recommendation internal safety inspection 2013-14 · 2014. 7. 25. · 5. ldo/diesel tank wall...

RECOMMENDATIONS OF INTERNAL SAFETY WEEK INSPECTION 2013-14 1/42

INTERNAL SAFETY INSPECTION 2013-14

RECOMMENDATION: DRILLING RIGS RIG S-1(Loc. NLB): 1. Industrial Hygiene Survey (Illumination survey, Vibration measurement, Air quality measurement) to be carried out at regular interval. 2. PME in new format is urgently required. 3.There should be provision of Mobile Phone Hut at well site. 4. BOP control Unit top shed to be repaired. 5. SRV & Pressure Vessel test record with chart should be available. 6. Calibration of weight Indicator and pressure gauge should be done. 7. Power pack noise barrier should be provided. 8. Mud agitator pump vibration should be rectified. 9. Eye washer should be installed in mud tank area. 10 .ETP and centrifuge is highly recommended. 11. Gas cylinder should be painted with proper colour code. 12. Mock fire drill to be carried out at odd hours. 13. Hot and cold work permit should be filled up properly. 14. Job Safety Analysis and Risk Register should be maintained. RIG S-2(Loc. HUP): 1. Industrial Hygiene Survey (Illumination survey, Vibration measurement, Air quality measurement) to be carried out at regular interval. 2. Electrical records should be kept in order. 3. There should be provision of Mobile Phone Hut at well site. 4. SRV & Pressure Vessel test record with chart should be available. 5. Calibration of weight Indicator and pressure gauge should be done. 6. Record of Job Safety analysis to be maintained in proper format. 7. More Near miss incidents to be to be recorded. 8. LDO/Diesel Tank wall thickness should be as per OISD recommendation. 9. PPE should be provided for contractor personnel. 10. One more walking tray to be provided near Power Pack for easy access. RIG S-3(LOC. HVK): 1. Industrial Hygiene Survey (Noise level survey, Illumination survey, Vibration measurement, Air quality measurement) to be carried out at regular interval. 2. Musk should be provided to reduce/control bad chemical smell. 3. LDO/Diesel Tank wall thickness should be as per OISD recommendation. 4. SRV & Pressure Vessel test record with chart should be available. 5. Calibration of weight Indicator and pressure gauge should be done.


6. ETP and centrifuge is highly recommended. 7. There should be provision of Mobile Phone Hut at well site. 8. More persons to attend MVT, First Aid and Fire Fighting training. Also to maintain proper Training Record. 9. Rusted cable trays top cover are to be replaced. RIG S-5(Loc. NLG) : 1. Industrial Hygiene Survey (Noise level survey, Illumination survey, Vibration measurement, Air quality measurement) to be carried out at regular interval. 2. There should be provision of Mobile Phone Hut at well site. 3. LDO/Diesel Tank covering wall thickness should be as per OISD recommendation. 4. Water Tank skid to be repaired/replaced. 5. ETP is highly recommended. 6. PPE should be provided to contractor personnel. 7. SRV & Pressure Vessel test record with chart should be available. 8. Calibration of weight Indicator and pressure gauge should be done. 9. Mock Fire Drill to be carried out in odd hours. RIG S-6(Loc. HWQH): 1. Industrial Hygiene Survey (Noise level survey, Illumination survey, Vibration measurement, Air quality measurement) to be carried out at regular interval. 2. PME documentation should be up to date format 3. There should be provision of Mobile Phone Hut at well site. 4. LDO/Diesel Tank covering wall thickness should be as per OISD recommendation. 5. Walkway and railing at ETP platform should be placed in order. 6. Trip Tank to be replaced/repaired. 7. Mock Fire Drill to be carried out in odd hours. 8 SRV & Pressure Vessel test record with chart should be available. 9. Calibration of weight Indicator and pressure gauge should be done. RIG S-7(Loc. NLE): 1. Industrial Hygiene Survey (Noise level survey, Illumination survey, Vibration measurement, Air quality measurement) to be carried out at regular interval and recorded properly. 2.There should be provision of Mobile Phone Hut at well site. 3. SRV & Pressure Vessel test record with chart should be available. 4. Calibration of weight Indicator and pressure gauge should be done. 5. LDO/Diesel Tank covering wall thickness should be as per OISD recommendation. 6. High Density lining to be provided in the pits. 7. More persons to attend MVT, and Fire Fighting training. Training


matrixto be prepared. 8. Job Safety analysis to be maintained in new format. 9. Fire alarm should be available. 10. HDP lining to be provided in the pits. 11. BOP control unit should be placed at recommended distance. 12. ETP railing guard to be provided. 13. Mock Fire Drill to be conducted in odd hours. 14. BOP drill should be in odd hours. RIG S-8(Loc. MFF): 1. Industrial Hygiene Survey (Vibration measurement, Air quality measurement) to be carried out at regular interval. 2. There should be provision of Mobile Phone Hut at well site. 3. SRV & Pressure Vessel test record with chart should be available. 4. Calibration of weight Indicator and pressure gauge should be done. 5. LDO/Diesel Tank wall thickness should be as per OISD recommendation. 6. MSDS near chemical loading point and mud mixing tanks should be displayed. 7. Supply clean water for Eye washer. 8. ETP is highly recommended. 9. Stabbing board for Casing line spooler fixing. 10. Power Pack sound barrier should be provided 11. Mud Tanks top floor grating need replacement(rusted) 12. Leakage of oil in the Rig Pumps to be prevented. 13. Rusted top cable trays to be replaced. 14. More Safety Display boards are recommended. RIG CH – 2(Loc. HWTH): 1. Industrial Hygiene Survey (Illumination survey, Vibration measurement, air quality measurement, PME) to be carried out at regular interval. 2. PME documentation should be up to date format 3. SRV & Pressure Vessel test record with chart should be available. 4. Calibration of weight Indicator and pressure gauge should be done. 5. More persons to attend MVT, First Aid and Fire Fighting training. Also to prepare training matrix. 6. Record of Job Safety analysis to be maintained. 7. LDO/Diesel Tank wall thickness should be as per OISD recommendation. 8. ETP is highly recommended. 10. Mud Tank Motor guarder is rusting; needs to be replaced. 11. HDP lining to be provided in the Effluent pits. 12. Communication system should be improved. 13. Leakage of Fire Trailer Pump hose and valve should be arrested. 14. Mock Fire Drill to be carried out in odd hours.


RIG CH-3(LOC. BGN): 1. Industrial Hygiene Survey (Noise level survey, Illumination survey, Vibration measurement, Air quality measurement) to be carried out at regular interval. 2. PME documentation should be up to date format. 3. .More persons to attend MVT ,also to prepare Training Matrix. 4. Capacity of Fire Tank is below OISD recommendation of 50 KL. Also to provide Fire Monitor in the Fire Distribution Line as per OISD 189. 5. SRV & Pressure Vessel test record with chart should be available. 6. LDO/Diesel Tank covering wall thickness should be as per OISD recommendation. 7. MSDS display should be more prominent. 8. Eye washer shower to be fitted. 9.. High Density lining to be provided in the pits. 10. Effluent and Retainer Pit condition is found full of cuttings. 11. Different cylinder should be painted with proper colour code. 13. More persons to attend MVT, First Aid and Fire Fighting training. 14. Communication system should be improved 15. There should be provision of Mobile Phone Hut at well site. RIG CH-4(Loc. BHA): 1.Industrial Hygiene Survey (Noise level survey, Illumination survey, Vibration measurement, Air quality measurement) to be carried out at regular interval. 2. More persons to attend MVT, First Aid and Fire Fighting training. Also to Maintain Training matrix. 3. PME documentation should be up to date format. 4. There should be provision of Mobile Phone Hut at well site. 5. Mock Fire Drill to be carried out in odd hours. 6. SRV & Pressure Vessel test record with chart should be available. 7. Calibration of weight Indicator and pressure gauge should be done in interval. RIG CH-6(Loc. MKA): 1. Industrial Hygiene Survey (Noise level survey, Illumination survey, Vibration measurement, Air quality measurement) to be carried out at regular interval. 2. PME documentation should be up to date format. 3. There should be provision of Mobile Phone Hut at well site. 4. Calibration of weight Indicator and pressure gauge should be done. 5. Record of Job Safety analysis to be maintained in proper format. 6. More persons to attend MVT, First Aid and Fire Fighting training. Also to


prepare training Matrix . 7. Testing Records of SRV and Pressure Vessel to be maintained at well Site with chart should be available. 8. LDO/Diesel Tank covering wall thickness to be about 10 inches 9. MSDS display near chemical loading point and mud mixing tanks should be more prominent and first Aid Box to be kept at Derrick floor. 10. Height of the Hopper shade is to be raised and properly stacking of chemical bags 11. Kill pump should make ready for use and delivery line nipple to be replaced and grouting of the line is to be proper. RIG 110 M-A(Loc. NKX): 1. Industrial Hygiene Survey (Noise level survey, Illumination survey, Vibration measurement, Air quality measurement) to be carried out at regular interval and recorded properly. 2. Replacement of outfit (except mast) may be best option. There should be provision of Mobile Phone Hut at well site. 3. SRV & Pressure Vessel test record with chart should be available. 4. Calibration of weight Indicator and pressure gauge should be done. 5. LDO/Diesel Tank wall thickness should be as per OISD recommendation. 6 JSA to be documented. 7. LDO/Diesel Tank wall thickness should be as per OISD recommendation. 8. Water Tank folding railing to be fitted. 9. Chemical storage rack is rusted; needs to be replaced. 10. Eye wash should be available at mud tank area. 11. Wooden planks on the Derrick need to be replaced. 12. High Density Polyethylene lining to be provided in the Effluent pits. IR BHEL-A(WDW#151 1. Industrial Hygiene Survey (Vibration measurement, Air quality measurement) to be carried out at regular interval. 2. PME in new format should be use. 3. Replacement of outfit may be best option 4..There should be provision of Mobile Phone Hut at well site. 5. SRV & Pressure Vessel test record with chart should be available. 6. Calibration of weight Indicator and pressure gauge should be done. 7. LDO/Diesel Tank wall thickness should be as per OISD recommendation. 8. MSDS near chemical loading point and mud mixing tanks should be displayed. 9. Walkway on the mud mixing pump is in poor condition 10. Leakage mud mixing pump engine should be rectified. 11. Mud nallah near vibrating screen is in bad shape. 12. All the engine battery should be kept in wooden box. 13. Leakage of water pump should be rectified. 14. Water tank skid to be repaired/replaced. 15. Electrical shock treatment display should be replaced. 16. Rig mast needs to be painted. 17. Date of inspection of Fire extinguishers should be written on the body.


18. More persons to attend MVT, First Aid and Fire Fighting training. Also to prepare Training Matrix.

RECOMMENDATIONS: WORKOVER RIGS RIG CH-1(NHK- 537): 1. Industrial Hygiene Survey (Noise level survey, Illumination survey, Vibration measurement, Air quality measurement) to be carried out at regular interval and recorded properly. 2. SRV & Pressure Vessel Testing to be carried out as per OISD recommendation and records with chart to be maintained properly. 3. More persons to attend MVT, First Aid and Fire Fighting training. Training Record to be maintained and updated properly. 4. PME should be new format for all crew personnel 5. More nos. of Nearmiss incidents to be recorded and circulate through mail RIG CH- 2 (KCM-003): 1. Industrial Hygiene Survey (Noise level survey, Illumination survey,Vibration measurement, Air quality measurement,) to be carried outat regular interval and recorded properly. 2. Risk Register and record of Job Safety analysis to be maintained. 3. Gas Testing Record to be maintained at well site. 4. SRV & Pressure Vessel Testing to be carried out as per OISD recommendations and records with charts to be maintained. 5. More persons to attend MVT, First Aid and Fire Fighting training. Training Matrix to be maintained. 6. Exposed Cable in tray to be covered. 7. More nos. of Nearmiss incidents to be recorded and circulate through mail. 8. Tool Box talk should be conducted in every shift. 9. PME should be new format for all crew personnel RIG CH-5(NHK#405): 1. Industrial Hygiene Survey (Noise level survey, Illumination survey,Vibration measurement, Air quality measurement,) to be carried outat regular interval and recorded properly. 2. Risk Register and Record of Job Safety analysis to be maintained. 3. More persons to attend MVT, First Aid. Training matrix to be maintained 4. MSDS should be displayed in bigger format near Chemical Loading point. 5. Kill manifold should be replaced. 6. Earthing points should be covered by sand bags. 7. Cable tray should be laid over electrical flexible lines. 8. Daily gas testing reports are to be recorded. 9. PME should be new format for all crew personnel 10. More nos. of Nearmiss incidents to be recorded and circulate through mail


RIG CH-6 (Barekuri#7): 1. Industrial Hygiene Survey (Noise level survey, Illumination survey,Vibration measurement, Air quality measurement, PME) to be carried out at regular interval and recorded properly. 2. Risk Register and record of Job Safety analysis to be maintained. 3. More persons to attend MVT& First Aid. Training matrix to be maintained 4. BOP function & SRV test records should be available at site. 5. PME should be new format for all crew personnel 6. More nos. of Nearmiss incidents to be recorded and circulate through mail RIG RG-B: 1. Industrial Hygiene Survey (Noise level survey, Illumination survey,Vibration measurement, Air quality measurement, PME) to be carried out at regular interval and recorded properly. 2. Risk Register and record of Job Safety analysis to be maintained. 3. Gas Testing Record to be maintained at well site. 4. More persons to attend MVT, First Aid and Fire Fighting training. Training Record to be maintained and updated properly. 5. More nos. of Nearmiss incidents to be recorded and circulate through mail RIG RG-D(Makum#044): 1 .Industrial Hygiene Survey (Noise level survey, Illumination survey, Vibration measurement, Air quality measurement,) to be carried out at regular interval and recorded properly. 2. Risk Register and Record of Job Safety analysis to be maintained. 3. More persons to attend MVT, First Aid and Fire Fighting training. Training Record to be maintained and updated properly. 4. Fire trailer Pump along with suitable capacity Fire Tank should be incorporated with the Outfit to meet any emergency situation. 5. Bleed line of well servicing pump to be properly grouted. 6. Toilet covering bamboo wall should be replaced with suitable materials. 7. More nos. of Nearmiss incidents to be recorded and circulate through mail RIG RG-E: (NHK#462) 1. Industrial Hygiene Survey (Noise level survey, Illumination survey,Vibration measurement, Air quality measurement,) to be carried outat regular interval and recorded properly. 2. Risk Register and Record of Job Safety analysis to be maintained. 3. Gas Testing Record to be maintained at well site.


4. More persons to attend MVT, First Aid and Fire Fighting training. Training Matrix to be maintained. 5. Fire trailer Pump along with 50KL capacity Fire Tank should be incorporated with the Outfit to meet any emergency situation. 6. Record of Pit Level Safety meeting to be maintained at well site. 7. Record of Nearmiss incidents to be maintained and circulate through mail. 8. Record of Hot Work and Cold Work permit to be maintained in separately. 9. General House keeping and plinth condition to be improved. 10. More nos. of Nearmiss incidents to be recorded and circulate through mail RIG RG-C: NHK#438 : 1. Industrial Hygiene Survey (Noise level survey, Illumination survey,Vibration measurement, PME) to be carried out at regular interval and recorded properly. 2. SRV & Pressure Vessel Testing to be carried out as per OISD recommendation and records to be maintained properly. 3. More persons to attend MVT, First Aid and Fire Fighting training. Training Record to be maintained and updated properly. 4. General House keeping and plinth condition to be improved. 5. Fire trailer Pump along with suitable capacity Fire Tank should be incorporated with the Outfit to meet any emergency situation. 6. Record of Pit Level Safety meeting to be maintained at well site. 7. Record of Hot Work and Cold Work permit to be maintained properly. 8. Proper Visitor’s Entry Procedure to be introduced. 9. MSDS to be displayed near Chemical Loading point. 10. More nos. of Nearmiss incidents to be recorded and circulate through mail RIG CARDWELL-C: 1. Industrial Hygiene Survey (Noise level survey, Illumination survey,Vibration measurement, PME) to be carried out at regular interval and recorded properly. 2. More persons to attend MVT, First Aid and Fire Fighting training. Training Record to be maintained and updated properly. 3. Fire trailer Pump along with 50 KL capacity Fire Tank should be incorporated with the Outfit to meet any emergency situation. 4. Record of Job Safety analysis to be maintained. 5. Gas Testing Record to be updated. 6. Engine Inspection Report to be maintained properly. 7. Leakages in Engines and Pumps are to be rectified and outfit engine is to be properly lagged. Interconnected rubber hoses o be replaced. 8. General House keeping and plinth condition to be improved. 9. Proper Visitor’s Entry Procedure to be introduced. 10. Fire Alarm to be made available at well site. 11. More nos. of Nearmiss incidents to be recorded and circulate through mail


RIG IR-BHEL–D(NHK#321): 1. Industrial Hygiene Survey (Noise level survey, Illumination survey,Vibration measurement, PME) to be carried out at regular interval and recorded properly. 2. More persons to attend MVT, First Aid and Fire Fighting training. Training Record to be maintained and updated properly. 3. Fire trailer Pump along with suitable capacity Fire Tank should be incorporated with the Outfit to meet any emergency situation. 6. Record of Job Safety analysis to be maintained. 7. Leakages in Engines and Pumps are to be rectified and outfit engine is to be properly lagged. 8. SRV & Pressure Vessel Testing to be carried out as per OISD recommendation and records with charts to be maintained properly. 9. MSDS to be displayed near Chemical Loading point. 10. Proper Visitor’s Entry Procedure to be introduced. 11. Water storage tank skid to be repaired/replaced. 12. More nos. of Nearmiss incidents to be recorded and circulate through mail. RIG KREMCO: (NHK#123) 1. Industrial Hygiene Survey (Noise level survey, Illumination survey, Vibration measurement, PME) to be carried out at regular interval and recorded properly. 2. Fire trailer Pump along with 50 KL capacity Fire Tank should be incorporated with the Outfit to meet any emergency situation. 3. Record of Pit Level Safety meeting to be maintained at well site. 4. Record of Hot Work and Cold Work permit to be maintained properly. 5. General House keeping and plinth condition to be improved. 6. MSDS to be displayed near Chemical Loading point. 7. Proper Visitor’s Entry Procedure to be introduced. 8. SRV & Pressure Vessel Testing to be carried out as per OISD recommendation and records with charts to be maintained properly. 9. More nos. of Nearmiss incidents to be recorded and circulate through mail. RIG IR BHEL-C: 1. Industrial Hygiene Survey (Noise level survey, Illumination survey,Vibration measurement, PME) to be carried out at regular interval and recorded properly. 2. More persons to attend MVT, First Aid and Fire Fighting training. Training Record to be maintained and updated properly. 3. Fire trailer Pump along with suitable capacity Fire Tank should be incorporated with the Outfit to meet any emergency situation. 4. Record of Job Safety analysis to be maintained. 5. Gas Testing Record to be updated. 6. Leakages in Engines and Pumps are to be rectified and outfit engine is to be properly lagged.


7. General House keeping and plinth condition to be improved. 8. Proper Visitor’s Entry Procedure to be introduced. 9. MSDS to be displayed near Chemical Loading point. 10. SRV & Pressure Vessel Testing to be carried out as per OISD recommendation and records to be maintained properly. 11. Record of Pit Level Safety meeting and Tool Box talk to be maintained at well site. 12. Record of Hot Work and Cold Work permit to be maintained properly. 13. More nos. of Nearmiss incidents to be recorded and circulate through mail RIG SKYTOP-B:(NHK#323) : 1. Industrial Hygiene Survey (Noise level survey, Illumination survey, Vibration measurement, PME) to be carried out at regular interval and recorded properly. 2. Fire trailer Pump along with suitable capacity Fire Tank should be incorporated with the Outfit to meet any emergency situation. 3. Record of Job Safety analysis to be maintained properly. 4. Record of Near miss incidents to be maintained and updated properly. 5. Record of Pit Level Safety meeting to be maintained at well site. 6. Leakages in Engines and Pumps are to be rectified and outfit engine is to be properly lagged. 7. General House keeping and plinth condition to be improved. 8. Proper Visitor’s Entry Procedure to be introduced. 9. SRV & Pressure Vessel Testing to be carried out as per OISD recommendation and records to be maintained properly. 10. Staircase is loose needs to be supported properly. 11. Working platform support bolt to be fitted. 12. Air leakage of BOP control unit to be rectified. 13. Emergency kill pump to operative. 14. Battery of the engines to be kept in wooden box. 15. 2” Pump bleed line to be grouted. 16. More nos. of Nearmiss incidents to be recorded and circulate through mail RIG CARDWELL-B (KLN#17) : 1. Industrial Hygiene Survey (Noise level survey, Illumination survey, Vibration measurement, PME) to be carried out at regular interval and recorded properly. 2. Fire trailer Pump along with suitable capacity Fire Tank should be incorporated with the Outfit to meet any emergency situation. 3. Record of Job Safety analysis to be maintained properly. 4. Record of Nearmiss incidents to be maintained and updated properly. 5. Record of Pit Level Safety meeting to be maintained at well site. 6. Leakages in Engines and Pumps are to be rectified and outfit engine is to be properly lagged. 7. General House keeping and plinth condition to be improved. 8. Proper Visitor’s Entry Procedure to be introduced.


9. SRV & Pressure Vessel Testing to be carried out as per OISD recommendation and records to be maintained properly. 10. Form ‘J’ and ‘B’ to be maintained properly. 11. More persons to attend MVT, First Aid and Fire Fighting training. Training Record to be maintained and updated properly. 12. Fire Alarm to be made available at well site. 13. More nos. of Nearmiss incidents to be recorded and circulate through mail 14, Frictional brake twin stopper to be checked properly. RIG RG-A( DKM# 02) : 1. Industrial Hygiene Survey (Noise level survey, Illumination survey,Vibration measurement, PME) to be carried out at regular interval and recorded properly. 2. Pit level meeting to be conducted in every month. 3. Record of Near miss incidents to be maintained and updated properly. 4. Proper Visitor’s Entry Procedure to be introduced. 5. Record of Hot Work and Cold Work permit to be maintained properly. 6. More persons to attend MVT, First Aid and Fire Fighting training. Training Record to be maintained and updated properly. 7. SRV & Pressure Vessel Testing to be carried out as per OISD recommendation and records to be maintained properly. 8. General House keeping and plinth condition to be improved. 9.More nos. of Nearmiss incidents to be recorded and circulate through mail RIG K-600: 1. SRV & Pressure Vessel Testing to be carried out as per OISD recommendation and records to be maintained properly. 2. Record of Hot Work and Cold Work permit to be maintained properly. 3. Industrial Hygiene Survey (Noise level survey, Illumination survey, Vibration measurement, PME) to be carried out at regular interval and recorded properly. 4. More persons to attend MVT, First Aid and Fire Fighting training. Training Record to be maintained and updated properly. 5. More nos. of Nearmiss incidents to be recorded and circulate through mail. 6. Gas detector to be made available and testing record to be maintained at well site. 7. Fire alarm system to be made available. 8. Fire mock drill to be done at regular interval. 9. More persons to attend MVT, First Aid and Fire Fighting training. Training Record to be maintained and updated properly. 10. BOP drill, BOP function test, BOP pressure test to be done and record to be maintained properly. 11. Pit level meeting to be conducted in every month. 12. First aid box to be made available at well side. 13. Fire tank, fire pump connection to be done. 14. More nos. of Nearmiss incidents to be recorded and circulate through mail. 15. Record of Job Safety analysis to be maintained properly.


16. Job Safety Analysis to be filled up in proper format.

RECOMMENDATIONS: MUD PLANTS MUD PLANT 07 1. Effluent pit surrounding wall to be raised or to make a separate pit adjacent to the existing pit. 2. All guards near the mixing tank should be more rigid. 3. Nearmiss incidents should be recorded. KATHALGURI MUD PLANT 1. Concrete post of the shade over solution storage tanks to be repaired 2. Wooden structure of the shades over solution storage tanks should be repaired. 3. Wooden platform should be provided for engine batteries.. 4. Skid of Gas driven pumps needs to be earthed and all electrical fittings within its shade must be of FLP type. 5. More ventilation in chemical godown is recommended. 6. More numbers of Fire Extinguisher should be kept at plant. 7. Sand buckets should be kept for fire fighting. 10. Training for First Aid, Fire Fighting & PME of employees is due. 11. Job Safety Analysis to be carried out. 12. Nearmiss incidents should be recorded. SHANTI MUD PLANT 1. Concrete post of the shade over solution storage tanks to be repaired 2. Wooden structure of the shades over solution storage tanks should be repaired. 3. All the gunning lines are badly corroded, need to be replaced 4. Suction & delivery lines are rusted; need to be replaced 5. Inlet line and pipe clamps from storage tank to pumps were found to be badly corroded / rusted. Need to be replaced 6. Hoper Platform should be repaired 7. Roof of common salt storage area needs to be extended and repaired to minimize contact with rain water. 8. Stairs / Walkway near the exhaust pipe of Gas driven pump needs to be shifted. 9.Skid of Gas driven pumps needs to be earthed and all electrical fittings within in it’s shed must be of FLP type. 10 Nearmiss incidents should be recorded


RECOMMENDATIONS : OCS GENERAL OBSERVATIONS:

1. Implementation of change management is not properly maintained in most of the installations.

2. Most of the installations were not painted as per schedule due to non availability of paints.

3. Grass cutting in most of the installations was not taken up regularly. 4. Most of the Crude Oil Storage Tanks are not painted in OCSs/Tank Farms as

per schedule. 5. Boundary wall to be constructed in each installation. 6. Scrap disposal as suggested by earlier safety audits were not disposed due to

non availability of contracts. 7. Near miss accident reporting was not available at most of the installations. 8. 240 V Lighting Transformer to be installed in each installation. 9. Intrinsically safe 30 v (max) Remote Start Stop Switch to installed for Remote

Push Button/Remote Control in hazardous areas. 10. NGR to be put in Generator Neutral for detecting earth leakage. 11. Earth Leakage Relay to be put in outgoing feeders. 12. Marking of earth pits with dates and latest records in most of the installations

was not done. 13. Electric siren not available in most of the installations. 14. Foam pouring system not tested in most of the installations. 15. Fire incident records are not available at most of the installations.

OCS-1

1. Oil leakage in ET (one valve) – to be arrested. 2. Leakage in steam lines and valves inside - to be arrested. 3. More safety/statutory Boards to be displayed in the installation. 4. Pressure gauge for LTTU needs to be cleaned. 5. Skid of disposal Pump-2 is heavily corroded – to be maintained properly.

OCS-2

1. Oil spillage in crude oil storage tank area – to be checked. 2. Oil leakage in COD Pump area – to be checked. 3. Leakage in Formation Water Storage Tank – to be arrested. 4. Accident statistic report to be updated properly.


5. Leakage in newly constructed Water Tank for fire fighting – to be repaired. 6. Proper entry for drenching pump house to be constructed.

OCS-4

1. Minor oil leakage in COD Pump Valve. 2. Boundary wall for the installation is to be constructed as per industry

standard. 3. Radar Tank Gauges are not working in both the crude oil storage tanks.

OCS-5

1. Leakage in few steam lines/valves. 2. Oil leakage in valves of crude oil line inside the tank dyke area. 3. FWD Pump leakage. 4. Oil leakage in charging pumps to be arrested. 5. Shed in ET exhaust needs modification for the exhaust lines to come up.

OCS-6

1. Leakage in valves of the main crude oil storage tank. 2. Oil leakage in COD Pumps. 3. Oil spillage in FWD tank area. 4. Boundary wall is required as per industrial standard. 5. Shed to be provided for the newly installed indirect water bath heater.

OCS-8

1. Minor leakage in few valves of crude oil lines in Crude Oil Tank area. 2. Discharge damper to be put in one of the COD Pumps. 3. Oil spillage in COD Pump area. 4. Cable gland of one of the FWD Pumps found to be non-FLP – to be replaced.

Jaipur OCS

1. Adequate safety/statutory Boards to be displayed in the installation. 2. Toolbox meeting/Gas testing records not updated. 3. Batteries to be kept inside safe enclosure in COD Engines. 4. Housekeeping needs proper attention. 5. Fire ring line to be painted as per guidelines. 6. Marking of the piping with flow direction to be taken up. 7. Water disposal pump house to be maintained & cleaned properly.

Ushapur OCS


1. Proper walkway is required in manifold area. 2. Minor oil leakage in valve/ discharge dampener of CODP. 3. Illumination in generator house as well as in recharging pump house needs

improvement.

Jorajan OCS

1. Crude oil leakage inside main Crude Oil Storage Tank Dyke. 2. 4” Gas line leakage near rear gate of the installation. 3. Coupling guard of chemical dosing pumps needs to be fitted. 4. Shed for fitter house inside the installation in shabby condition and needs

repairing. 5. Proper pressure gauges to be vessels of the process area.

Langkashi OCS

1. Oil spillage in Crude Oil Tank Area - to be arrested. 2. Exhaust lines of engines for CODP &Gensets to be properly insulated. 3. Earthing strips in Process area and main storage tank area needs to be

properly laid to avoid any accidents. 4. Earthing Pits to be numbered with latest readings & dates. 5. Earth electrode for ET- 2 to be covered properly. 6. Cable trench for FWDP House to be sand filled. 7. Genset-2: Unused cables to be terminated properly.

Kathalguri OCS

1. Oil Spillage in Crude Oil/Formation Water Tank Area. 2. Gradient in Oil drainage to old oil sump is not proper- needs to be modified. 3. Proper walkways to be made in the process area. 4. Earth pits numbering and readings to be updated. 5. Lighting transformer to be installed. 6. Master separator drain line (2”) valve leakage - to be arrested. 7. Batteries in COD Engine to be placed in a safe enclosure. 8. Individual pressure gauges in operating lines of manifold to be placed.

Nagajan OCS

1. Dyke/bund in crude oil tank and formation tank area to be made as per industry standard.

2. Painting of crude oil disposal tanks and water disposal tanks to be taken up.

3. Exhaust line of Generator 2 to be insulated. 4. Temperature Gauge to be fitted in Indirect Heater. 5. Lighting transformer to be installed. 6. General housekeeping of the installation needs proper attention.


7. Roof for “Main Discharge “ valve needs repairing. 8. Earth Pit numbering and readings to be updated.

Moran# 1 OCS 1. Oil spillage in CODP area. 2. Walkway needs improvement in tank dyke area. 3. Sufficient identification labels to be put in manifold area. 4. Most of the earthing strips are made of GI wires – to be replaced by GI

stripes. 5. Earthings to be provided in ET-1 & ET-2 6. Double earthing to be put in 3 phase separator no. 2 8. Individual Pressure Gauges to be installed in each Manifold Flow Lines 9. Insulation Mat to be put in CODP Motor Panels

Kharsang OCS

1. Leakage in steam lines/valves inside the installation - to be arrested. 2. Proper DGMS approval is not available. 3. House keeping including grass cutting needs improvement. 4. Illumination in sump is not sufficient. 5. Housekeeping of AC feeder room needs to be improved. 6. Lighting transformer to be installed. 7. Catagorization of safety zones to be properly marked 8. Shed to be provided for Mass flowmeter before its commissioning. 9. Separate files to be maintained for testing of PVs and SRVs. 10. Sufficient diagrams and safety boards to be displayed.

Kathaloni OCS

1. Minor oil spillage in CODP house. 2. Pressure gauges to be put in each line of the Manifold. 3. SRV test records to be maintained as per OMR guidelines 4. High mast to be installed and commissioned.

Dikom OCS

1. Oil leakage in Crude Oil Tank Area - to be arrested. 2. Oil leakage in CODP Area - to be arrested. 3. Oil leakage in ET Area – to be arrested. 4. Coupling guard to be provided for FWDP. 5. Few NRVs of manifold are leaking - to be arrested. 6. Shed in mass flowmeter needs to be repaired/replaced. 7. Pressure Transmitter needs to be removed from the present position and put

in the delivery line. 8. Few documents(gas testing/equipment log book/near miss etc) are not

properly recorded and updated 9. Sufficient diagrams and safety boards to be displayed.


Tengakhat OCS

1. Equipment List / Illumination file to be updated. 2. Asbestos part in flarepit boundary wall to be replaced by concrete walls as

per safety standards. 3. Proper tags/identification labels to be put in manifold area. 4. Crude Oil Storage Tanks to be painted.

Shalmari-1 OCS

1. Oil leakage in Crude Oil Tank Area - to be arrested. 2. Oil leakage in CODP Area - to be arrested. 3. Discharge Dampener in CODP#1 to be installed. 4. Pit Level Meeting/ Accident Report to be maintained as per safety standards. 5. Gas Tester to be calibrated. 6. Flow improver dosing system near main tank area is not proper and safe -

needs improvement. 7. Storm water drain of Main storage tank area to be repaired for proper

drainage. 8. Coupling guards of Formation water disposal pumps to be provided. 9. Double Earthing to be provided for the ET and separators.

Shalmari-2 OCS

1. Separate documents to be maintained for Shalmari#1 and Shalmari#2 OCS 2. Crude Oil Tank leakage through bolts - to be arrested. 3. Indirect Heater to be properly insulated. 4. GI Wires used for earth connections - to be replaced by GI Strip 5. Lighting Transformer Neutral connection found temporary. 6. Water sprinklers of Crude Oil Tank#5 not working properly 7. Housekeeping of FWDP House found very poor, needs to be improved. 8. Housekeeping in Boiler area is very poor, tarpaulins used as shed for the

boilers, needs improvement as per requirements of safety standards. 9. Sufficient Display/safety boards to be updated and placed in the installation.

Makum OCS 1. Oil spillage in Crude Oil Tank Area – to be arrested. 2. Oil spillage/leakage in ET Area – to be arrested. 3. Oil spillage/leakage in CODP House - to be arrested. 4. Oil spillage/leakage in FWDP House - to be arrested. 5. Housekeeping needs improvement. 6. Batteries of COD engines to be kept in safe enclosure. 7. Water spillage in Indirect heater - to be arrested.


8. Cable trench in Genset House to be sand filled Hapjan OCS

1. Minor oil spillage in COD Pump house & ET - to be arrested. 2. Crank shaft end of one of the COD Pumps needs to be properly guarded. 3. Spark arrestor in one of the COD Engines to be provided. 4. Insulating mats for some electrical panels are in poor condition - to be

replaced by the proper mats. 5. Approach way in ET needs to be repaired. 6. Equipment log book to be properly maintained and updated.

Bhogpara OCS

1. Walkway in group vessel area near the nalluah to be repaired. 2. Piping and flow diagram needs to be displayed 3. Batteries for engine of drenching pump to be kept in safe enclosure. 4. Separate file to be maintained for equipments installed. 5. Spark arrestors in one CODP engine to be provided. 6. Cable trench of LT room to be properly sand filled.


RECOMMENDATIONS : EPS

Deroi EPS

1. Earthling to be provided in ET 2. Flow diagram to be displayed. 3. Site Plan/layout of installation to be displayed. 4. HSE Policy/Vision Statement to be displayed. 5. Hazardous Area classification/electrical single diagram to be displayed.

Bhagjan EPS

1. Oil spillage/leakage in Crude Oil Tank Area and bowser loading pumps to be arrested.

2. Spark arrestor to be installed in exhaust line of one of the bowser loading pumps.

3. Cable trench in main feeder room to be sand filled 4. Controller gauge for Indirect heater controller needs to be checked and

calibrated, if required. 5. Insulating mats for Generator House electrical panels needs replacement

Kumchai EPS

1. Fire Wall to be provided in CODP-3. 2. Earth pits’ numbering and readings to be updated . 3. Sludge in the main tank area to be cleaned.

Bhekulajan EPS

1. Oil/sludge accumulated below crude oil tanks - needs to be cleaned. 2. Oil spillage in ET - to be checked. 3. Housekeeping needs improvement. 4. Two numbers of earth pits were found uncovered. 5. Electrode wise earth resistance records to be maintained in addition to

combined resistance. 6. Proper demarcation to be made for the Bio remediation area. 7. Shed for CODP house to be repaired.

Hatiali EPS

1. Oil spillage/leakage in Crude Oil Tank Area - to be arrested. 2. Sufficient display/safety boards to be placed inside the installation. 3. Gate of flare pit needs to be placed as per safety requirement.


4. Painting of installation piping, vessels, tanks, equipment ,etc needs to be taken up. 5. Coupling guard to be provided in one generator. 6. Foundation/Skid for Chemical dosing pumps found improper - to be checked and repaired. 7. Discharge Dampener to be fitted in one CODP.

Chabua EPS

1. Minor oil spillage in CODP House - to be arrested. 2. Painting of installation piping, vessels, tanks, equipment ,etc needs to be

taken up. 3. One inlet line of crude oil was found vibrating - to be properly

anchored/grouted. 4. Leakage in fire monitors - to be arrested. 5. General housekeeping needs improvement. 6. Sufficient display/safety boards to be placed inside the installation.

DIAN EPS

1. Large accumulation of spilled Crude Oil below Crude Oil Tanks – to be cleaned. 2. One line in Bowser Loading Point found leaking – to be checked and repaired. 3. Flare Pit Wall should be made as per Safety Standard. 4. Fire Water Monitor appears to be very close to Storage Tank – to be relocated as per Safety Standard. 5. Entire Area needs proper leveling & hardening 6. Individual Pressure Gauges to be installed in Manifold Flow Lines. 7. Painting of piping, vessels, tanks, valves etc. of the installation to be taken up. 8. Sufficient Safety Boards to be displayed.

Kuchijan EPS

1. Leakage in CODP House - to be arrested. 2. Batteries of COD engine to be kept in safe enclosure. 3. Sufficient boards for diagrams/safety signboards to be displayed. 4. Gas testing records to be maintained and updated. 5. Single line diagram to be displayed. 6. Boundary wall for the installation is required as per industry standard.


RECOMMENDATIONS : QPS

Barekuri QPS

1. Oil spillage/leakage in Crude Oil Storage Tank Area- to be arrested /cleaned. 2. Oil spillage/leakage in COD Pump area- to be arrested /cleaned. 3. Oil spillage/leakage in booster Pump area- to be arrested /cleaned. 4. Coupling guard to be provided for the flow improver dosing pumps. 5. Sufficient display/safety boards to be placed inside the installation. 6. Boundary Wall is required as per industry standard. 7. General housekeeping needs major improvement.

NKF QPS

1. None of the crude oil storage tanks covers were found in place making it extremely hazardous.

2. Breather valves are to be put in storage tanks. 3. Heavy Oil spillage in CODP pump house - to be arrested and cleaned. 4. Exhaust pipe of CODP pumps to be properly insulated. 5. Proper manifold with identification labels to be made in the installation. 6. Most of the earthling strips found missing and are temporarily fixed with GI

wires – to be replaced with GI Strips. 7. Leakage in valves and flange of steam lines to be stopped. 8. Two stage separator controller gauge not working. 9. Boundary wall for the installation is required as per industry standard. 10. Skid of two stage separator to be leveled properly.

HJC QPS

1. Boundary Wall to be constructed as per industry standard. 2. Installation Area needs leveling& hardening. 3. Gear Box Cover in one CODP to be provided. 4. Cable trench in Genset House to be sand filled. 5. Shed to be provided over CFS of Genset House.

Balijan QPS

1. Flow diagram/fire contingency plan not displayed. 2. Sufficient display/safety boards to be placed inside the installation. 3. General housekeeping of the installation needs improvement. 4. Earthling pits to be numbered with date of testing and readings. 5. Proper identification labels to be put in manifold area. 6. Fire extinguishers to be put in proper place.


RECOMMENDATIONS: GAS COLLECTING STATION

General Points:

1. General Housekeeping in the installations needs improvement.

2. All lines in the process (KOV) area are to be painted as per colour

code and flow directions to be marked.

3. Valve nos. to be marked as per fire contingency plan.

4. Condensate vapour drains line of glycol Re-boiler unit to be directed

upwards with suitable liquid storage facility wherever applicable.

5. Oil spillage over skid of compressors needs to be periodically

cleaned.

6. Modalities should be formed to make fire water line charged within

shortest possible time from OCSs after fire siren.

7. No. of near miss records in the installations are found to be Nil.

People needs to be encouraged for more and more near miss

incident reports.

8. Portable air compressors battery should be placed in wooden box.

9. Pit level safety meeting records to be maintained in prescribed

format issued by S&E dept.

GCS-1

1. Protective guards over moving parts( Flywheel & belt drives ) of Gas

Compressor

2. Cable trench in air compressor shed should be covered with sand.

3. Condensate vapour drain line of Glycol re-boiler located across the

walkway is required to be lifted/diverted to avoid head injury.

4. Suitable access to be made for the fire water monitor located near old

operator room so that the monitor can be operated in all direction without

any obstruction.

5. Periodic noise level record to be maintained.

6. Rubber mat to be placed near electrical panel of Gas compressor.

GCS-2

1. Equipment not in use/operation should be marked.

2. Fire hydrant line of GCS -2 of old and new shed is not found in charged

condition. (Since June’2013 as per record). Necessary action to be taken to

make water for firefighting, available, in the installation at the earliest.

3. A Fire Safety audit is recommended for the installation.


4. Valve leakage found in 1500 PSI Knock out vessel (KOV) to be rectified.

5. Rubber mat to be provided in front of Glycol pump starting panel.

6. Rubber mat to be provided in front of methanol pump starting panel.

7. Testing record of overhead crane of old shed to be maintained.

GCS4

1. SCADA communication tower earth pits to be maintained and Earth

resistance value should be marked on it.

2. Glycol Reboiler exhausts to be insulated.

3. Assembly point to be marked.

GCS-5

1. Unused pipe lines and valves should be removed.

2. Assembly point should be in a safe area.

3. Approach footpath with platform to be made for fire water monitor and TPC

points.

GCS-6

1. Suitable walkways over drain & pipe are required to be made to approach

the pit pump.

2. Glycol reboiler exhaust pipe to be insulated.

3. Glycols vapour drain line located across walkway to be lifted to avoid head

injury.

4. A handle on fire water monitor and a suitable platform is required to be

provided to operate the monitor near air compressor house.

5. Protective guard to be provided over moving parts of water pump located

inside air compressor house.

6. Illumination of the old air compressor shed to be improved.

GCS-7

1. Rubber mat to be provided near electrical panel in air compressor shed.

2. Risk register and Contingency plan to be signed.

3. Periodic Noise level record should be maintained.

4. Mock fire drill conducted during inspection, it was found that fire water monitor

jet did not reach the knock out vessel (KOV) area.

GCS-8


1. Protective Guard to be provided over moving parts (Flywheel & belt

drives) of Gas compressor and over coupling of methanol pump.

2. Rubber mat in front of electrical panel of LPB-3, GL-1 and GL-3 to

be provided.

3. Fire assembly point to be marked.

4. Rubber mat to be provided in front of electrical panel of air

compressor shed.

5. Delivery line from Glycol reboiler to be insulated.

6. Glycol reboiler pilot solenoid valve cable glanding to be done.

7. Rubber mat in front of Glycol reboiler burner control panel.

8. Crude oil spillage found in drain near the vessel area to be cleaned.


DIKOM GCS

1. Knock out Vessel (KOV) area floor mattressing to be done.

2. Guard over moving parts of the methanol pump to be provided.

3. Guards are to be provided over belt drives of the air compressors.

4. Exhuast pipe of the air compressors are to be insulated.

5. Statutory signboard should be updated and displayed properly.

Kathaloni GCS

1. DGMS Approval to be updated for the newly installed Gas compressors.

2. Railing to be provided for all walk over platform inside process area

wherever applicable.

3. Earth resistance values are to be marked on the earth pits.

4. Illumination level to be checked in the Gas compressor shed and necessary

action to be taken.

Langkashi GCS

1. Designated scrap yard to be made for the installation.

2. Fire water monitors to be maintained. Two more fire water monitors are to

be provided on the back side of the Gas compressor shed.

3. SRV Testing records are to be signed by Installation Manger.

4. Competent persons list should be made available in the installation.

5. Height of the Walk over platform near 30 Psi knock out vessel (KOV) area to

be increased to avoid head injury while walking on it.

6. Tool Box Talk should be conducted in the installation.


Kathalguri GCS

1. Guards should be provided over moving parts in the Gas compressor

package.

2. Guards should be provided over moving parts of air compressors.

3. Rubber mat should be provided in front air compressor starting panels.

4. Rubber mat should be provided in front of electrical starting panel of

Methanol pump.

5. 30 Psi Knock Out vessel KOV) drain line leakage to be stopped

immediately and necessary modification as required to be carried out.

6. Safety Relieve valves (SRV) of all the vessels are to be maintained

properly.

7. Exhaust pipe of Glycol Reboiler to be provided with necessary thermal

insulation.

8. CGI Roof of Glycol reboiler shed to be repaired.

9. Remote Ignition system to be provided for Glycol reboiler.

10. Number of Fire water monitor in the new GCS Shed is inadequate.

Shalmari GCS

1. Rubber mat to be provided in front instrument panel in air compressor shed.

2. Approach footpath to the entrance of Electrical Genset shed to be made.

3. Rubber mat to be provided in front of Genset starting panel.

4. Glycol reboiler level transmitter stand located just in front of the glycol pump

starting panel should be shifted.

5. Glycol reboiler shed CGI Roof to be covered to avoid rainfall into the

electronic remote ignition control system.

6. A significant amount of lube oil found in the water drain surrounding the

installation. Lube oil spillage to the water drain to be cleaned and further

drainage of lube oil in to the drain to be stopped.

Joypur GCS

1. Walkways near 250 PSI KOV to be concretized.

2. Earth resistance to be marked on the earth pit.

3. Exhaust pipe of Gas Lifter Compressor No:2(GL-2) to be provide with

Thermal insulation .

4. During the Mock fire drill, it was observed that the fire water monitor jet

does not reach to the Knock out Vessel area. Present system is not

adequate to control any fire incident in the Knock out vessel area.


Nagajan GCS

1. Protective guard to be provided over coupling of water pump located inside air

compressor house.

2. Rubber mat to be provided in front of methanol pump starting panel.

3. Illumination in the methanol pump shed needs improvement.

4. Rotating parts of the Cooler heat exchanger of GL-1 should be covered.

5. Suitable walk over to be made for easy access to the valves in the process

(KOV) area.

6. Fire water line with adequate no of water monitors and TPC point to be made

operable in the installation on urgent basis.

7. Glycol Reboiler Exhaust to be insulated.


9. Illumination of the installation needs improvement.

GCS Ushapur

1. Platform located near Engine of GL-2 has uneven stairs. The platform

should be replaced with a suitable one.

2. Water leakage from the corroded and broken portion of Cooler heat

exchanger of GL-3 to be rectified.

3. Fire water monitor is required near vessel area.

4. Rubber mat should be placed in front of Glycol reboiler pump starting

panel.

5. Delivery line from Glycol reboiler to be insulated.

6. Suitable platform to be made to operate the fire water monitor located

on the Road side near old SCADA RTU Room.

7. Approach footpath/walkover to be made for the pit pump.

8. Gaurd to be provided over coupling/moving parts of pit pump.

9. Protective guard to be provided over rotating belt drives of water

pump.

Jorajan GCS

1. Glycol Re-boiler should be provided with remote ignition facility.

2. Unused equipment should be marked/removed.

3. Rubber mat to be provided in front of electrical panel.

4. Protective guard to be provided over moving parts of Gas Compressors

(LPB-3, LPB-4,GL-2,GL-3 and GL- 4 ).

5. Poor illumination found in air compressor shed.

6. Approach to Methanol pump shed to be made.


7. The hazard associated with the communication tower adjacent to knock

out vessel area to be assessed and necessary maintenance of the tower

along with Guy ropes to be carried out. The feasibility of shifting the tower

to a safe area may be looked into.

8. One no of Fire water monitor is required near Knock out vessel area.

Digboi GCS

1. All Statutory sign boards are to be re-painted. The sign boards of identical

size should be placed in one side so that the view of the Gas compressor

area from the operator room is not obstructed.

2. Air receiver area floor mattressing to avoid fall injury due to slippage.

3. Unused equipment in the air compressor shed should be marked/shifted.

4. Rubber mat should be provided in front of air compressor starting panel.

5. Earth resistance values are to be marked on the earth pits.

6. Suitable Concrete boundary wall around the GCS should be constructed.

Hapjan GCS

1. Guard to be provided over moving parts of cooling water motor located in air

compressor shed.

2. Protective gaurds to be provided over moving parts (belt drives) of Gas

compressor package.

3. SRV testing records should be marked on all vessels.

4. Earth resistance value should be marked on the earth pits.

5. Scrap materials should be kept in scrap yard.

6. Fire safety audit to be conducted to assess the firefighting arrangement for

the installation

7. DGMS Approval for the installation to be updated for the newly installed Gas

Compressors.

8. Remote Shut down system should be maintained in operable condition.

Moran Central GCS

1. Equipment not in operation/not in use should be marked/shifted.

2. SRV testing records should be marked on air receiver vessel of portable

air compressor.

3. Scrap yard to be demarcated in the installation.

4. Protective guards should be provided over moving parts of Gas

Compressor.

5. A Fire Safety audit to be conducted to assess the adequacy of firefighting

system of the installation.


6. Relays of HT & LT breakers of the Electrical Substation to be periodically

calibrated and calibration records to be maintained.

7. Electrical cable drain of Electrical panel in side air Compressor shed to be

covered with sand.

8. Lighting switch (GCS Shed Light-2) located on the back side of the dry

transformer should be shifted.

RECOMMENDATIONS : FIELD GAS GATHERING STATIONS / WELL HEAD

SETUPS

HatialiFGGS(GW 263),

1. Scrap yard to be made for keeping scrap materials.

2. One Sign board containing installation name to be displayed at the main

entrance.

3. Sign boards present inside the installation to be updated and properly

painted.

4. Heater separator unit for Well 284 & 484 should be equipped with Remote

ignition system.

5. Earth resistance value should be marked on the Earth pits.

6. The walk over platform found near separator vessel (KOV) has irregular

steps. The Step’s design is not uniform and poorly fabricated and hence may

cause fall injury to persons walking over this platform. Hence it is

recommended to remove this walk over platform immediately and a suitable

walk over should be made in its place.

7. All Safety Relief Valve (SRV) date of testing to be updated.

8. One Fuel condensate drain line from HSU for SKT 02 found going directly

into the grass area. A concrete sump/designated pit to be made for collection

of condensate coming out from the unit.

9. Rubber mat to be placed in front of the electrical panel house. Electrical

panel house should be properly clean and maintained.

10. Guard on the moving part of the methanol pump to be provided.

11. Commissioning of fire water ring and fire monitors job should be completed

at the earliest.

Kathalguri FGGS

1. Tool box Talk to be conducted in the installation on regular basis.

2. Competent persons list should be available in the installation

3. Separate Files/Registers are to be maintained for Risk Register, MVT

records, Noise Level measurement record, Earth resistance Record and

Gas testing records


4. Signed copy of Fire Contingency Plan to be available in the installation.

5. Exhaust pipes of all the indirect heaters are to be provided with necessary

thermal insulation up to a height of 3m.

6. Approach road to be made for two nos. of existing fire water monitors

located on the back side of NEEPCO Delivery lines.

7. Rubber mat should be provided in front of Electrical panel. Cable drain in

the electrical panel shed should be filled with sand.

8. One Fire Assembly point to be made in the installation.

Kushijan FGGS

1. Pressure gauge glass of incoming line of indirect heater No-1(Kushijan-8)

found broken. Glass to be replaced.

2. Valve gland leakage and seepage of condensate found near the bypass valve

of AGC Lean Gas line. Bypass valve to be rectified/replaced as required.

3. The potential hazard associated with Guyed SCADA Communication tower

very inside the Vessel area to be assessed and corrective safety measures as

necessary to be taken. The feasibility of shifting the tower to a safe area with

self-supported tower may be looked into.

4. Condensate dispatch pump guard to be provided.

GW-285, IM

1. Emergency Telephone number’s Signboard to be displayed.

2. Rubber mat to be provided in front of electrical panel.

3. Earth pit should be made for Deep tube well submersible pump.

4. IM should ensure that Bowser truck is connected with two earthing during

loading.

5. Guyed Communication tower located very near to the vessel area found

without earthing connection. The hazard associated with the

communication tower to be looked into and feasibility for shifting the tower

to a safe area to be assessed.

6. Well Numbers should be marked in the Manifold area.

7. Water storage facility/tanks for firefighting should be made available in the

installation on urgent basis.

8. Process Flow diagram should be updated.

9. Noise level and periodic gas testing records to be maintained.

10. Illumination level of the installation needs improvement.

11. Protective guard to be provided over moving parts of Methanol pump.


LPG Off take Point

1. Fire water ring with adequate numbers of fire water monitors and TPC to

be installed at the earliest.

2. Foam pouring system is required for firefighting.

3. Liquid drain sump (pit) to be covered.

4. Risk register to be made for the installation

5. Date of commissioning to be inscribed in the display board.

6. Rubber mat to be provided in front electrical switch board panel in the

operator room.

RECOMMENDATIONS : WATER INJECTION

WELL#254 WATER INJECTION PLANT :

1. Overall painting of units and piping required. 2. Scrap materials to be disposed of for better housekeeping. 3. Sufficient Sand bucket required to be installed for fire fighting. 4. Electrical earth resistance pit to be maintained properly. 5. Works permit and Mock fire drill report to be maintained. 6. Fan belt guard required to be installed for all the engines.

WELL NO. # 21

1. Unit no.4 damaged platform skid to be repair/change. 2. Fan belt guard required to be installed for all the engines. 3. Fire contingency plan to be maintains. 4. More safety signboard to be display. 5. Painting of units, pipings and SRVs to be done with proper colour

codes. 6. Housekeeping needs to improved.

WELL#240

1. Scrap materials to be disposed of for better housekeeping. 2. Painting of units, pipings and SRVs to be done with proper colour codes 3. Sufficient Sand bucket required for fire fighting.. 4. Illumination level to be improved. 5. Form E to be maintained. 6. Mock fire drill record and work permit file to be maintained properly. 7. Fan belt guard required to be installed for all the engines.


GCS 6 WATER INJECTION PLANT :

1. Painting required for all the Units, sign boards andpipings. 2. Form E to be maintained. 3. Fire Contingency plan, Risk register and Near miss Accident Report to be

maintained in proper format. 4. Earth Resistance pit to be maintained properly. 5. Present Pump shed support & trust condition has deteriorated. The same has

to be dismantled and build new shed . 6. Overall housekeeping needs to be improved. 7. Fan belt guard required to be installed for all the engines.

WELL # 208

1. Form E and SRV testing record to be maintained. 2. Illumination around operator room area to be improved 3. Unit no.1 SRV to be paint in red colour. 4. Units no. 5 & 6 SRV outlet line to be directed towards a safe direction. 5. Mock fire drill and Pit level meeting file to be maintained in proper format. 6. Fan belt guard required to be installed for all the engines.

SHALMARI WATER INJECTION PLANT :

1. Noise level report to be updated. 2. Form J and Near miss accident report to be maintained properly. 3. Sufficient Sand bucket required to be put on the stand. 4. Electrical earthing required for all the Gas engine units. 5. Fan belt guard required to be installed in all Gas engine units. 6. Anchoring of Well no.-3 water injection line to be done. 7. Illumination level to be improved at the Installation. 8. Mock fire drill to be conducted and record to be maintained. 9. Painting of units, pipings and SRVs to be done with proper colour codes.

JORAJAN WATER INJECTION :

• Electrical earthing required for all the Gas Generating set units. • Fan belt guard required to be installed in all Gen sets. • Form J to be maintained properly. • Electrical insulating rubber mat required for high voltage power panel. • Mock fire drill to be conducted and record to be maintained. • Sufficient Sand bucket required to be put on the stand. LANKASHI WATER INJECTION PLANT :

1. Installation manager name to be updated. 2. Units no.2 & 3 SRV outlet line to be directed towards a safe direction. 3. Fan belt guard required to be installed in all Gas engine units. 4. Painting of units, pipings and SRVs to be done with proper colour codes.


5. Electrical earthing required for all the Gas engine units. 6. Damage electrical Insulating rubber mat needs to be replaced. 7. Form J to be maintained properly. 8. Mock fire drill to be conducted and record to be maintained. 9. Sufficient Sand bucket required to be put on the stand.

MORAN WATER INJECTION PLANT :

• Direction of the Safety Relief valve(SRV) outlet line in final 10” delivery line to directed towards a safe direction.

• Sufficient sand bucket to be procured for the stand. • Electrical earth pit Resistance to be maintained below 5 Ohms. • Form E to be maintained properly. • Unit No.1 SRV outlet to be directed towards a safe direction. • Fan belt guard required to be installed for all the engines. RECOMMENDATIONS :BOWSER UNLOADING STATION

DIGBOI BUS :

• Mock fire drill to be conducted regularly. • Bund to be installed for the tanks no. 3,4& 5. • Railing to be put around the oil- water sump for safety of human & animals. • Proper Walkway should be installed through the JV tank farm. • Fire fighting facility with proper water hydrant, water tanks and pump needs to

be commissioned. • Pigeon box to be installed at the BUS. • Earth pits around the unloading bed needs to be properly maintained.

DIKOM BUS :

• 02 nos. nozzles of fire Water hydrant needs to be replaced. • All signboards required to be repainted. • Fire Contingency plan to be maintained at the Installation. • DGMS approval letter to be display near the main gate. • Pigeon Box to be installed at BUS main gate. • Illumination level needs to be improved. • Sufficient Sand bucket required to be installed. • Charging pump pressure Relief valve outlet line to be directed towards a safe direction. • The tank bund steam outlet point to be diverted to safe direction.


CBUS DULIAJAN :

• Sump pump to be installed to minimize the deposition of crude in sump. • Earth filling required near the pump shed area to avoid collection of spilled over crude. • Fire Contingency Plan to be maintained. • Installation Layout diagram signboard to be installed near the entrance. • Electrical Earth pits needs to be maintained properly. • Fan belt guard needs to be put in all DG units. • SRV output direction of unit No.3 to be directed in a safe direction. • Pigeon Box required for the Installation.

RECOMMENDATIONS : BOILER BATTERY

1. Remote ignition system may be introduced for main burners of the

boiler batteries.

BB # 1 DULIAJAN :

1. Proper operator room required.

2. Trimming of tree branches to be done over Boiler shed.

3. Boiler battery shed to be repaired.

4. Damage rubber mat of electrical panel to be replaced.

5. Fire Contingency Plan File to maintained.

BB # 3 DULIAJAN :

1. 2 Nos. long shutdown boilers to be remove for better housekeeping.

2. Proper labelling in electrical switches for motors are required.

3. Fire Contingency Plan to be made.

BB#4 :

1. Damage Floor to be repaired.

2. Trimming of tree branches over Boiler shed.

3. Long shutdown Boiler to be removed for better housekeeping.

4. Fire Contingency Plan file needs to be maintained.

BB#5 :

1. Leakage from OCS static water tank no.2 needs to be repaired for better

house keeping.

2. Form E and Earth pit record to be maintained properly.

3. Railing required at Loco Boilers for safety of operators.

4. Main entrance gate of BB#5 to be manned by security.


BB # 515 (Digboi):

1. Wooden part of shed structure to be replace by steel structure.

2. Tool box meeting to be recorded in proper format.

3. Damage Insulating rubber mats to bereplaced by new ones for electric panels.

BB # 713 (DIGBOI) :

1.0 Lightning arrestors to be installed at the chimneys of the boilers.

2.0 Tool box meeting record to be maintained in a proper format.

BB MORAN :

• Old power control room inside the Boiler shed to be dismantled. • Approach path to stream line valve needs to improve. • Remove the scrap boiler for better housekeeping. • Demarcation of working area of individual Boilers with proper colour code. • Risk register and Record of Job safety analysis needs to be maintained properly. • General housekeeping to be improved.

RECOMMENDATIONS: FIRE SERVICE

KHARSANG FIRE SERVICE :

• Extension of Fire Tender shed and additional 01 no. fire tender to be procured. • Lightning arrester to be installed in the fire station.

MORAN FIRE SERVICE :

• Hose drying tower needs renovation. • New helmets to be procured. • Unused materials lying inside the fire tender shed premise to removed for free movement of equipments and personnel. • Pit level meeting to be conducted monthly. • Repainting of the old safety signboards and new ones needs to be installed.

DULIAJAN FIRE SERVICE :

• Fire Officers & Staffs to go through well fire control trainings. • Ladder of the Hose Drying tower needs to be replaced. • Electrical Insulation mat is required for high voltage power panel.


• Form E to be maintained. • Repairing of the fire tender shed floor and demarcation of the fire tender

parking area to be done. • Repainting of the old safety signboards and new ones needs to be

installed.

RECOMMENDATIONS : LABORATORY

Moran Chemical Lab

1. All domestic switch sockets should be replaced with industrial type.

2. Documentations should be improved.

3. Risk Register and Job Safety analysis reports to be maintained.

4. Fire Contingency plan should be maintained.

5. Domestic type 5A and 15A switch socket found in the Labs dealing with

volatile materials to be replaced with 5A and 15A Industrial grade

switch as per the convenience of the department.

R & D Lab

1. Form B, J, O, K and G are to be maintained.

2. Nearmiss Records to be maintained.

3. Rubber mat to be placed in front of electrical panels.

4. Illumination and ventilation facility in all the labs to be assessed and

necessary action should be taken.

5. No Ventilation is found in the Lab No: 9 (Mass Spectrometry Lab). None of

the three windows ACs were found in working condition.

6. Smoke detectors to be installed in all the laboratories.

7. One Domestic Refrigerator (Old and worn out condition) found in the Lab

No: 10(Oil Field Chemical Lab) should be replaced with Industrial

Refrigerator specific to Laboratory use.


volatile materials and sensitive equipments to be replaced with 5A and

15A Industrial grade switch as per the convenience of the department.

9. Shifting of Hydrogen and Nitrogen Cylinder to be looked into as these

cylinders are kept in closed room attached to the labs.

Chemical Labs, Duliajan,

1. Necessary Statutory records to be maintained.


2. Shifting of LPG Cylinder kept inside enclosed air conditioned room of

Analytical Lab to a safer area may be looked in to.

3. Earth pit located on the back side of Analytical Lab to be maintained.

4. Proper illumination required on the back side of Routine Oil analysis

Lab.

5. Space constraint for free movement of operating personnel observed

inside Analytical Lab, Routine oil analysis Lab, Oil special & Gas Lab

and PVT lab.


volatile materials and sensitive equipments to be replaced with 5A and

15A Industrial grade switch as per the convenience of the department.

7. Shifting of Hydrogen and Nitrogen Cylinder to be looked into as these

cylinders are kept in closed room attached to the labs.

RECOMMENDATIONS : MUD PLANTS

MUD PLANT 07 1. Effluent pit surrounding wall to be raised or to make a separate pit adjacent to the existing pit. 2. All guards near the mixing tank should be more rigid. 3. Nearmiss incidents should be recorded. KATHALGURI MUD PLANT 1. Concrete post of the shade over solution storage tanks to be repaired 2. Wooden structure of the shades over solution storage tanks should be repaired. 3. Wooden platform should be provided for engine batteries.. 4. Skid of Gas driven pumps needs to be earthed and all electrical fittings within its shade must be of FLP type. 5. More ventilation in chemical godown is recommended. 6. More numbers of Fire Extinguisher should be kept at plant. 7. Sand buckets should be kept for fire fighting. 10. Training for First Aid, Fire Fighting & PME of employees is due. 11. Job Safety Analysis to be carried out. 12. Nearmiss incidents should be recorded. SHANTI MUD PLANT 1. Concrete post of the shade over solution storage tanks to be repaired 2. Wooden structure of the shades over solution storage tanks should be repaired. 3. All the gunning lines are badly corroded, need to be replaced 4. Suction & delivery lines are rusted; need to be replaced 5. Inlet line and pipe clamps from storage tank to pumps were found to be badly corroded / rusted. Need to be replaced


6. Hoper Platform should be repaired 7. Roof of common salt storage area needs to be extended and repaired to minimize contact with rain water. 8. Stairs / Walkway near the exhaust pipe of Gas driven pump needs to be shifted. 9.Skid of Gas driven pumps needs to be earthed and all electrical fittings within in it’s shed must be of FLP type. 10 Nearmiss incidents should be recorded

RECOMMENDATIONS: CATEGORY-I WORKSHOPS

General Workshop

1. PPE should be used while working in the workshop.

2. Machine specific SOP should be displayed.

3. Site specific SOP of Pneumatic Hammar should be displayed.

4. Emergency Telephone numbers should be displayed in all the shops.

5. Scrap Yard should be marked with signboard.

6. Risk Register and Contingency plan should be maintained.

7. Illumination inside central Workshop needs improvement.

Transport Workshop

1. Electrical switch socket in battery charger room should be of flameproof

industrial type.

2. Proper guard to be provided for the light fittings inside of Ramp in Crane

Shop.

3. Rubber mat to be provided in front of all Electrical panel/switch board where

ever required.

4. Illumination level in Transport workshop needs to be improved.

5. Fire hose with nozzle is required for fire hydrant connection in the Transport

Workshop.

ICE Workshop

1. Electrical switch socket in battery charger room should be of flameproof

industrial type.

2. Bay area demarcation is required.

3. Mock fire drill should be carried out on regular basis.

4. Risk Register and Fire Contingency plan should be maintained.

5. Fire hose with nozzle should be provided for fire hydrant connection.


Electrical Workshop

1. Name of Installation manager to be displayed in the installation.

2. Toolbox record should be maintained in a separate register/File.

3. Mock fire drill should be carried out on regular basis.

4. Suitable barricade to be given around the Transformer (400V) located in the

workshop.

5. Provision for access to the spare parts to be made.

RECOMMENDATIONS: CATEGORY-II WORKSHOPS

Instrumentation Workshop

1. Form B, J, K, O should be maintained in Standard Form.

2. Mock Fire Drill should be regularly carried out.

3. Noise Level and Illumination record should be maintained.

4. Emergency Exit should be marked with signboard.

5. Domestic type 5A and 15A switch socket found in the Labs dealing with sensitive

equipments to be replaced with 5A and 15A Industrial grade switch as per the

convenience of the department.

6. Hydraulic testing record should be maintained for the air compressor Receiver

vessel.

Signboard with Installation Manager’ Name should be displayed in front of the

workshop

IT Workshop

1. All statutory documentation should be improved.

2. Pit level meeting should be carried out regularly.

3. Risk Register and Contingency plan should be maintained.

4. Waste disposal scheme to be made and record to be maintained.

5. Illumination level in the workshop to be improved.

6. SOP should be prepared and kept in the workshop.

Well Logging Workshop

1. Statutory records to be maintained properly.

2. Mock Fire Drill should be regularly carried out.

3. Risk Register and Contigency plan to be maintained.

4. Explosive handling checklist to be prepared and record to be maintained.

5. Electrical Single Line diagram to be displayed.


6. Statutory Training matrix to be prepared and record to be maintained.

7. Earth resistance to be marked on the earth pit near “Danger Explosive

material”.

8. One Fire hydrant point is required near Well Logging Workshops for TPC

connection.

9. Rubber mat to be provided in front electrical panel wherever required.

FC Workshop

1. All statutory documentation should to be maintained.

2. SOP should be prepared and kept in the workshop.

3. Emergency Exit is required in the first Floor.

4. Rubber mat should be provided in front of all electrical panel/switch board.

5. Scrap material should be kept in the scrap yard.

6. General housing keeping needs improvement.

RECOMMENDATIONS : PROCESS PLANTS

LPG PLANT :

1. Exhaust fan required at battery room. 2. Overhead crane testing to be done yearly and record to be maintained. 3. General painting of pipings, Vessels and Signboards etc. required.

WATER TREATMENT PLANTS RECOMMENDATIONS: Follow up action for the following last year recommendations:

1. Illumination level needs to be checked & improve if require at following

location:- A )Presetler&clariflocculator tank areas.

b) Entrance of the installation 2. Requirement of CCTV cameras needs to be ascertained for critical areas. 3. Online monitoring of raw water needs to be introduced & regular monitoring

needs to be done. 4. Water supply station management & infrastructure modification needs to be

review based upon “Best industrial Water supply management” practices in

India & abroad.


RECOMMENDATIONS : POWER HOUSE

POWER HOUSE, DULIAJAN

DULIAJAN POWER HOUSE:

1. More effort needed for Green Belt development. 1. More safety signboard needs to be display in Turbine hall. 2. Drainage system needs to be reviewed to avoid water logging during rainy

season

MORAN POWER HOUSE:

1. Railing required around the static water tank. 2. Lightning Arrestor to be installed at the turbine chimneys. 3. Scrap materials from battery room to be dispose of for better housekeeping. 4. Hydraulic and SRV testing of Pressure Vessels of gas plant Area to be maintained. 5. Risk register to be maintained.

RECOMMENDATIONS MATERIAL GODOWN

GENERAL RECOMMENDATIONS

1. Emergency light provision required at all godowns. 2. New electrical wiring to be done at all godowns. 3. Auto fire detection alarm system to be installed in all thegodown. 4. Tool box and Pit level meeting to be maintained properly. 5. Auto glow/Fluorescent signal to be provided for Emergency Exit to all

thegodown. 6. Duliajan Godown No.1 and 3 shed area to be expanded for better

housekeeping.

GODOWN NO.3

1. Floor height of newly racks of to be adjusted for safe passage of personnel movement.

2. Tube light position at first floor level to be raised.


GODOWN NO.4

1. Illumination level to be improved at Godown no. 4 (Annex, Chemical Godown).

2. Separate office room for staff required outside the godown. GODOWN NO.6

1. Emergency exit required. 2. Fire extinguishers required.

CONSUMER DEPOT

1. Sand Buckets to be installed for fire fighting. 2. Painting of fire equipments to be done. 3. Fencing of the storage tank to be repaired.

MORAN GODOWNS:

1. Godownno.1 : No smoking signboard. 2. Godown no.2( Drilling Items + Chemicals): 3. 4 Nos. exhaust fan required. 4. Emergency exit sign and Locking system. 5. Godown no. 4(B): Emergency exit required. 6. Godownno.4(A): Emergency exit, Exhaust fan required. No fire extinguisher. 7. Godown (HSD): Smoking sign needs at main entrance gate., License required

for storing HSD.

DIGBOI MATERIALS GODOWN NO. 1 &2 :

• To improve illumination level. • Sand buckets to be installed for fire fighting. • MSDS to be displayed properly. • Electrical insulation rubber mat to be provided in front of Incoming main line switch. • Pit level &Departmental Safety meetings , Tool box meetings to be

conducted regularly and reports to be maintained properly. • More persons to attend MVT, First Aid and Fire fighting training. RECOMMENDATIONS TANK FARM

Tengakhat ITF

1. Crude oil spillage observed in storm water drain inside tank area - to be arrested and cleaned.


2. Dyke wall of tank area to be converted into slope bunds for safe escape of working personnel in any direction in case of any emergency.

3. Bituminous foundation of crude oil tanks to be repaired, so as to make the base plate of tanks free from maintenance jobs in future.

4. CC work to be carried out in tank dyke area. 5. Walkway to be extended upto tank foundations. 6. Pressure Gauges in water disposal pumps to be placed. 7. Shed of ETP house is corroded - needs replacement. 8. More safety posters to be displayed in office area.

Duliajan CTF

1. Heavy oil spillage found inside dyke area of Tank 5 & 6. 2. Strom water drains inside this tank area filled with crude oil - needs immediate

cleaning. 3. Grass inside fire hydrant pond area to be cleaned. 4. Scrap pipes found lying inside the tank area. 5. Grating inside the oil separator area needs cover up.

Moran Tank Farm 1. Leakage in Charging Pump – to be arrested 2. Near miss Report not available 3. Fencing in ground water tank to be provided. 4. Painting of Tanks to be taken up.

Kharsang Tank Farm

1. Housekeeping needs improvement. 2. Illumination in Bouzer Loading Pump Shed is not sufficient - to be improved. 3. Crude Oil Tanks to be painted. 4. Identification of hazardous area to be made. 5. Separate documentation to be maintained for the Kharsang Tank Farm and

Kharsang OCS.

recommendation internal safety inspection 2013-14 · 2014. 7. 25. · 5. ldo/diesel tank wall...

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