unit, how many SRUs are required to operate to meet the CPCB/SPCB and MoEF norms.

21) Furnish information of air emmission norms ( like emmission from different stacks, SOx, NOx, SPM, etc.).

22) Furnish the information on effluent treatment quality w.r.t. actual Vs MINAS/stipulated standard during the period 2013-14.

23) Confirm the availability of valid consent & authorisation for air, water and Hazardous Waste issued by SPCB for the period from April 2013 to March 2014.

24) Compliance status of all the Pre Commissioning Safety Audits recommendations

till date.

25) Non-compliance notice(s) received during 2013-14 & till date from statutory authorities like PESO, DGMS, Factory Inspector, Boiler authority, OISD, CEA, MoFE,CPCB/SPCB, Coast Gaurds, etc. and their status to be submitted.

26) Furnish the status of progress of implementation of M B Lal committee’s recommendations.

Above data is filled in as per the guidelines given below and is verified by me. Signature of Principal Panelist/ Head HSE Name /Designation Date

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NOTES 1. Man-hours include overtime as well as the contractor's man hours worked during the

year. Projects man-hours shall be indicated separately. 2. Fatalities should not be converted into lost time, but shall be indicated separately.

Fill up Sheet 9 of 21. 3. Material losses (Direct losses) include the loss/damage to equipment, products,

public property, cost of fire fighting materials, medical expenses involved, compensations paid in money etc. Fill up Sheet 9 of 21.

4. a) Potential loss of production will be accounted by the product slate i.e.

Increase/decrease of all the individual products (with reference to the Planned / committed targets) as a result of fire or accident. It shall be assumed that all the units operate at their peak capacities under normal conditions and any increase / decrease of product slates because Shutdown cannot be corrected. The increase / decrease of each product LPG, Gas, Kerosene etc. etc. should be calculated viz. and loss of revenue thereof to be reported in Rupees Million. Fill up Sheet 9 of 21.

b) Potential loss of handling (of products at gantries through associated Pipelines,

in bottling of LPG etc.) is the quantity of products that could not be handled due to fire or accidents. It shall be assumed that facilities operate at peak loads and shortfall in 'Handling' cannot be made up. Potential loss of handling shall be calculated only under two categories viz. Bulk Products and LPG in cylinders. The loss due to shortfall in handling shall be calculated and reported in Rupees Million. Fill up Sheet 9 of 21.

5. For each refinery, one form shall be filled. Data submitted in the application shall be

provided for the period from April 2013 to March 2014. 6. OISD shall carry out site verification through external safety audit / surprise safety

check for locations where ESA / SSC has not been carried out so far. 7. Pipelines to/from jetties / refineries / terminals as applicable shall be considered as

part of the refinery complexes. 8. Corporate / Head offices, Regional offices and Townships which are away from

process installations shall not be considered in filling the above format. However, projects and construction activities within the process complexes shall be considered.

9. Data shall include related information regarding contractor’s personnel engaged.

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LIST OF PROCESS UNITS / FACILITIES

(See Notes given below ) Sr. No. NAME OF UNITS / FACILITIES Nos. On stream Hours for the year

1 CDU 2 VDU 3 Visbreaker 4 FCCU 5 Propylene Recovery Unit 6 Continuous Cat. Reforming Unit (CCRU) 7 DHDS 8 Hydrogen Unit 9 Sulphur Recovery Unit 10 Amine Regeneration Unit 11 Sour Water Stripping Section (SWS) 12 Bitumen Blowing Unit 13 Merox-LPG,Kero/ATF, VB Naphtha,

Gasoline

14 ETP 15 Thermal Power Station 16 POL, LPG TTL, BG Truck Lorry 17 LPG bottling Plant 18 Once thro'Hydrocracker Unit 19 Coker Unit 20 Wax Extracting Unit 21 Kerosene Treating Unit 22 Wax Deoiling Unit (Sweating Stoves) 23 Bauxite Filteration Unit 24 Acid Treating Unit 25 Wax Moulding Unit/Pelletising Unit 26 HRSG / GTs 27 Ammonia Refrigeration Unit 28 Blue Oil Distillation Unit Bench "H" 29 Kero/HSD/Vacuum- hydro

desulphanisation Unit

30 Propane De-asphalting Unit 31 Furfural Extracting Unit 32 Solvent Dewaxing Unit 33 Hydro finishing Unit 34 NMP Extraction Unit 35 Hydrocracking Unit

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36 Universal Dow Extraction Unit 37 Methyl Tertiary Butyl Ether (MTBE) 38 Pilot Distillation Facility (PDF) 39 Sulphuric acid unloading facility 40 Coke calcination Unit 41 Wax hydro-finishing Unit 42 OP feed pilot plant 43 Light Reforming Unit 44 Naphtha Splitter 45 Cryogenic LPG 46 Haxane Unit 47 Hydrofinishing Unit 48 Biturox Unit 49 Hydrogen Recovery Unit 50 LPG Recovery/propylene separation 51 CO Boiler 52 Central Tank farm 53 Oil Collecting station 54 DHDT 55 ISO SIV process 56 Naphtha Cracker 57 Naphtha Cracker Unit ( Ethylene) 58 LLDPE 59 HDPE 60 Polypropylene Unit 61 MEG Unit 62 Other units

NOTES: 1) Entries as applicable to the respective refineries must be made in the above table as

such. Additional units / facilities that are not already covered here should be incorporated as other units after item no. 62.

2) Unit name should be given in detail and not in abbreviations. 3) Nos. of units existing under each name/type in the installation must be indicated in

the column 3 of the above table. 4) Unit/facility-wise shall fill the on-stream hours only in the year in the 4th column of

the above table.

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ANNEXURE-I

Category for Award Evaluation Category

• Oil & Gas Assets (Onshore) • Offshore Production Platforms • Offshore Drilling Rigs • Refineries • Other Processing Plants • Cross Country Pipelines • POL Marketing Organizations – Zones / Regions • LPG Marketing Organizations – Zones / Regions • Individual contribution toward Safety during April 2013 to March 2014 • Near Miss Reporting

NOTES: 1) All applications should be submitted in the prescribed format and required back up

documents should be submitted along with application wherever required.

2) Data submitted in the application should be provided for the period 1st April 2013 to 31st March 2014.

3) OISD shall carry out site verification through External Safety Audit / Surprise Safety Check for locations where ESA/SSC has not been carried out so far.

4) The nomination for ‘Individual Award category’ should be submitted in the prescribed format attached as Annexure-II. The nomination should be duly authenticated by the Unit Head and justification for the nomination should be supported by the necessary documentary evidence. The contribution must be real and significant.

5) The Compliance to all relevant statutory norms is the foremost criteria for consideration in safety awards evaluation. To this effect the relevant documents, that are duly signed where ever applicable, such as Factory license, Pollution Control Board consents and authorization for operation, PESO license for storage of petroleum products, and compliance to OISD STD 105, 116, 117, 118, 141, 144, 150, 156, 159, 169 and 210 to be submitted.

6) The compliance to OISD STD 105, 116, 117, 118, 141, 144, 150,156, 159, 169 and 210 must be submitted standard wise and each standard the critical points wise in specific manner. Please note that Qualitative statements like yes, No and complied are discouraged.

7) Status of progress of implementation of M B Lal committee’s recommendations.

8) The compliance to MINAS norms with respect to CPCB & respective SPCB.

9) Consent of CPCB with respect to hazardous waste & consent to operate from state pollution control board.

10) Near Miss Incident reporting: Followings are to be submitted as per format given in Annexure-III. • Whether Internal Investigation Report of all Major incidents has been submitted to OISD?

If no, likely date by which it will be submitted. • Whether similar incident has occurred in past at the same location? If yes, give brief

description of the incident & confirm whether learning was shared within the organisation.

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DETAILS OF FATALITIES

Note:

* Incidents should be categorized as Fire, Explosion, Electrocution, fall from height, gas inhalation, slip/trip, others (to be specified).

Date

Location

Brief on Incident

Type of Incident *

Fatalities (Nos.)

At Project-site (Employee)

In Refinery operations (Employee)

Company Contractor Company Contractor

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DETAILS ABOUT FIRE, MAN-HOURS LOST, DIRECT LOSS

AND PRODUCTION / HANDLING LOSS

Sr. No

Date Location Type of incident#

Man-hrs Lost, in Million

man-hours

Direct Loss in ₹

Lakhs

Production / Handling Loss Name of the Product

Qty in Thousand MT

Potential Loss of Revenue in ₹ Million

Total

Note:

# Incidents should be categorized as Fire, Explosion, Electrocution, fall from height, gas inhalation, slip/trip, road accident and others.

.

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DETAILED ANALYSIS OF INCIDENTS IN 2013-14

Sr. No.

Description Manufacturing Marketing Company Employee

Contract employee

For all employees

Company Employee

Contract employee

For all employees

1 Total million Man-hours worked

2 No. of fatal incidents

3 Number of Fatalities

4 Fatality Accident Rate (FAR)

5 Fatal Incident Rate (FIR)

6 No. of lost time work injury Incidents resulting in > 1 day absence from job (LTI)

7 Total Recordable injury rate (TRIR)

8 Number of road accidents

9 Number of fatalities in Road accidents

10 Distance traveled in KM

11 Road Accident Rate (RAR)

12 FAR in Road Accidents (FARR)

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NOTES:

1) Details of all incidents involving company employees as well as contract employees should be included in the table above.

2) Total Man-hours worked = Total man days worked for the period X man hrs worked per day (Where number of man days worked for a period is number of men at work on each day of the period.)

3) Incase employee (Company or contractor) resume duty after some time and subsequently again get disabled due to same

injury which caused his earlier disablement; the period of such subsequent disablement is also to be included in man days lost. The day of injury as well as day of resumption of job should be excluded from man day’s loss calculations.

4) Fatality accident rate (FAR) = Number of fatality X 108 hrs worked Number of man hours worked

5) Fatal Incident Rate (FIR) = Number of fatal incidents X 100,000,000 hrs worked Number of man hours worked

6) Total Recordable injury rate = No. of injuries in all reportable (fatalities+workday lost) incidents X 106 hrs worked

(TRIR) Number of man hours worked

7) Road Accident Rate (RAR) = Number of Road accidents X 106 Kms Total Distance traveled (in KMs)/ year by all trucks for product movement by the location.

8) Fatality Rate in Road Accident = Number of fatalities in Road accidents X 106 Kms (FARR) Total Distance traveled (in KMs) in the year by all trucks involved in product movement

for the location.

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QUESTIONNAIRE ON SAFETY MANAGEMENT SYSTEM

1.0 EXTERNAL SAFETY AUDITS: (FROM THE FIRST ROUND OF AUDIT ONWARDS)

(A) STATUS OF IMPLEMENTATION OF RECOMMENDATIONS OF THE EXTERNAL SAFETY AUDITS:

Round Date of audit

Total no. of Recommendations

Reco. not complied as on

31.03.2013

Progress during Year 2013-14 Remarks

Plan for the year 2013-14

Actual complied in 2013-14

Schedule for balance Recco.

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2.0 MANAGEMENT OF CHANGE:

1. Please Attach a copy of the approved procedure of management of Change showing the name and designation of the approving authority & the date of issue.

2. Indicate who maintain the records for changes taken place through management of change procedure, (designation of the Person)?

3. Please furnish the information in following table:

4. Please attach comments of internal safety audit team on compliance to stipulated procedure of Management of change for the

changes taken place during the year?

Changes in 2013-14

Approving authority (Designation) Updation of P&ID/ Manuals / Drawing

Verified by (designation & date)

Certified by (designation & date)

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3.0 OPERATING PROCEDURE:

1. Fill in the details in the following format about the operating manuals available in the control room

2. Whether following are covered for each unit in the separate operating manual/ procedure:

(a) Steps for each of the operating phases viz. Normal Operation, Start-up and Shut down, Emergency operation, Emergency Shutdown etc.

(b) Operating Limits indicating consequence of deviation. steps required for correcting or avoiding deviations.

(c) Safety and Health consideration viz. hazards of chemicals used in the process, precautions to prevent exposure

including engineering controls, administrative controls and personal protective equipment, control measures to be taken if physical contact or airborne exposure occur, quality control of raw materials and control of hazardous chemical inventory level, any special or unique hazards.

(d) Safety system and their functions (Interlocks, PSVs, Trips, Alarms, Detection System etc.).

Attach copy of relevant portion in the manuals and also observations of Internal Safety Audit team who audited the unit / facility during the year are required to be indicated.

Sr. No.

Unit/Facility Last date of updation

Due date for next updation

Prepared by (Designation)

Approved by (Designation)

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3. List out the documents accessible to employees and contractor employees respectively for their awareness on operating procedures viz. pocket manual, safety manuals etc..

4. Whether operating procedure are in place to include safe work practices for :

(a) Control of hazard during lock out / strike. (b) Confined space entry. (c) Handing over and taking over process equipment?

(Attach the copy of the relevant portions from the documents)

5. Whether operating manuals / procedures explain clearly the system of control over the entry into the restricted areas under

the process units / facilities for

(a) Maintenance personnel (b) Contractors personnel (c) Laboratory personnel (d) For any other personnel

If yes, indicate in brief the system for authorization for entry (viz. Work Permit, Gate Pass etc.) and designation of the authorizing person in the plant for such entries? Also attach the copy of relevant portion in the manual.

Document Availability to Contractor’s employee Availability to Employees

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4.0 TRAINING:

1. Please furnish details in following Table (Indicate total no. of employees)

2. Indicate the percentage of employees exposed to refresher training during 2013-14. 3. What is the frequency of refresher training for any employee? 4. Indicate the system being followed to record the training courses attended by any employee. Is it computerized or manual

system? Attach a copy of the relevant portion. Also indicate the name and designation of the person maintaining these records.

5. Based on records, Indicates the means used to verify that the employee had understood the training? If yes, indicate the method used for such evaluation/ certification? Attach the copy of relevant documents.

6. Indicate the percentage in each category as under exposed to safety training during the year 2013-14:

Contract / Employees Drivers

Khalasis

CISF/ Contract Security persons

7. When was the fire training ground facility commissioned (as per OISD -STD- 116)? If not, what is the completion schedule? In case of small installations what is the system to impart the fire fighting trsining to employees?

Training imparted to new employees before taking Charge during 2013-14

Training imparted to existing employees before taking charge of new rotational assignment during 2013-14

Certifying authority

No of Management Employees

Duration (in days)

No. of Non-Management employees

Duration (in days)

No of Management employees

Duration (In Days)

No. Of Non-Management employees

Duration (In Days)

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5.0 RELIABILITY AND CONTROL DEFEAT OF CRITICAL SYSTEM AND DEVICES: (SHUTDOWN SYSTEMS, ALARMS, GAS DETECTION SYTEMS, INTERLOCK SYSTEM ETC.)

1. For each facility, whether such critical systems/devices have been listed, failure of which may cause serious accidents or

release of material causing serious environment impact? Attach a list of such devices.

2. Who is the approving authority (Name & Designation ) for the above list and when was it approved? Furnish the information in following format;

3. In the following format, indicate the designation of the officer empowered to permit bypassing of critical system/ devices for

the specified period:

Sr.No.

Class of critical device/ system Frequency of calliberation Schedule of amintenance

Duration Designation of the official For the Shift For < 24 hrs. For < 7 days For longer duration

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6.0 MAINTENANCE AND INSPECTION:

1. Please attach the copy of approved procedure to train each employee involved in maintaining the integrity of process equipment and familiarise him about the process and related hazards.

2. Indicate designation of the officer who maintains documents for inspection and testing procedures. Who is the approving authority for the procedures and when it was last approved? When is the next review scheduled?

3. Indicate designation of the officer who maintains the records on the inspection and test conducted on process equipment?

4. Please attach the list of lifting tools and tackles tested as per statutory requirement during the year 2013-14? Also mention the frequency of testing for these tools.

5. Indicate the frequency of updation of as built drawings (including P&IDs and Engineering Drawings)? Who is maintaining the record of updation of these drawings?

6. Was the Root cause analysis carried out for incidents that took place inside the plant?

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ANNEXURE-1I

Nomination Form for Oil Industry Safety Award – ‘Individual Category’

Name of Employee : (Contractor / Company) Employee Identification No : Organization / Location : Brief Description **

Justification**: Why the performance is considered significant?

Proposed By : Name : Signature : Date :

Authentication of Unit Head : Name : Designation : Unit / Location: Signature : Date :

Note: ** The description should specify under which of the following area (s) the employee / contract employee has made the significant contribution.

1) Prevention of any incident of fire or accident from its potential occurrence. 2) Effective handling of plant abnormality & emergency in plant operation to prevent escalation to unsafe situation. 3) Prompt response & control of the incident & preventing damage through effective fire-fighting and rescue. 4) Innovative suggestions for enhancing safety & its implementation etc. 5) The justification should be well supported by the documentary evidence.

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6) The nomination should be duly authenticated by the unit head. ANNEXURE-1II

DETAILS OF NEAR MISSES AND MILLION MAN HOURS WORKED

Sl. No. Location

Type of Near Miss

Date & Time Duration Description of the

Near Miss

Whether Near Miss incident submitted to OISD?( Furnish the reference & date)

Corrective measure implemented

Fire Incident

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ANNEXURE-1V

COMPLIANCE / DEVIATION TO OISD STANDARDS

OISD Standard Name of the Standard Compliance/ deviation status

OISD STD 105 Work Permit System

OISD STD 106 Pressure relief and disposal system

OISD-STD-108 Recommended Practices on Oil Storage and Handling

OISD-STD-109 Process Design and Operating philosophies on blow down and sewer system

OISD-STD-113 Classification of Area for electrical installations at Hydrocarbon processing and handling facilities

OISD-STD-116 Fire Protection facilities for Petroleum Refineries and Oil/Gas Processing Plants

OISD-STD-118 Layouts for Oil and Gas Installations

OISD STD 128 Inspection of unfired pressure vessels

OISD-STD-129 Inspection of storage tanks

OISD-STD-132 Inspection of pressure relieving devices

OISD STD 142 Inspection of firefighting equipment

OISD-STD-144 Liquefied Petroleum Gas (LPG) Installations

OISD-STD-150 Design and Safety Requirements For Liquefied Petroleum Gas Mounded Storage Facility

OISD-STD-152 Safety instrumentation for process system in hydrocarbon industry

OISD-STD-163 Process Control Room Safety

OISD-STD-164 Fire Proofing in Oil & Gas Industry

OISD-GDN-178 Guidelines on Management Of Change

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OISD-GDN-207 Contractor Safety

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OIL INDUSTRY SAFETY DIRECTORATEoisd.nic.in/PDF/NOTICE/Group1Refineries.pdf · oil industry safety...

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