Gujarat Refinery - Where Growth is Essence of Life
Transcript of Gujarat Refinery - Where Growth is Essence of Life
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1 Brief Introduction to IOCL, Gujarat Refinery
2 Systems in Place
3 ERDMP Exercise
4 Challenges & Suggestions
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Installed Capacity: 54.2 MMTPA
Under Construction Refinery: 15.0 MMTPA
Subsidaries: 11.5 MMTPA
Panipat 15.0
Koyali 13.7
CPCL/ CBCU 10.5
Paradip 15.0
Haldia 7.5
Barauni 6.0
BGR 2.35Digboi 0.65
Guwahati 1.0
Mathura 8.0
(Figures in Million Metric Ton/Annum)
Total Capacity as on 01.04.2012: 65.7 MMTPA
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WORK IN PROGRESS
PM ADDRESSING GATHERING AFTER LAYING FOUNDATION STONE
FIRST GENERAL MANAGER OF GUJARAT REFINERY MAJ. GEN. SHARDANAND SINGH PRESENTING MODEL OF GUJARAT REFINERY TO PRESIDENT DR. S. RADHAKRISHNAN
PANDIT JAWAHARLAL NEHRU LAYING FOUNDATION STONE OF GUJARAT
REFINERY ON 10TH MAY 1963
• Foundation stone laid on 10th May 1963• Commissioned in October 1965 with 2.0 MMTPA• Current Refining capacity upgraded to 13.7 MMTPA in 1999
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YEAR
4.3 MMTPA Capacity expansion is under final approval
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GUJARATREFINERY
A MOTHER INDUSTRY
RIL
GNFCCHEMICAL
INDUSTRIES
NIRMA
PPFS
LABFS
TO
LU
EN
E
LSHS
VEG.OILINDUSTRY
GSFC
FGH
SULPHUR
IOBL
LABFS
HUL, SILVASAPFRC
B
BITUMEN
CRMB, IOCL
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Gujarat Refinery
LABFS
FGH
PFRCB
Reformate
ATF
LSHS
NIRMA
Rajasthan, MP, Gujarat
Taloja (Mumbai), Chennai
Guwahati (for blending)
Delhi, Hyderabad, BangalorePunjab, Mumbai, Bangalore
Product Location
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Indian Railways
TATA Power
Gujarat National fertilizers Ltd.
Gujarat State Electricity Corp. Ltd.
National Fertilizers Limited
IPCL Reliance
Nirma Industries
National Alumiunium Company Ltd.
National Highway Authority of India
HindalcoHindustan Unilever Limited
Common public
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ED(I/C)
GM (F)
ED(T)
DGM (TS-I/C)
DGM (PJ-I/C)
GM (HSE)
GM(P&U)DGM (MN-I/C)
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GACL
Gujarat Refinery
RIL
GSFC
VADODARA Railway Station
ToAhmedabad
ToMumbai
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GR PLOT PLAN
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PRODTANKS
PRODTANKS
500 MWIDE
GREEN BELT
DHDS/H2-II
KAPL
SMPL
CETP
BITUMEN FILLINGPLANT
Main Fire Station
NORTHNORTH
PRODTANKS
PROD TANKS
PRODTANKS
PRODTANKS
PROD TANKS
TANKSTANKS
PRODTANKS
AU-5
Crude Tanks
H2 -III/ DHDT Tanks
LABMTBE/FGHTANKS
TANKS
SRU
Calico LandFor Coke yard
PRODTANKS
Coker unitVGO-HDT unit , MEROX Units under RUP
MSQU
CRU
Admin Building
FLARE
NEW GT
Crude Tanks
Crude Tanks
TANKS
TANKS
MODEL UNIT FCC
TANKS
TANKS
GRE
AU3
UDEX
AU-II
AU-I TPS
CGP
KA
PL
SRU
GHC/H2-I
GHCSTORES
3rd Green Belt
2nd Fire StationG
antry
LPG
Green Belt
To Koyali To Bajwa
To Township
Refinery Main Gate
TRG Tech. Bld
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DESCRIPTION AREA IN ACRESPlant Area including MKT & PPL 859Ecological Park + 3 Nos. Green belt area 148 Others (Town ship, CISF, Parks, etc.) 258
Total 1265
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SYSTEMS IN PLACE
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Sr Description Certifying Agency Year Implemented
1 ISO 9001 DNV 19952 ISO-14001 DNV 1997
3 OHSAS-18001 DNV 1999
4 5 -Star rating
British Safety CouncilBSC 2002
5 ISRS Level-9 DNV 2003
6 ISMS (Study by M/s. DuPont in 2006)
IOCL 2009
7ISO 14064 Verification
Green House Gas Emission BV 2011
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Indianoil Safety Management System (ISMS)
Sr Description Year Implemented
1 ISMS-1001 Work at Height 20092 ISMS-1007 Scaffold Safety 20093 ISMS-1003 Safety during Excavation Work 20094 ISMS-1012 Start up Clearance 20095 ISMS-1011 Management Of Change 20096 ISMS-1002 Confined Space Entry 20107 ISMS-1004- Hot Work 20108 ISMS-1006 Work Permit System 20109 ISMS-1013 Storage & Handling of Chemicals 2010
10 ISMS-1005 Energy Isolation (Electrical) 2011
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Disaster Management Plan
MAIN POINTS•CLASSIFICATION OF EMERGENCIES & BRIEF DESCRIPTION OF REFINERY•ON SITE DISASTER MANAGEMENT PLAN•PROCEDURE FOR ACTIVATION OF THE EMERGENCY PLAN•ROLES & RESPONSIBILITIES OF DISASTER COORDINATORS •STATUTORY STIPULATIONS •HAZARD IDENTIFICATION & SCENARIO SELECTION•BOMB THREAT CONTINGENCY PLAN •RESPONSE•TRAINING / SIMULATION EXCERCISE•RESOURCES TO CONTROL EMERGENCY
Updated : August 2011
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Fire Monitors at fire site
Debriefing Sessions after mock drills
Fire Drills : Once in a Month
On-site Disaster Drill : Once in three months
Off-site Disaster Drill: Once in a year
On-site Disaster Drill during night
EMERGENCY PREPAREDNESS
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CREDIBLE SCENARIOS
• LPG leakage followed by unconfined vapor cloud explosion and fire in LPG area
• CO Gas leakage from FCC unit Regenerator• Oil Spillage from largest storage tank followed by vapour cloud
explosion / fire
• Hydrogen Sulphide gas leakage
• Water flooding Scenario
• Double Fire Contingency
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Details of Emergency Response Disaster Management Plan (ERDMP)
Mock Drill Dt. 25.08.2012
for
Accreditation by DMI, Bhopal
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Details of Mock Drill
• Mock drill conducted on 25th Aug 2012 at 3.00 PM
• Witnessed by personnel from – DMI, Bhopal– District Administration
• Second IOCL Refinery after Mathura Refinery
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OBJECTIVES OF DRILL
• Petroleum & Natural Gas Regulatory Board (PNGRB) constituted codes of practices for Emergency Response and Disaster Management Plan (ERDMP) regulations 2010.
• To fulfill the requirements of the regulation, ERDMP of Gujarat refinery to be verified by third party {i.e. M/s DMI (Disaster Management Institute) Bhopal}.
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SELECTION OF SCENARIO
• SCENARIO: H2S gas leak in SRU-III due to failure of Pressure Transmitter (PT)
tapping point (3” dia.) on feed line (30” dia.) to Acid Gas KOD at SRU-III battery limit line located at 18 m from ground level.
• WHY THIS SCENARIO:– As per Comprehensive Risk Analysis Report, H2S gas leak has
emerged as the only scenario falling under Offsite emergency for Gujarat Refinery.
– Considering the nearest source of release of H2S from plant boundary is from SRU3 block and that is at a distance of about 130 Meters.
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H2S LEAK SCENARIO DRAWING
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REFINERY PLOT PLAN
SRU III
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SRU III PLOT PLAN
LOCATION OF LEAK IN SRU III
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LOCATION OF LEAK AND H2S DETECTOR
LOCATION OF LEAK IN SRU III
H2S DETECTOR
HOOTER AND BEACON
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RISK CONTOUR DIAGRAM
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ROLE DEFINITION
• PN Department: Operational actions required to arrest the leak Evacuation measures
• F&S Department: Role briefing and training. Incident assessment, Area evacuation and Siren. Respiratory protection, Rescue operation, Area cordoning-off Water curtain – Up-wind & Down-wind side
•Medical Department: Placement of ambulance inside & outside Refinery premises Mobilization of Doctors & Paramedical staff Site medical camp
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ROLE DEFINITION(Cont’d) • HR Department:
Coordination / communication with District Administration Communication to Sarpanch of local villages (Koyali) Announcement through PA System in neighbourhood Relief / rehabilitation measures
• CISF: Gate management Contract workers – Assembly Security outside Refinery premises
COMPLIANCE TO ROLE DEFINITION OF DMP
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Minute to Minute Activity Plan for Mock Drill
TIME ACTIVITY RESPONSIBILITY3.00 PM Hooter goes off at SRU III (Tag No. 2111-XA-005).
High level alarm is noticed in the H2S detectors in the vicinity.
MN (INST) to force the hooter.Panel Officer - SRU III
3.01 PM Panel Officer informs shift-in-charge & instructs field operator to investigate after wearing gas mask & personal H2S monitor.
Panel Officer - SRU III
3.05 PM Field operator reports leak from Pressure tapping on Acid gas line at about 18 M level near battery area (Tag No. 2111-PT-2001) and breaks the glass.
Field operator – SRU III
3.07 PM Shutdown action taken by PN and initiation of depressurization of system.
PNM – SRU III
3.10 PM Shift-in-charge, CPNM & DGM (PN) arrive at site and after assessing the situation calls for sounding the major fire siren.
DGM (PN)
3.15 PM Evacuation calls from Assembly point # 9 & # 11 SMNM (KKM)SPUM (NRC)
3.15 PM Search operation starts. (4 casualties – unconscious state)DGM (PN) requests ED (T)’s permission for declaration of Disaster and seeking mutual aid.
F&SDGM (PN)
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TIME ACTIVITY RESPONSIBILITY3.15 PM3.25 PM
Disaster siren is sounded. All personnel will report to DCR / Site
3.25 PM PNM – SRU receives information from Panel Officer that H2S is high at ONGC terminal. PNM informs the same to DGM (PN)
Panel Officer, PNM, DGM (PN)
3.27 PM DGM (PN) informs DCR & ED (T) regarding apprehension that gas may move outside the boundary wall and requests monitoring at ONGC terminal.
DGM (PN)
3.28 PM GM (HSE) informs ED (T) for declaration of Offsite disaster. After taking permission, he informs District authorities.DGM (PN) informs F&S about offsite disaster and take action of sending offsite crew.
GM (HSE)
DGM (PN) & CMFS
3.33 PM Offsite team comprising Fire tender, ambulance, jeep with loudspeaker, CISF, Police and other Security personnel reach the road near ONGC terminal
F&SMedicalHR
3.35 PM Evacuation call received from ONGC terminal F&S member
3.45 PM Completion of depressurization. PNM – SRU III
3.50 PM All clear at Site by DGM (PN) and from offsite by DCR DGM (PN) & F&S
3.55 PM Sounding of all clear siren. F&S
4.10 PM Debriefing at ED Conference Room All Observers & Coordinators
Minute to Minute Activity Plan for Mock Drill
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GLIMPSES OF ERDMP MOCK DRILL
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CHALLENGES IN DEVELOPMENT OF ERDMP
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BRIEF of Disaster Management Plan
• ERDMP of Gujarat Refinery has been revised as per PNGRB guidelines issued in 2010 .
• ERDMP of Gujarat Refinery is in two parts - first part is On-site and second part is Off-site Emergency Plan.
•The probable scenarios identified after detailed study of past incidents.
•Outcome of Comprehensive Risk Analysis study by EIL.
•The ERDMP is dynamic in nature & updated every year to address all the changes in the organizational structure
and/or to incorporate the major changes.
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Content of Regulation & Its Application in ERDMP Preparation
1. Classification of emergencies
2. Implementation schedule
3. Statutory requirements
4. Pre-emergency planning
5. Emergency mitigation measures
6. Emergency preparedness measures
7. Emergency response procedures and measures
8. Emergency organization and responsibilities
9. Infrastructure requirements
10. Declaration of on-site and off-site emergency
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11. Resources for controlling emergency 12. Demographic information13. Medical facilities14. Evacuation 15. Public relations and information to public 16. Reporting of the incident 17. Emergency recovery procedures 18. ERDMP for tank trucks and pipelines carrying petroleum
products 19. Integration of the ERDMP with National Disaster
Management Authority (NDMA) guidelines and action plan on Chemical Disasters (Industrial)
20. Security threat plan and action plan to meet the eventualities.
Content of Regulation & Its Application in ERDMP Preparation
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OUR SUGGESTIONS
1. Validity of the third party certification of ERDMP should be specified in the Regulation. (Atleast 3 years validity).
2. There should be different ERDMP regulation for different Industries and for different functional divisions like Refinery, Pipeline, Marketing etc.
3. ERDMP format is different as per State Authorities.
4. Proximity to city entails a greater role of State Administration thereby curtailing the role of main Industry during Offsites emergency.
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DISCUSSION
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