Oil Industry Safety Directorate · DIRECTOR,OISD WE ADD SAFETY. In-transit Incident...

workshop on

Understanding genesis of in-transit accidents, its mitigation measures &

way forward

8-9 November 2019

Oil Industry Safety Directorate

This presentation is for general informational and learning

purposes only and does not constitute or purport to render

advise. The views and opinions expressed in this presentation

are those of the author and do not necessarily represent official

policy or position. The material is intended, but not promised or

guaranteed to be current, complete or up-to-date. The author

assumes no responsibility for the content, accuracy or

completeness of the information presented.

Disclaimer

3

Our Job is to….

4

…….prevent this from happening

5

Our Job is to….

We work for you, with you, to make you more safeAUTHOR:DEVENDRA M MAHAJAN,JOINT

DIRECTOR,OISD

WE ADD SAFETY

In-transit Incident Statistics

.................Oil Industries-India


19 15 8 6 7

139

195

148

127

96

2014-15 2015-16 2016-17 2017-18 2018-19

TRANSPORT ACCIDENTS IN LAST FIVE YEARS

Transport (Fires) Transport (Accidents)

TRANSPORT ACCIDENTS

TRANSPORT FIRES

Oil industry Incident Statistics

AUTHOR:DEVENDRA M MAHAJAN,JOINT

DIRECTOR,OISD

0

20

40

60

80

100

120

140

160

180

2014-15 2015-16 2016-17 2017-18 2018-19

Transport Total IOCL 104 110 151 114 60

Transport Total BPCL 97 159 97 58 49

Transport Total HPCL 110 170 124 119 113

COMPANY WISE TRANSPORT INCIDENTS

Transport Total IOCL Transport Total BPCL Transport Total HPCL

IOCL

BPCL

HPCL

Incident Statistics

172

244224

164

12662

59

90 69

34

60

105

61 3227

50

80 73 63 65

2014-15 2015-16 2016-17 2017-18 2018-19

FATALITIES (TRANSPORT) IN LAST FIVE YEARS

Fatalities(Transport) IOCL BPCL HPCL

Incident Statistics


DIRECTOR,OISD

QUALITITIVE ANALYSIS


Qualitative Analysis


DIRECTOR,OISD

0

1

2

3

4

5

6

14-15 15-16 16-17 17-18 18-19

0.862068966

5.46875

1.282051282

0

0.970873786

Poor Road ConditionsFigures in %



DIRECTOR,OISD

0

5

10

15

14-15 15-16 16-17 17-18 18-19

4

13

6

3

6

Equipment failureFigures in %



DIRECTOR,OISD

0

10

20

30

40

14-15 15-16 16-17 17-18 18-19

Negligence by othersFigures in %



DIRECTOR,OISD

0

20

40

60

80

100

14-15 15-16 16-17 17-18 18-19

Negligence by TT driverFigures in %

QUALITATIVE ANALYSISOF IN-TRANSIT ACCIDENTS


DIRECTOR,OISD

0%

10%

20%

30%

40%

50%

60%

70%

80%

Negligence by TTdriver

Equipmentfailure

Natural Calamity Poor RoadConditions

Negligence byothers

QUALITATIVE ANALYSIS OF IN-TRANSIT ACCIDENTS


DIRECTOR,OISD

Negligence by TT driver65%Equipment failure

6%

Natural Calamity2%

Poor Road Conditions

2%

Negligence by others25%

Last Five years

Negligence by TT driver Equipment failure Natural Calamity Poor Road Conditions Negligence by others

90 % Negligence

Genesis and Mitigation


What is this Negligence?


DIRECTOR,OISD

ROAD ACCIDENTS IN INDIA – 2017Published by

TRANSPORT RESEARCH WINGMINISTRY OF ROAD TRANSPORT & HIGHWAYS,

GOVERNMENT OF INDIA ,

Published in July 2018

4,64,910 Accidents 1,47,913 Fatalities 4,70,975 Injuries



DIRECTOR,OISD

Traffic rules violation %

accidents

%

Fatalities

%

injuries

Over-speeding 70.4 66.7 72.8

Driving on wrong side 6.3 6.4 6.4

Drunken driving/

consumption of alcohol &

drug

3.0 3.2 2.5

Use of mobile phone 1.8 2.1 1.7

Jumping red light 1.4 1.2 1.3

No violation & not known 17.1 20.3 15.3

ROAD ACCIDENTS IN INDIA – 2017 , GOVERNMENT OF INDIA ,MINISTRY OF ROAD TRANSPORT & HIGHWAYS,TRANSPORT RESEARCH WING-Published in July 2018

Why Over speed?


DIRECTOR,OISD

ROAD ACCIDENTS IN INDIA – 2017 , GOVERNMENT OF INDIA ,MINISTRY OF ROAD TRANSPORT & HIGHWAYS,TRANSPORT RESEARCH WING-Published in July 2018

74 % Accidents

due to Over speeding

Why Over speeding?

Are they gettingany direct/ indirectbenefit of overspeeding?

What makes the driver to drive fast? No. of tripsMorning Hrs.Benefit of low temperatureIs there any competition

MITIGATION


DIRECTOR,OISD

Tanker

• Design

• Licensing

• Maintenance

• Vehicle Tracking

• inspection

• Technical up gradation

Driver• Selection

• Training

• Motivation / Incentive Scheme

• Trip Monitoring

• Counseling

• Disciplinary measures

• Fatigue / sleepiness

Environment

• Driving safety Policy

• Roads

• Traffic density

• Weather

• Time of the day

• Parking location


…………..Design/Safety features


Design & Safety features


DIRECTOR,OISD

The Petroleum (Amendment) rules, 2011. For POL tank trucks design OISD-RP-167 Pressure vessels for transportation of LPG -The Static and Mobile Pressure Vessels (Unfired) Rules 2016, IS: 2825, OISD-STD-159-LPG Tank Trucks - Requirements of Safety on Design / Fabrication and Fittings.

OISD-RP-157STANDARD FOR SAFETY IN TRANSPORTATION OF BULK PETROLEUM PRODUCTS

REAR CRASH GUARDSide guard for lateral protection

Design & Safety features


DIRECTOR,OISD

DESIGNThe Petroleum (Amendment) rules, 2011. For POL tank trucks design OISD-RP-167 Pressure vessels for transportation of LPG -The Static and Mobile Pressure Vessels (Unfired) Rules 2016, IS: 2825, OISD-STD-159-LPG Tank Trucks - Requirements of Safety on Design / Fabrication and Fittings.OISD-RP-157

STANDARD FOR SAFETY IN TRANSPORTATION OF BULK PETROLEUM PRODUCTS


…………..Driver




DIRECTOR,OISD

Training


DIRECTOR,OISD

Training

Outcome- Are we working on the root cause?

TRAINING-Emotional Quotient


DIRECTOR,OISD

पापा, धीरे चलाना गड्डी

Involve Family of TT crew in health check up ,safety

training

Sharing of Incident by Victim/family

member Video/live

TRAINING


DIRECTOR,OISD

1. DRIVING2. TRAFFIC RULES3. RISK INVOLVED4. EMERGENCY

• The properties of the material carried, • The handling method applicable • Use of the fire extinguishing

equipment • Emergency procedure to be followed.

• Safety measures against the Risk involved

• Fire extinguishing method/media

He should be aware of


………….. Technology


MITIGATION-Technical Upgradation


DIRECTOR,OISD


………….. Incentive and Punishment


Incentive and Punishment


DIRECTOR,OISD


………….. Audit


Our Initiative


DIRECTOR,OISD

We audit and ensure …..

• Vehicle Tracking System(VTS)• Internal Valve with Excess Flow Check Valve

(IEFCV),• Rear & lateral under run protection in TTs,

• ‘Valve box’ & ‘Crash Guard’ to be provided forprotecting ‘valves / manifold

• Defining the size of parking area in LPG Plants,

• List of safety equipment to be carried by truckrevised to 20 from existing 5.

Way Forward

Oil Industry Safety DirectorateAUTHOR:DEVENDRA M MAHAJAN,JOINT

DIRECTOR,OISD

Way Forward


DIRECTOR,OISD

Strengthen the training mechanism

Behaviour base safety training

Ensuring healthy and safe life to drivers

Emotional touch in training

Unsafe behaviour of TT crew can result in….

The incident



DIRECTOR,OISD

FIRE INCIDENT AT

LPG PLANT IN

TANK TRUCK AT TANK LORRY DECANTATION FACILITY


DIRECTOR,OISD


DIRECTOR,OISD

Date & Time: 12th September, 2019 at about 10:23 hours

Location: Tank Truck (TT) at Tank Lorry Decantation Gantry

Injuries: Five persons reportedly received burn injuries and were admitted to thehospital.

Sequence:

1st batch of the LPG tank trucks were taken inside the plant on 12/09/2019 at07:00 hrs.

At around 10:00 hrs, 2nd batch of LPG tank trucks were allowed inside the plantfor the unloading operations.

The loaded LPG tank trucks are routed through Weigh Bridge for grossweighment and are positioned behind each bay awaiting their turn.

Tanker no. ‘A’ was positioned behind the TLD bay no: 02

THE INCIDENT


DIRECTOR,OISD

THE INCIDENT

Tanker no. ‘A’ was positioned behind the TLD bay no: 02

The driver of the truck then attached the male fittings on LPG liquid and LPG vapourpipeline manifold on the LPG tank truck.

In the meantime, TT no. ‘B’ and TT no. ‘C’ were placed behind bay no. 1 & 3respectively.

Similarly, loaded LPG TT’s were awaiting their turn by positioning behind the respectiveTLD bays undergoing fixing of liquid & vapour male fittings.

At 10:23 hrs, the driver of the tank truck no: ‘A’ (which is placed inside the TLD bay no:02, and connected to TLD LPG liquid and vapour LPG pipelines via unloading armsassociated with breakaway couplings) reverses the tank truck.

The unloading arms (liquid & vapour) are stretched to the maximum and rips the 2”threaded ball valve on the LPG liquid pipeline of the tank truck. Immediately liquid LPGfrom the tank truck starts to leak.


DIRECTOR,OISD

THE INCIDENT

Liquid LPG leak from the fully loaded tank truck enveloped whole of the TLD andadjacent area creating a thick white fog.

LPG vapours were seen travelling towards Motor Control Centre (MCC), DieselGenerator room, weigh bridge room, fire engine room and main gate.

Sprinkler in TLD was operated and dispersal of LPG using water monitors wasundertaken.

Around 10:50 hrs, the LPG vapour gets ignited which leads to Unconfined VapourCloud Explosion (UVCE).

The fire traced itself back towards the LPG source tank truck TT no: ‘A’ and started toburn with high intensity.


DIRECTOR,OISD

THE INCIDENT


DIRECTOR,OISD

THE INCIDENT

Bent Liquid LPG Breakaway Coupling inside TLD Bay: 02


DIRECTOR,OISD

THE INCIDENT

Damaged manifold valves of TT


DIRECTOR,OISD

THE INCIDENT

Sheared off LPG liquid manifold valve of TT


DIRECTOR,OISD

THE INCIDENT

The leaked TT which caused the incident


DIRECTOR,OISD

THE INCIDENT

Manifold valves & IEFCV’s of subject TT


DIRECTOR,OISD

THE INCIDENT

Internal EFCV of incident TT


DIRECTOR,OISD

THE INCIDENT

Internal Excess Flow Check Valve (IEFCV)


DIRECTOR,OISD

OBSERVATIONS

Operability of Breakaway Coupling

Breakaway coupling/ emergency release couplings which have beeninstalled in this Plant are not designed to release in backward/ reversedirection of the movement of the TT

Supervision of TLD

From the CCTV footage it is observed that the fitting of the unloadingarms and opening of the LPG valves from the TLD manifold LPGpipelines is done by the drivers and no intervention from the TLDoperators or supervision of officer.


DIRECTOR,OISD

OBSERVATIONS

Violation of SOP’s

a) Wheel chokes are not positioned.

b) Checking of integrity of the LPG arms connection.

c) The operator was not available at his work spot.

Breakaway coupling of the TLD unloading arm did not get activatedin reverse motion of the tank truck.

Failure of IEFCV operation of the TT due to the bending of internalshaft and housing of IEFCV.

Failure of shearing of IEFCV at the provided weak spot on the outervalve of the IEFCV.


DIRECTOR,OISD

RECOMMENDATIONS

Adherence to SOP’s for unloading operations by TLD

operators & drivers.

To ensure operators do not leave their work spot for any

reason unless the operation is completed.

To ensure Breakaway coupling mechanism works inboth directions.


DIRECTOR,OISD

QUESTIONS UNANSWERED

The identity of the person behind the wheel of the accidented TT couldnot be traced because of the lack of CCTV footage of TLD.

Since the affected TT was the 1st of the second lot to enter thepremises, why did the driver choose to park behind TLD bay: 02 andnot TLD bay: 01 or TLD bay: 08 (towards extreme ends).

Why did the driver move the vehicle after fixing the loading arms insideTLD.

Why the driver has not been traced, since he is the most criticalwitness in this particular incident.


DIRECTOR,OISD

Oil Industry Safety Directorate · DIRECTOR,OISD WE ADD SAFETY. In-transit Incident...

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