paradip refinery the energy gateway to eastern...

Paradip Refinery The Energy Gateway to Eastern India

Content of Presentation • Indian oil- Overview

• About Paradip Refinery- Brief Introduction & Job Quantum

• Safety Management System of Paradip Refinery

• Initiatives taken for Zero Accident at Paradip Refinery

• Emergency Preparedness

• Occupational Health & Hygiene

AVU

MS & Naphtha Tank Farm

IndianOil - Overview

Brief History of IndianOil Birth of IndianOil

• 1958 (Aug) – Indian Oil Refineries Ltd formed

to erect refineries & laying petroleum pipelines

• Chairman: Shri Feroze Gandhi

• 1959 (June 30th) – Indian Oil Company Ltd formed

for marketing and distribution of petroleum products

• Chairman: Shri S Nijalingappa

Indian Oil Corporation Limited

Indian Oil Corporation Ltd. 1st Sept 1964

Indian Oil Company Ltd. 1959

Merger

❑ Assam Oil Company Ltd. merged in 1981 ❑ IBP Co. Ltd. merger effective May 2007 ❑ BRPL merger effective March 2009

Indian Refineries Ltd. 1958

IndianOil’s Value-chain

Key product portfolios / functions / groups

7

Paradip Refinery ❖ Capacity:- 15.0 MMTPA (Grass-root Refinery)

❖ Investment Approval : 28th February 2009

❖ Project Cost : Rs. 34,555 Crores

❖ IOC’s largest investment in a single Project

Job Quantum

• Land Reclamation/Dredging/Filling : 27.4 Mn M3 (2,366 Acres) (3 - 4 M sand fill)

Dredger

• Piling : 1.0 Lac (Max Dia-1400 mm, Depth-40 M)

Piling Rigs

Job Quantum

• Concreting (RCC & PCC) : 11.6 Lakh M3

(3 times volume of Burj Khalifa, Dubai)

Concrete: 3.3 Lac M3

Eiffel Tower, Paris : 9,441 MT

• Structural Steel (incl. Tor Steel): 2.8 Lac MT

(Equivalent to 30 Eiffel

Towers or about 350 Rajdhani Trains)

Job Quantum

• Pipes Consumed: 2,400 KM

(almost the length of Ganges, 2,525 KM)

- Piping Fabrication 60.0 Lac Inch Dia

- Piping Erection 112 Lac Inch Metre

•Largest Dia Pipe: 104” (8.7’)

(Mercedes-Benz “S’” can pass through )

Largest Diameter Pipe

Job Quantum

• Tanks/Mounded Bullets: 79 Nos.

• Cables: 20,000KM (about 1.8 times Dia of Earth:12,756 KM)

Largest Bullet (L-99.4m, D-6.4m)

Job Quantum

• Equipment (Static & Rotary): 3,300

Nos.

• 32 heavy equipment (weighing >300 MT)

• Transported via sea route from vendors shop on self propelled/ pulled barges up to Paradip Port

• Erection by M/s Mammoet using 4 Heavy Duty Cranes of capacity – 2000 MT, 1600 MT, 1200 MT & 600 MT (brought from Singapore/ Netherland/ Middle East etc)

Vacuum Distillation Column (M/s L&T, Wt.:

1208 MT, Ht.: 57 M, Dia.: 14 M )

- on Self-Propelled Barge - Aug’11

Erection of VDU Column – Nov’ 11

Paradip Refinery – Process Units PROCESS UNITS CAPACITY (’000 TPA) PROCESS LICENSOR

Primary Processing Unit

Atmospheric & Vacuum Unit (AVU) 15,000 Open art by FWEL

Secondary Processing Units

Indmax (Fluidized Catalytic Cracking Unit) 4,170 IOC R&D

Delayed Coking Unit (DCU) 4,400 Foster Wheeler, USA

VGO Hydro Treating Unit (VGO-HDT) 5,400 Axens, France

Other Major Processing Units

Diesel Hydro Treating Unit (DHDT) 5,200 Shell Global, Netherlands

Propylene Recovery Unit (PRU) 1900 Basell, Italy

Naph. Hydrotreater /Catalytic Reformer (NHT/CCR) 3,900 / 2,900 UOP, USA

Alkylation Unit 650 ExxonMobil, USA

Butane Isomerization Unit (Butamer) 300 UOP, USA

Sulfur Recovery & Tail Gas Treating (SRU/TGTU) 2 x 525 TPD Black & Veatch, USA

Kero / FCC LPG/ FCC Gasoline Treating Units 1,200/1,850/400 Merichem, USA

SR LPG Treating unit 210 UOP, USA

Sulfuric Acid Regeneration Unit 185 TPD MECS

Sour Water Stripper (SWS) Train 1/2 402.6 / 228.8 TPH Open Art

Amine Regeneration Unit (ARU) Train ½ 478.8 / 947.9 TPH Open Art

Crude Oil Terminal & Handling Facilities

• Crude oil is imported by marine VLCC tankers.

• Crude oil unloading: via SPM-1 and 48”Ø sub-sea pipeline - to Crude Storage Tanks

• SPM-2 & SPM-3 – Envisaged at Paradip.

1 VLCC = 3,20,000m3 1 VLCC = 7 Crude oil tanks 1 VLCC Crude oil - ~ 7 days of AVU T’put).

Crude Oil Terminal & Handling Facilities

Crude Oil Terminal

and Pump Station

SPM-1

SPM-2

SPM-3

Paradip

Refinery

Paradip Port

Crude Unloading Source

Line Size ( inch)

Avg Parcel Size (m3)

Disch Press Kg/cm2

Discharge Rate (m3/hr)

Pumping Time Reqd. (hr)

Total Time Reqd. (hr)

SPM 48” 3,20,000 8-11 8,000-12,000 38-40 46-48

SOUTH JETTY 38” 1,00,000 10 4,000 25 30-38

SOUTH OIL JETTY

Crude Unloading Source

Line Size ( inch)

Avg Parcel Size (m3)

Disch Press Kg/cm2

Discharge Rate (m3/hr)

Pumping Time Reqd. (hr)

Total Time Reqd. (hr)

SPM 48” 3,20,000 8-11 8,000-12,000 38-40 46-48

SOUTH JETTY 38” 1,00,000 10 4,000 25 30-38

Aromatics Units

Refinery Units

Buildings

Utilities

Future Expansion

Offsite

BOO-1: H2 & N2

BOOT-3 Tankage

BOO T-4: Raw Water

Deferred Units

N

Total Area : 3,344 acres (Township/ Approach Road – 399 acres, Plant – 2945 acres (incl. 580 acres for Green Belt))

Plot Plan

• Block layout adopted for plant as per OISD-STD-118. • Separation distances maintained as per OISD-STD-118. • Risk analysis carried out . • EIA study carried out. • ERDMP approved by DMI, Bhopal • Mutual aid with neighboring Industries established. • OISD PCSA carried out for facilities ready for commissioning. • PESO clearance obtained for storage of Cl2, LPG, H2,

Plant Layout

Safety Management Systems of Paradip Refinery has been

prepared on the basis of :-

• Process Safety Management of Occupational Safety &

Health Administration (OSHA), USA

• Corporate Guidelines on Safety, Health and Environment Management System of Indian Oil

• OISD Guidelines on Safety Management System in Petroleum Industry (OISD-GDN-206)

The Energy Gateway to Eastern India

Paradip Refinery

Safety Management System of Paradip Refinery

• To prevent any unsafe condition and eliminate or mitigate

their probable consequences.

• To control loss to personnel, equipment, material and

environment.

• To standardize the procedures which should continue to be

followed by one and all unless a change in the system is

duly authorized by a competent person.

HSE Management System of Paradip Refinery


Paradip Refinery

SAFETY

• Zero Accident.

• Zero Fire.

• OPL Sharing.

• Increasing Near miss

Incident Reporting.

• Improve Housekeeping.

• Raise safety awareness through safety education & Training.

HEALTH

• Monitor & maintain for hygiene at work place.

• Carry out pre-employment, & periodic medical health check up of employees.

• Conduct surveys &

investigations on potential health hazards.

• Train employees in First-

Aid, Occupational Health & hygiene.

ENVIRONMENT

• Carry out continuous Stack monitoring & ensure emission is within the stipulated norms.

• Reduce CO2 emission from the plant.

• Reduce consumption in

fresh water .

• Increase the re-use of treated water.

A I M


Paradip Refinery

17 Elements of Safety Management System of Paradip Refinery

1. Safety Organization & Leadership

2. Process Safety Information (PSI)

3. Process Hazard Analysis (PHA)

4. Standard Operating Procedures(SOPs)

5. Pre-startup Safety Review (PSSR)

6. Mechanical Integrity (MI)

7. Management of Change (MOC)

8. Permit to Work System (PTW)

9. Incident Investigation and Analysis

10.Emergency Planning and Response

11. Contractors Safety Management

12. Safety Training & Development

13. Transportation & Traffic Safety

14. Compliance Audit & Assurance

15. Occupational Health Management

16. Employees Participation

And

17. Off-the Job Safety

HSE Organisation & Leadership of Paradip Refinery

Executive Director

General Manager ( HSE)

Chief Manager (F&S)

Dy. General Manager (HSE)

Chief Manager (HSE)

Manager ( Safety)

Engineers, Sr. Engineers Dy. Managers

CISF (Fire Wing) 111 Nos.

Sr. Manager ( Fire Protection) Dy. Manager

( Process Safety) Dy. Manager

( Environment)


Paradip Refinery

Process Safety Information

Process Hazard Analysis &

Operating Procedures


Paradip Refinery

Process Safety Information / Process Hazard Analysis & Operating Procedures

Complete and accurate written information is compiled for the following three categories:

1) Process chemicals

2) Process technology

3) Process equipment

The information represents current operation. All data sheets, drawings, specifications and other documents are updated / revised based on the present condition of the process. MOC is enforced for incorporation of all modifications.

Computerization of the information has been done & is available through

RDBMS facilitating easy up-dation and retrieval. It is put on local network for

easy accessibility of all concerned.


Paradip Refinery

Process Chemicals - MSDS

Process chemicals include all raw materials, intermediates / finished products and chemicals used in the refining process. For each process chemical, following information is made available through MSDS:

Physical properties

Fire & explosion Hazards

Reactive Hazards

Health Hazard Data:

Corrosive properties of the chemical, runaway reaction and over-

pressure hazards

Information on fire fighting media, use of personal protective equipment

(PPE), emergency treatment for exposure and release / spill

containment.


Paradip Refinery

Process Technology

Process technology information of all the process including the following

are available both in Soft & hard Fashion:

1. Written process descriptions

2. Process chemistry

3. Block Flow Diagram(BFD), Process Flow Diagrams (PFD) & Process & Instrumentation Diagrams.(P&ID)

4. Safe operating limits of process parameters like pressure, temperature, flow rate etc. and the consequences or results of deviation that could occur if operating beyond the established process limits

5. Maximum inventory levels for process chemicals

6. Material and energy balances.


Paradip Refinery

Process Equipment

Process equipment include columns, vessels, heat exchangers, reactors, pumps & compressors, valves, piping; drilling rigs & work-over rigs; cross country pipelines; tanks, loading & un-loading facilities and other equipment that contain process chemicals. Design data of all process equipments area documented and include the following:

Materials of construction

Design specifications

Codes, standards and industry accepted engineering practices used for design and fabrication

Electrical classification


Paradip Refinery

Process Hazard Analysis

The PHA is done by a multidisciplinary team using one or more of the following methodologies that are appropriate to identify, determine and evaluate the hazards of the process being analyzed.

•What if, checklist

•Hazard and Operability Study( HAZOP)

•Failure Mode and Effects Analysis

•Fault Tree Analysis

PHA is carried for all new process, any modifications in the existing process & on processes depending on age and operating history of the process


Paradip Refinery

Operating Procedures

Written down operating procedures are available for all process plants for safe operation . The operating procedures provide specific instructions on what steps to be taken or followed while carrying out the following:

Startup - including procedure for initial startup of the process or equipment as well as startup after normal and emergency shut downs. Normal operation - including limits of the "normal" operating ranges for parameters such as pressure, temperature and flow, the consequences of operating outside these limits, and the actions that should be taken to correct or avoid deviation from the normal ranges.

Temporary operation - Including special requirements while operating in the temporary mode and the acceptable duration of the temporary operating mode.

Normal shut-down - Including actions to be taken to safely shut down the process or equipment and conditions to be avoided

Emergency operation and shut-down - Including the conditions under which an emergency shut-down is required along with assignment of authority and responsibility to ensure that shutdown is executed in a safe and timely manner

• Monthly Safety Day celebrated on 1st working day of every month at 10 Zones on different safety themes.

• Lessons learnt from Hi-Po near miss incidents of previous month shared. • On spot quiz is conducted & prizes distributed.

SAFETY THROUGH INVOLVEMENT & PARTICIPATION

• Demonstration of Safety Equipment in line with MSD theme carried out at site during Monthly Safety Day celebration.

• Identified Safe workers recognized by affixing STAR sticker on helmet during Monthly Safety Day celebrations.


• Recognition given to winners on Housekeeping & Near Miss

Competition


Paradip Refinery




Paradip Refinery

• Mandatory HSE induction training to all new entrants.

• 100 % compliance on use of Job specific Personal Protective Equipment.

• System of imparting daily Tool Box Talk prior to start of job is in place.

• Job Safety Analysis of Critical activities carried out.

• Enforcement & Adherence to Work permit system

• Regular Class Room & On Job trainings.

• Daily Safety announcement at main gate & project sites.

Initiatives taken for Zero accident


Paradip Refinery

http://iocl.com/index.asp

• System of Award & recognition of safe workers in place.

• Publishing & wide distribution of leaflets/ pocket card on lessons learnt from past incidents

• Publishing and circulation of weekly Safety e- bulletins.

• Discussion of case studies & encouraging workers to report near miss incidents during various safety awareness campaigns.

• Mandatory Health Check up of all contract workers at site. • Celebration of Monthly Safety Day on various themes at 10 different

locations involving Top management.

Initiatives taken for zero accident at Paradip Refinery


Paradip Refinery


• On line near miss incident reporting, investigation & analysis.

• Mandatory use of full body harness & life line while working at height.

• Conduct Mock drills & demonstrations on regular basis.

• Implementation of color coding of helmets for ready identification.

• Implementation of Penalty scheme for safety lapses.

Initiatives taken for zero accident at Paradip Refinery


Paradip Refinery


Safety Inspections


• “NO MOBILE” & “NO CO-PASSENGER” stickers provided in hydras.

Traffic Safety


LOTO System at Paradip Refinery


Paradip Refinery


Paradip Refinery Project A Sunrise Project for a Sunshine Future

Special Training Program for Drivers & Equipment Operators conducted.

Initiatives taken for Zero accident


Demonstration of Safety gadgets &

Enacting stage shows


Paradip Refinery


PROACTIVE SAFETY APPROACH – TRAFFIC SAFETY


Paradip Refinery

Class Room Training To Employees & Contract

Workers on General Loss Control Rules &

Safe Work Procedures.

PROACTIVE SAFETY APPROACH- SAFETY EDUCATION & TRAINING

Contractor workers

Employees CISF

Employees

Employees

Contractor workers

Contractor workers CISF

Paradip Refinery practices the following Audits for improvement in Safety System: • Internal Safety Audit on Half yearly basis as per OISD-145. • Internal System Audit on Yearly Basis. • Internal & External Audit for OHSAS on half Yearly Basis • Surprise Safety Audit by OISD Team on Yearly Basis. • External Safety Audit by OISD team once in Three Years. • Pre-commissioning Safety Audit for each New Facility.

SAFETY AUDITS FOR IMPROVEMNT

The Energy Gateway to Eastern India Paradip Refinery

EMERGENCY PREPAREDNESS

Glimpses of On-Site Disaster Drill

•Emergency Management Plans - on site & - off site

•On-site drills once in 3 months against the statutory norm of once in 6 months

•Off-site drill with Dist. Administration once a year

•Mutual aid Agreements with Neighboring industries


Fire protection facilities provided:

•- Fire Water including storage , pump house & network

•- Foam System

•- Clean Agent Fire Protection system

•- Carbon Dioxide System

•- Dry Chemical Extinguishing System

•- Fire Detection and Alarm system

•- Communication System

•- Portable fire fighting equipment

•- Mobile fire fighting equipment

Fire Protection System

• 2 X 14000 m3 capacity

• Storage is for 4 hours of maximum water demand

• During emergency make up from Raw water reservoirs

(Pump Capacity 2000 M3/hr. Header size : 36” Dia)

49

Fire Water Storage

2 water reservoirs ( Capacity 2,65,000 M3 each) Fire Water Storage Tanks

Fire Water Pumps • Jockey Pumps- 02 nos. electrical Drive

• Main Pumps- 14 nos. ( 7 Motor driven & 7 Diesel Engine driven)

• Capacities : Jockey pump - 350m3/hr & Main Pumps 795 m3/hr

• Auto sequential operation provided.

50

51 Clean Agent Flooding for Control Room

Mobile Fire Fighting Equipment 4 nos. of Foam Tenders fabricated on Volvo Chassis Foam tank Capacity 6000 L Pump Capacity 8000 LPM Foam Pump 500 LPM 1 Hydraulic Platform Boom Height : 54 M 2 nos. Foam Nursers : Tank Capacity : 12000 L Pump Capacity : 600 LPM One DCP Tender of 2 spheres each of 2000 KG capacity One Emergency Rescue Tender (ERT) Quick Response Vehicle (QRV) •

52

Fire Stations

• 2 Fire Station one at South site and other at North Site.

• CISF (Fire wing) deployed for Paradip Refinery

53

54

Chlorine Absorption System

Chlorine Absorption System

1. In case of chlorine leaking at 1 PPM from its container / system, the system will automatically start. i.e. blower & pump will start simultaneously.

1. The pump will deliver NAOH from tank through the top of absorption tower & blower will suck the leaked chlorine from bottom of absorption tower.

1. Due to counter current between NAOH & Cl2, chlorine will be neutralized.

1. Neutralized chlorine will be vent out to atmosphere through blower & FRP ducting.

Infrastructure

ASSEMBLY POINTS: Assembly point in North side:

AP-1: Administration building

AP-2: North Fire station

AP-3: OM&S building

AP-4: Tank firm area

Assembly point in South side:

AP-1: Near Technology building

AP-2: CPP Area

AP-3: DM plant area

AP-4: Main control Room

AP-5: CRWS lift station

AP-6: ETP area

Emergency Preparedness Drills

56

• Live Demonstration on Fire Fighting & Safety and rescue equipment organized during the Republic Day Function on 26th January 2015 at Township Stadium.

DEMONSTRATION OF EMERGENCY HANDLING CAPABILITIES

58

On the occasion of “ Odisha Disaster Preparedness Day-2014” on 29th October, 2014, Paradip Refinery demonstrated its F&S capability to a large gathering of public at the Collectorate ground in Jagatsinghpur in presence of Shri Satya Kumar Mallick, Collector & DM, Jagatsinghpur, Ms. Sudha Singh, SP Jagatsinghpur, other officials from Jagatsinghpur The demonstration was also keenly watched by the general public and a large no. of school children. At the end, Collector & DM, Jagatsinghpur Shri Satya Kumar Mallick thanked all the participants & appreciated the emergency handling capability developed by Paradip Refinery.

Participation in Odisha Disaster Preparedness Day

DEMONSTRATION OF EMERGENCY HANDLING CAPABILITIES

• Objective

• Promote health care of the man behind the machine

• Early detection of occupational disease

• Occupational health monitoring is in line with OISD-GDN-166

• Major activities are

• Pre-employment medical examination

• Periodical medical examination - target organs

• Well person screening of employees above 40 years

• Thorough examination of food handlers - skin infection, chest infestation, worm infestations

• Sound level monitoring in high noise areas - once in 6 months

• Checking and surveillance of First Aid boxes

• Provision of safe drinking water

• Proper disposal of Bio-medical waste

• External Auditing – Twice in a year

OCCUPATIONAL HEALTH & HYGIENE


Thank You

paradip refinery the energy gateway to eastern...

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