gujarat refinery - where growth is essence of life

Gujarat Refinery - Where Growth is Essence of Life 1


1 Brief Introduction to IOCL, Gujarat Refinery

2 Systems in Place

3 ERDMP Exercise

4 Challenges & Suggestions


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


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


YEAR

4.3 MMTPA Capacity expansion is under final approval


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


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


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

http://www.ril.com/


ED(I/C)

GM (F)

ED(T)

DGM (TS-I/C)

DGM (PJ-I/C)

GM (HSE)

GM(P&U)DGM (MN-I/C)


GACL

Gujarat Refinery

RIL

GSFC

VADODARA Railway Station

ToAhmedabad

ToMumbai


GR PLOT PLAN


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


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


SYSTEMS IN PLACE


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


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


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


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


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


Details of Emergency Response Disaster Management Plan (ERDMP)

Mock Drill Dt. 25.08.2012

for

Accreditation by DMI, Bhopal


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


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}.


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.


H2S LEAK SCENARIO DRAWING


REFINERY PLOT PLAN

SRU III


SRU III PLOT PLAN

LOCATION OF LEAK IN SRU III


LOCATION OF LEAK AND H2S DETECTOR

LOCATION OF LEAK IN SRU III

H2S DETECTOR

HOOTER AND BEACON


RISK CONTOUR DIAGRAM


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


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


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)


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


GLIMPSES OF ERDMP MOCK DRILL


CHALLENGES IN DEVELOPMENT OF ERDMP


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.


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


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


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.


DISCUSSION

gujarat refinery - where growth is essence of life

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