ON

1
NUMALIGARH REFINERY LIMITED
PRESENTATION
ON
Emergency Response Disaster Management Plan
and Best Practices at NRL
FIRE SAFETY DEPARTMENT OF NRL
2
THE GENESIS
1. Proposal for Refinery included in Assam
Accord August 15, 1985 2. Numaligarh
Refinery Limited incorporated April 22,
1993 3. Commercial Production commenced
Oct. 1, 2000 4. NRL became subsidiary of
BPCL March 31, 2001
3
(No Transcript)
4
OUR LOCATION- IN THE STATE OF ASSAM
AOD
BRPL
NH-52
NH-37
NH-39
IOC,GHY
NRL
N
E
W
Refinery Capacity DST. from
(MMTPA) NRL (Km) IOCL, Ghy
1.00 260 AOD, Digboi
0.65 310 BRPL 2.35
460 NRL 3.00
----
S
5
NRL PLOT PLAN
PANKA GAON
CRUDE PIPE LINE IN
STORM WATER OUTLET
GREEN BELT
101A
101B
101C
101D
CRUDE TANKS
(FUTURE)
CRUDE TANKS
CRUDE TANKS
FLARE
K
O
S
250
KV

R
V
D
V
DG set
H
S
D
DRY SLOP
C
NAPHTHA
WET SLOP
FO
A
F
R
T
D
C
O
DCU
C
CDU/VDU
Pump house
(White oil.)
HCU
C
GREEN BELT
CPC WARE HOUSE
SCRAP
YARD
Black oil
White oil
CISF
COMPLEX
U
Gantry A
Gantry B
CENTRAL
CONTROL
AREA FOR
BOTTLING
PLANT
Oil loading gantry
ETP
ROOM
LOADING GANTRY
H2U
Scaling platform
N2
Compressor
HOUSE
WARE
house
Plant
RWTP
HORTON SPHERE
SRU
RAiL
CONTROL ROOM
STORE
CPP
DM PLANT
OPEN
COOLING
CENTRAL
STORAGE
WORKSHOP
TOWER
YARD
GREEN BELT
OPEN STORAGE YARD
CONTROL ROOM
S
S
CTC
RW
MEDICAL
I
PT
LPG
NRL
LAB
CENTRE
CANTEEN
ADM.
RESERVOIR
R
T
LOADING
E
BLDG.
GANTRY
Adm
U
FW
EIL
FIRE STATION
PO
RESERVOIR
bldg
CISF MATERIAL GATE
NRMT MAIN GATE
BANK
CISF MAIN GATE
GREEN BELT
lt--- NH - 39---gt
/
6
OUR PROMOTERS
Share holding pattern of the refinery
7
THE PROJECT AT A GLANCE

• Installed Capacity 3 MMTPA
• Area Refinery - 750 Acres
• Township - 250 Acres
• Approved Project Cost Refinery - Rs. 2489.12
  Crores
• Marketing Terminal - Rs. 235.52 Crores
• -----------------------------------------
  ----------------
• Total - Rs. 2724.64 Crores
• Both Refinery and Marketing Terminal completed
  within approved Project Cost
• Annual turn over Rs.7874Crore
• Gross Profit for the financial year 2009-10 is
  Rs. 521Crore
• Profit After Tax Rs.232Crore

8
HIGHLIGHTS

• Eco-friendly Refinery
• First Sulfur Recovery Unit
• for processing Assam
• Crude
• Installation of Ground Flare

Clean Green Environment
9
MILESTONES

• Management Systems
• IMC Ramakrishna Bajaj National Quality awards for
  2009.
• Jawaharlal Nehru Centenary Awards for Energy
  Performance of Refineries for the year 2004-05
  and for 2007-08.
• National Energy Conservation Award consecutively
  for 2007(2nd Prize in refinery sector) and
  2008 by Bureau of Energy Efficiency.
• Oil Gas Conservation Award in 2008 by Centre of
  High Technology.
• TERI Corporate Environmental excellence Award
  consecutively for 2007 and 2008.
• Safety Management
• Oil Industry Safety Awards for the year 2005-06
  and for 2008 by OISD.
• National Safety Award in 2008.
• Shrestha Suraksha Puraskar consecutively for 2006
  and 2007 by National safety council.
• Green Tech Safety Gold Award for 2005-06 by
  Greentech Foundation, Hyderabad and for 2007-08
  by Greentech Foundation, Delhi.

10
MILESTONES (Contd.)

• Environment Management
• Best green Location Refinery in 2009 by BPC
  Mumbai Refinery
• Chairman's award for Excellence in Green
  (Refinery) in 2007-08 by Corporate HSE S award ,
  BPCL
• Information Technology
• Awarded Best Industry Status in IT Agency
  National Petroleum Management Programme
  for year 2001-02.
• Fastest implementation of SAP

11
HSE Our Primary Concern

• Achieved 15.96 Million LTA free man-hours (3292
  days).
• Regular study of water quality of Dhansiri river
• Continuous monitoring of the status of ambient
  air quality.
• Waste Management System
• - Solid Waste Disposal Yard
• - Secured Land Fill
• - Melting Pit
• Post commissioning Environment Audit by NEERI.
• Use of sweet fuel for internal consumption

12
SAFETY MANAGEMENT SYSTEM OF NRL

• NRL is certified by DNV for OHSAS 18001
  since 2002 along with ISO 9001 14001 for
  Quality Environment also. NRL also achieved
  ISRS level -9
• 1) Safety points covered under internal and
  external management system audit.
• 2) Safety points are discussed everyday in
  the morning meeting.
• 3) Quarterly the status of various safety
  points implementation are reviewed at the
  level of Director (Technical) in Apex safety
  Committee Meeting.
• 4) Every month, in Functional Co ordination
  meeting, Managing Director takes monthly
  report on safety performance.
• 5) Safety Audit by OISD
• Status of OISD related points are regularly
  sent to OISD every three months.
• The DGFASLI audit compliance report are also sent
  to RLI, Kolkata periodically.

13
SAFETY COMMITTEES
NRL has 3-tier safety committees

• Sectional safety Committee
• - Conducted monthly by Shift In Charges of
  the various units
• Area Safety Committee
• - Conducted quarterly with equal
  participation of
• management and Non-management staff
• Apex Loss Control Committee
• - Conducted quarterly with all unit
  heads,VKNRL non-
• management staff and convened by
  Director (T)

14
FIRE PROTECTION FACILITIES AT NRL

• Fire water system
• I. Fire water pumps and Reservoir.
• II. Fire Water Network (As per OISD
  116 , other relevant codes IS standards)
• Fire water network of length 55
  km is laid in closed loop multidirectional flow.
  
  
• It includes
• Hydrants
• Monitors
• Water spray
  system
• Deluge system
  
• Foam Protection System
• Fixed Foam System
• Semi fixed Foam System
• CO2 Total Flooding System
• First Aid fire fighting Appliances
• Mobile fire fighting equipments
• Gas Detection Alarm system

15
FIRE PROTECTION FACILITIES
I. Fire Water Pumps

• 100 back up with 4 Diesel driven pumps

• Second Source of Fire water Raw water reservoir
  of capacity (2 x 12000) m3

PA-101
PA-102
PA-102A
PA-103
PA-104
PA-105
RESERVOIR-7000 M3
PA-106
LEGEND
PA-107
CAPACITY
Pump Head
3 JOCKEY PUMPS 65 M3/Hr.
11kg/cm2 (Electric Driven) 4 MAIN FW PUMPS 700
M3/Hr. 10.5 kg/cm2 (Electric Driven) 4
MAIN FW PUMPS 700 M3/Hr. 10.5 kg/cm2
(Diesel Driven)
PA-108
PA-109
PA-109
RESERVOIR-7000 M3
PA-110
16
FIRE PROTECTION FACILITIES (Contd.)
II. Fire Water Network
17
FIRE PROTECTION FACILITIES (Contd.)
III. Foam System
IV. CO2 System
V. FM200 (Compound of Carbon, Fluorine
Hydrogen) System
18
FIRE PROTECTION FACILITIES (Contd.)
VI. Mobile Fire Fighting Units
VII. First Aid Fire Fighting Equipments (Approx
1200 nos.)
19
VII. Gas Detection Alarm System

• The Fire Detection and alarm system is
  micro-processor based and covers the entire
  refinery and NRMT. The system consists of Fire
  detecting sensors manual call points

Total 279 nos. of Manual Call points are
installed in around the road network.

• A separate Fire Detection ,Alarm Suppression
  System is installed in CPP (Captive Power Plant)

20
SOME SAFETY EQUIPMENTS

• Safety Kit box located at strategic locations
  containing
• Canister Mask SO2, Cl2, NH3, H2S
• Hand Gloves Chemical, Lather, Kelver, Cotton,
  Electrical
• Face Shield Chemical, Furnace
• Goggles Bocal Blue, Safety Goggles
• Ear Protection Muff, Plug
• Safety Torch
• Dust Musk
• Water Gel
• Compressed Air Breathing Equipment
• Articulated Boom
• Mobile Oil Spillage Recovery Unit

21
Mobile Fire Fighting Units
22
Mobile Fire Fighting Units
DCP TENDER
23
Mobile Fire Fighting Units
24
EQUIPMENTS
MOBILE OIL SPILLAGE RECOVERY UNIT
ARTICULATOR
25
COMMUNICATION FACILITIES

• 1. Intercom / BSNL / Fax
• LAN / Internet / VSAT.
• Group Dialing System
• 4. Public Address System
• 5. Siren at 9 locations including 2 at
  township.
• 6. Multi channel VHF sets with eleven Base
  stations
• Range - Base Station 25 Km, Hand sets 5
  km
• 7. Fire alarm Detection system.
• Remarks All the above facilities have UPS or
  
• emergency power.

26
MANUALS DOCUMENTS

• CONSTRUCTION SAFETY MANUAL (ENGLISH / ASSAMESE)
• SAFETY MANUAL
• FIRE MANUAL
• ONSITE DISASTER MAMAGEMENT PLAN
• OFFSITE DISASTER MANAGEMENT PLAN
• FIRE ORDER
• MATERIAL SAFETY DATA SHEET
• CONTRACTOR SAFETY MANUAL
• FIRE PROTECTION SAFETY POCKET MANUAL
• VISITORS FAMILIARISATION SAFETY CARD
• LEAFLET ON LPG SAFETY

27
Onsite Offsite Disaster Management Plan
28
ORGANOGRAM FOR OFFSITE EMERGENCY PREPARDNESS PLAN
SDO Office, Bokakhat Tel 268382 (O), 268387 (
R) 94351-54221(M)
Supdt Of Police Tel. 285233 (O),
284234 (R)
Hospital Co- ordinator Tel [phone]
Jt. Director Health Service Tel 282438 (O),
280397(R)
OIL Co-ordinator Supdt. Engg. 265561(O) 4429
(R)
Civil Supply Officer Tel 280532 (O)
NRL Authority, D(T) 265401 (O), 266425
(R) GM(O) 265529(O), 266423(R)
CHIEF OFFSITE EMMERGENCY CO-ORDINATOR DEPUTY
COMMISSIONER Tel. 280222 (O),280221 (R)
94350-95420 (M) alternate ADDL. DY. COMMISSIONER
(RR) Tel. 280261(O),281019(R) 94350-54474
(M) CONTROL ROOM AT OFFICE OF DC / ADC
Dist. Transport Officer Tel 282181 (O)
Fire Service Co- ordinator Golaghat Fire Brigade
280300 Bokakhat Fire Brigade 269733(O)
Ex. Engineer, PWD (Road) Tel 280226 (O), 280426
(R) Asst. Ex. Engineer, PWD (Bldg) Tel 280365
(O), Ex. Engineer, PHED Tel284763(O)
94350-90808(M)
Railway Authority Div. Rly. Engineer, TSK Tel
0374 -2333570 (O)
Divisional engg. Tel Mob 9435000384
CO Marangi Tel [phone] (M)
Ex. Engineer ASEB Tel 280312 (O),
94350-54337(M)
Ex. Engineer NH Tel 280319(O)
Inspector of Factories Mob 9435160729
Panchayat VDP Mob9854872854
DIPRO Mob9435002199
29
ORGANOGRAM FOR ONSITE EMERGENCY PREPARDNESS PLAN
30
FIRE SAFETY TRAINING

• TRAINING FACILITIES
• TRAINING HALL AT FIRE STATION
• FIRE TRAINING GROUND AS PER OISD 116
• TRAINING POLICY AS PER OISD - 154
• TYPES OF TRAINING
• FRESHER TRAINING FOR NEW EMPLOYEES
• RE-FRESHER TRAINING FOR ALL EMPLOYEES
• OTHERS
• CONTRACTORS SUPERVISORS / WORKMEN
• CISF OTHER SECURITY STAFF
• POL DRIVERS

31
Fire Fighting Training
Fire Fighting Training to CISF Jawans
Fire Fighting demonstration in public
32
MOCK DRILLS

• 1) MINOR FIRE
• DRILLS ARE CONDUCTED ONCE A MONTH
• 2) MAJOR FIRE
• DRILLS ARE CONDUCTED ONCE IN A QUARTER
• 3) ONSITE DISASTER
• DRILLS ARE CONDUCTED HALF-YEARLY
• 4) OFFSITE DISASTER
• CONDUCTED ON ONCE A YEAR

33
MOCK DRILL REPORT
34
GLIMPSES OF MOCK DRILL
Rescue operation by NDRF persons
35
GLIMPSES OF MOCK DRILL
High Expansion Foam Generator
36
GLIMPSES OF MOCK DRILL
Relief Camp during off site disaster mock drill
Rescue Operation
Review Meeting after Mock Drill
37
SAFETY INCENTIVE SCHEMES

• INCENTIVE LINKED WITH MILLION LTA FREE MAN
  HRS.
• OUTSTANDING SAFETY PERFORMANCE AWARD.
• HOUSEKEEPING AWARD (FOR UNITS).
• SECTIONAL SAFETY AWARDS.
• SAFETY AWARD FOR CONTRACTORS.
• TURN AROUND SAFETY AWRAD
• BEST SAFETY AWARD FOR NRL EMPLOYEES
• BEST SAFETY AWARD FOR CONTRACTS EMPLOYEES
  (AMC/PROJECT)

38
RECENT PROJECTS
COMPLETED PROJECTS

• Motor Spirit Unit
• Utilization of Natural Gas
• Diesel Quality Up gradation Project
• 12 MW Steam Turbine Generator
• Pipeline Dispatch Receipt Terminal

FUTURE PERSPECTIVE

• Naphtha Splitter Project
• Wax Project
• Production of Needle Coke

39
Key Tasks Adopted in NRL for Improvement of
Health Fire

• Health Hazard Survey for Employees
• As a good corporate citizen among oil industries
  in India, NRL has under taken the health hazard
  survey for critical tasks and high hazard areas
  in plants and other areas
• On the site Safety training for employees
• A specific training programme adopted for
  training of employees at the site.
• Contractor Safety Evaluation for Turn Around
  Jobs
• NRL was having a full-fledged contractor safety
  evaluation during turn
• The system of evaluation for contractors is very
  elusive considering all aspects of HSE.
• Survey of fire fighting and safety equipments
• The fire fighting and safety items in refinery
  are surveyed by a multidisciplinary team of
  operation, Maint and FS to exactly evaluate the
  correct equipments for fire fighting and safety.
  All required actions are taken by FS for the
  same.
• Internal Safety Audit by members from group
  companies
• The system of Internal Safety Audit is being
  prevailed in NRL as per OISD guidelines.

40
EXAMPLES OF POSITIVE ACTION TAKEN

• From last year onwards, NRLs all meetings
  starts with a safety moment where safety
  points are discussed.
• NRL is always meeting MOU target of Training
  of NRL personnel, workers of contractors,
  CISF security guards etc on safety.
• General Loss Control Rules/Dos/Donts
• Hazard Communication
• Contractor must familiarize himself from NRL EICs
  about all known potential fire, explosion or
  toxic release hazards related to his contract. He
  in turn will ensure that same information has
  been passed to his supervisors and workmen.
• Contractors Penalty clause
• In order to improve and maintain safe working
  environment we are planning to introduce a
  special conditions of contracts for HSE (Health
  Safety and Environment) regulation for
  contractors.
• Note Generally we do counseling to the workers
  if they are found practicing unsafe acts or work
  in unsafe condition before imposing the above
  penalty clauses.
• PPE NRL has adopted colour code for PPEs
  to improve safety culture at NRL with effect
  from 1st January, 2011.

41

• Thank You