details of additional details sought vide mail dated 18.08.2015 for

Transcription

DETAILS OF ADDITIONAL DETAILS SOUGHT VIDE MAIL DATED 18.08.2015 FOR PROPOSAL NO IA/HR/IND2/27783/2013 (Reference 44th EAC meeting held on 20‐21st July, 2015) INDEX – ADDITIONAL DETAILS  Certified compliance report from the Regional Office, Chandigarh
for implementation of environmental conditions in the existing unit.
 Submit safety audit report of the existing depot.
 Status note on implementation
recommendation on safety.
of
MB
Lal
Committee
 Conduct two weeks air quality monitoring for CO, VOC, methane
and non-methane hydrocarbon etc.
 Details w.r.t. Emergency preparedness plan.
 Photograph of green belt.
 Certified compliance report from the Regional Office,
Chandigarh for implementation of environmental
conditions in the existing unit.
 Submit safety audit report of the existing depot.
OCCUPATIONAL SAFETY AND HEALTH AUDIT
(IS-14489: 1998)
OF
BHARAT PETROLEUM CORPORATION LIMITED
PIYALA INSTALLATION, PIYALA P.O. ASAOTI, TEHSIL
BALLABHGARH, DISTT. FARIDABAD, HARYANA
Ref No. BPCL/PYL/SA-02
MONTH/YEAR-FEBRUARY/2015
PAGE: 1
1.0 INTRODUCTION
Occupational health and safety (OH&S) audit is a systematic, objective, documented
and independent evaluation to determine whether, the activities conform to the
requirements of the occupational health and safety systems and procedures.
The purpose of the OH&S audit is to identify the areas for improvement or corrective
action. The goal of the audit is to provide the auditee with an opportunity to assess its
own OH&S system against an OH&S system standard and identify areas for
improvement; to determine the conformity of the implemented OH&S system with
specified requirements and identify areas for improvement; and to meet regulatory
requirements.
M/s Bharat Petroleum Corporation Ltd., Piyala Installation, Village Piyala P.O. Asaoti,
Tehsil Ballabhgarh District Faridabad, Haryana-121001 sent an enquiry
to carryout
Safety Audit for the year 2015 by M/s Earth Protection Group Environmental
Consultant Pvt. Ltd. The safety audit has been carried out as per the guidelines given
in the “Indian Standard Code of Practice on Occupational Safety and Health Audit
(IS-14489: 1998).
Our auditors adopted a structured process of collecting information on the efficiency,
effectiveness and reliability of the total Safety and Health management system and
drawing up recommendations for corrective action. M/s Earth Protection Group
Environmental Consultant Pvt. Ltd. has exercised all reasonable skills, care and
diligence in carrying out the audit. This report is not deemed to be any undertaking,
warranty or certificate.
2.0 OBJECTIVES
OH&S audits are conducted with the following objectives:

to carry out a systematic, critical appraisal of all potential hazards involving
personnel, plant, services and operation method; and

to ensure that OH&S system fully satisfies the legal requirements and those of
the company’s written safety policies, objectives and program.
(IS-14489: 1998)
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3.0 METHODOLOGY
The methodology of conducting safety audit is as follows:
-
Pre-audit activities
-
Audit-on site activities
-
Post-audit activities
Pre audit activities
The pre-audit session includes the collection of all background information from the
depot on a pre-designed comprehensive questionnaire such as:








Installation Information
Product Information
Process Information
Chemical Handled
Organization Structures.
Off site facilities etc
Accident details of past years with cause analysis
Details of Fire/Explosion/Toxic Releases in past years with cause analysis
Audit on site activities

Understand and evaluate Management System by:
-
Preliminary discussions and interviewing the depot personnel.
-
Examination of the management policy, documents and data, evaluation of
physical conditions and work practices.

Asses strength and weaknesses, Internal Risks And Internal Control Measures

Gather Audit Evidences by way of assessment, verification and sampling

Evaluate audit findings, summarize it, and work-out exceptions and observations

Exit meeting with depot officials
Post audit

Prepare Draft Report, which must include Environmental affairs, Legal affairs
along with the recommendation for each finding.

Outcome of audit surveys is/was discussed with Depot's Management and all
findings were communicated to them.

Issue Final Report

Follow-up
(IS-14489: 1998)
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4.0 SCOPE OF STUDY
The scope of the study is as follows:
1. Hazard identification: Identification of potential hazards which could trigger loss
causing events like fire, explosions, fatalities, work injuries, etc in process,
storage and loading/unloading areas.
2. Prevention of fire and toxicity hazards: Critical examination of all areas and
activities that involve fire and explosion hazards, and submit recommendations
where required, with an objective of minimizing losses.
3. Fire detection and protection arrangements: Providing comments on the
adequacy of existing fire detection and protection arrangements (portable as well
as fixed) in the depot premises and suggest improvements, where required.
4. Emergency preparedness: Assessment on the adequacy of available facilities
like first aid, security fire fighting, communication, etc. in view of effective handling
of the possible emergencies at the installation.
5.0 AUDIT TEAM
The audit team comprising the members from EPGEC as well as installation
representatives, the details is as under:
Name of auditors
Dr. Rajeev Kanaujia
Designation &
Organization
Executive Director, EPGEC
Project
Designation
Chief Auditor
Mr. Mohd Asif
Manager (Projects), EPGEC
Auditor
Mr. Yogesh Chinchole
Dy. Manager (HSSE),BPCL
Signature
Coordinator
6.0 TEAM VISIT
A team comprising of experts of Earth Protection Group Environmental Consultant
Pvt. Ltd. (EPGEC) undertook the visit of the installation during 19th February-2015.
During the visit, the whole installation was inspected and discussions were held with
officers of the installation with a view to address on EPGEC Methodology, work
progress and initial findings.
(IS-14489: 1998)
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7.0 OVER VIEW OF THE SITE
BPCL, Piyala Installation is situated near Village Piyala. It is located in District
Faridabad, Haryana on National Highway-2 (Delhi-Mathura Road) at a distance of
about 2.5 Kms and about 45 Kms. from New Delhi. The main nearby town is
Ballabhgarh.
8.0 INSTALLATION DESCRIPTION
8.1 GENERAL
The Piyala Installation of BPCL was commissioned in the year 2007 and it is
constructed as per the latest OISD norms. The installation is center for collection,
storage and distribution of MS, HSD, SKO, ATF and Ethanol, the product is stored in
floating / fixed roof above ground tanks & cylindrical shaped underground tanks. The
supply of fuels comes mainly through pipeline from Mumbai /Bina refinery.
8.2 MANPOWER AND SHIFT TIMING
The staff strength of the installation comprises of 25 installation personnel including
14 management, 8 non management staff and 03 clerks apart from this 25 Security
Guards, 03 gun man & 01 supervisor. The installation operates in two shifts. The
shift timing is given below:
General Shift: - 0830 to 1700 hrs
I shift: - 0600 to 1400 hrs
II shift:-1400 to 2200 hrs
MMBPL (Night Shift):-1200 am to 0800 hrs
(IS-14489: 1998)
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8.3 RAW MATERIAL, PRODUCTS AND BY-PRODUCTS
SN
TANK NO.
PRODUCT
TANK TYPE
ROOF TYPE
CAPACITY
1.
TK-1
MS
AG
Floating
26750
2.
TK-2
MS
AG
Floating
26750
3.
TK-3
MS
AG
Floating
26750
4.
TK-4
MS
AG
Floating
26750
5.
TK-5
HSD
AG
Floating
15600
6.
TK6
HSD
AG
Floating
15600
7.
TK-7
HSD
AG
Floating
15600
8.
TK-8
HSD/MS
AG
Floating
15600
9.
TK-9
SKO
AG
Floating
8200
10.
TK-10
SKO
AG
Floating
8200
11.
TK-11
MS Slop
AG
Fixed
858
12.
TK-12
HSD Slop
AG
Fixed
858
13.
TK-13
HSD
AG
Fixed
858
14.
TK-14
ATF
AG
Fixed
9000
15.
TK-15
ATF
AG
Fixed
9000
16.
TK-16
ATF
AG
Fixed
9000
17.
TK-17
ATF
AG
Fixed
9000
18.
TK-18
HSD
AG
Fixed
858
19.
TK-19
MS
AG
Fixed
858
20.
UT-1
MS
UG
NA
200
21.
UT-2
MS
UG
NA
200
22.
UT-3
HSD
UG
NA
200
23.
UT-4
SKO
UG
NA
200
24.
UT-5
MS/ETHANOL
UG
NA
200
25.
UT-6
HSD
UG
NA
15
26.
UT-7
HSD
UG
NA
15
27.
UT-8
SLOP
UG
NA
20
28.
UT-9
SLOP
UG
NA
20
29.
UT-10
SLOPATF
UG
NA
20
30.
UT-11
SLOP ATF
UG
NA
20
(IS-14489: 1998)
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8.4 MANUFACTURING PROCESS
The Operations and activities carried out at BPCL Piyala Installation mainly involve
collection, storage and distribution of fuel(s) from the Supply Sources to the Catered
Region.
8.5.1 Tank Lorry Unloading
Installation rarely receive product in TL from other locations. However facility is in
place for unloading tank lorry. It is done by gravity. Following procedure to be
followed:
1. TL for unloading is to be parked on the bay no. 1.
2. Earthing clamp to be fixed on unpainted surface of TL.
3. Front and rear tyres are to be secured by putting wooden wedge.
4. Master switch to be put off for disconnecting electric supply from the battery to
the rest of tank lorry.
5. TL to be parked in neutral gear.
6. Fire extinguishers to be kept in front of the tank lorry.
7. Invoice should be shown to the gantry officer before unloading.
8. After checking temperature/density of the product and tallying with invoice, proper
hose to be connected to appropriate sump for unloading.
9. After unloading, TL to be checked for emptiness by the officer.
8.5.2 Tank Lorry Loading
Installation having facility for loading MSII, MSIII, HSDII, HSDIII, SKO, SPEEDII,
SPEEDIII, HISPEEDII and HISPEEDIII. Installation are loading average 80- 100 TLs
daily.
1. Park the TL on the allotted bay.
2. TL crew has to follow all safety norms as listed above.
3. Start loading by punching card.
4. Gantry officer shall check and punch his card to allow TL to move out.
5. Operation shall lock it and punch his card. It will lift electric barrier and allow TL to
move out of the gantry area.
6. Pumps shall be operated automatically.
(IS-14489: 1998)
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8.5.3 Loading of Rake
Installation can load complete rake comprises of 50 BTPN wagons at a time.
Installation having adequate pumping facility to load rake within free time. Following
procedure to be followed:
1. Security shall inform about the placement of rake to the concern officer.
2. Lines from the tank to be prepared for loading wagons.
3. All wagons are to be checked for emptiness.
4. Top and bottom valves are to be closed.
5. Proper loading arm to be put in the filling pipe of wagon and bonding clip to be
fixed.
6. All wagons are to be located as per loading sheet and checked.
7. Release memo to be sent after the loading is completed.
8.5.4 Unloading of sick wagon
Whenever TXR staff of railway failed to repair loaded wagon for leakage, product is
required to be unloaded. Installation having facility to unload sick wagon. Discharge
pipe of sick wagon is to be connected to appropriate sump. It is to be unloaded in the
same tank using pump in the sick wagon pump house. Installation having one pump
for each product.
8.5.5 Storage of Bulk Product
Installation storing MS, HSD & SKO in above and under ground tanks. Detail of tanks
are given as above. Quantity of product in the tanks is measured by taking dips. Dips
are taken before and after the operation. Weekly dips are taken for monitoring.
Quality of product is monitored by taking samples once in a month. It is called as
monthly monitoring samples.
8.5.6 Receipt through MMBPL pipe line
Installation receive MSII, MSIII, HSDII, HSDIII & SKO through cross country pipeline.
Quantity monitoring to be done daily operating tanks and once in week of idle tanks.
Quality monitoring to be done by taking monthly monitoring samples and sending it to
lab for testing. Receipt operation is supervised and controlled by MMBPL.
(IS-14489: 1998)
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9.0 ELEMENTS OF OCCUPATIONAL SAFETY AND HEALTH (OS&H) SYSTEM
COVERED IN THE AUDIT
AREAS COVERED
The Safety Audit of M/s Bharat Petroleum Corporation Ltd., Piyala Intallation,
Ballabhgarh, Faridabad as mentioned earlier is being carried out as per the guide
notes mentioned in IS-14489-1998 The areas of Occupation Safety and Health
System covered in this audit are as follows:
1. Occupational Health and Safety Policy
2. OS&H Organizational set up
3. Safety related education and training
4. Employees participation in OS&H Management
5. Motivational and promotional measures for OS & H
6. Safety manual and rules
7. Compliance of the statutory requirements
8. New equipment review/inspection
9. Accident reporting, analysis, investigation and implementation of recommendations
10. Risk assessment including hazard identification
11. Safety inspections
12. Health and safety improvement plan / target
13. First aid facilities
14. Personal protective equipment
15. Good house keeping
16. Machine and general area guarding
17. Materials handling equipment
18. Electrical and personal safeguarding
19. Ventilation, illumination and noise
20. Work environment monitoring system
21. Prevention of occupational diseases including periodic medical examination
22. Safe operating procedure/system
23. Work permit system
24. Fire prevention, protection and fighting system
25. Emergency preparedness plans
26. Process/depot modification procedure
27. Transportation of hazardous substances
28. Hazardous waste treatment and disposal
29. Safety in storage and warehousing
30. Contractor safety system
31. Safety for customers.
(IS-14489: 1998)
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10. 0 OBSERVATIONS
10.1 OCCUPATIONAL HEALTH AND SAFETY POLICY

As per the legal requirement of section 7-A (3) and 41-B (2) of Factories Act 1948
(as amended to date). Installation has a corporate written Health, Safety and
Environment policy. The copy of corporate safety policy is enclosed as Annexure1.

The policy has been prepared as per the guideline of the statuary requirement
and also documented in Hindi.

The Policy is signed by Executive Director.

The Corporate Policy was declared in 2003-04 and after commissioned of the
installation Policy was adopted in 2007.

All the workers known the policy, it is also displayed in various conspicuous
places to ensure that policy is well drawn and known to all employees.
10.2 SAFETY AND HEALTH ORGANIZATION
10.2.1 Safety Department:
The BPCL, Piyala Installation has no separate Safety Department, but the
responsibility is currently with an Officer, details as given below:
Name
: Shri Yogesh Chinchole
Designation
: Dy. Manager (HSSE)/Safety Officer under Factories Act
Qualification
: B.E. (Mechanical) & Advance Diploma in Industrial Safety (ADIS)
Experience
: 12 Years

Safety officer is assisted by security personnel.

The
Safety
officer
reports
to
Installation
In-Charge
functionally
and
administratively.

Safety officer retained to latest technique of safety management through
attending training programmes and seminars.

Safety officer has not been given any additional responsibilities, which are
inconsistent with or detrimental to the performance of his duties.

At the time of any emergency, safety officer have the power to shut down the
installation operation.
(IS-14489: 1998)
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10.2.2 Safety Committee (s)

The installation has a Safety Committee under chairmanship of Installation Incharge. Safety Committees meeting are held once in every three months. The
details of Safety Committee are as under:
Management Representative:
1. Mr. Anil Srivastava
Chairman
2. Mr. Sunil Kamble
Member
3. Mr. Hirender Singh Negi
Member
4. Mr. Yogesh Chinchole
Member
5. Mr. Amber Zaidi
Member
6. Ms. Siva Parvathi
Member
Worker Representative
1. Mr. Ved Prakash
Member
2. Mr. Manoj Kumar Singh
Member
3. Mr. Bhrigunath Mahto
Member
4. Mr. Swaminath Mahto
Member
5. Mr. Pralhad Singh
Member
6. Mr. Surinder Singh Tewatiya
Member

The tenure of safety committee is one year.

Safety Committees meeting held once in every three months. The minutes of last
safety committee meeting is enclosed as Annexure-2.

The management representatives of Safety Committee are selected by
nominations and the workers nominate worker representatives.

At meeting overall assessment is being done and various problems as per the
requirement are discussed in the meeting such as prevailing unsafe condition
and practices, analysis of accident reported in the proceeding months, review of
the points of the last meeting and any safety related problems and preventive and
remedial measures for improving standard of safety.

The recommendations of the Safety Committee meeting are implemented
through the respective concerned officer. The progress is discussed in the next
meeting and checked in the daily round.
(IS-14489: 1998)
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
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The minutes of the safety committee meetings are circulated among the
members of the committee and also displayed on notice board.

The safety committee members are apprised of the latest development through
discussion in safety committee meeting and through attending training programs.
10.2.3 Safety Budget

The annual safety budget of the installation is Rs. 6.7 Lacs, 90% of the total
safety budget has been utilized till date.

This safety budget is adequate and the pattern of the expenditure of safety
budget is in increasing trend.

The safety budget used for the maintenance of the fire fighting facilities, PPEs,
Safety Activities and training.

This budget get reflected in the annual report of the company.
10.3 SAFETY RELATED EDUCATION AND TRAINING

BPCL has no provision for separate training department at installation level. The
training department in BPCL exists at regional level.

The employees working in these companies are given thorough training at the
time of recruitment and induction. In respect to induction of new and transferred
employees there is a clear formal procedure. The new entrants are given
exposure to well set safety department at Noida for training regarding safety
features.

All permanent employees have been trained in safety and health in the last five
years. Each employee has to go for refresher-training course at BPCL’s own
safety training department.

The training schedule includes constant training on the job and participation in
exercise particularly for fire/spillage control and special conditions under which
the product is stored and handled.

The training programs are imparted both in English as well as in Hindi.

The management is also conducting in-plant training for Security Personnel,
Contractor Workmen and Tank Truck Crew and record is maintained.

The senior management personnel get safety training by attending training
programme, seminars, conferences etc.
(IS-14489: 1998)
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
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Safety slogan board, instruction boards about the possible dangers and
properties of the hazardous material will be displayed in the installation.

The training calendar at corporate level is available in the installation.

The installation management has the provision of visit of the institutions/
organizations for safety training purposes.
10.4 EMPLOYEES PARTICIPATION IN OS&H MANAGEMENT

The management has involved the participation of employees in installation
Safety Committee.
10.5 MOTIVATIONAL AND PROMOTIONAL MEASURES FOR OS&H

Installation has a safety suggestion scheme, in which any one can give our
suggestion in written form to safety officer in any working days or drop it in safety
suggestion box.

Installation has not participated in National Award/ Suggestion Scheme.

The safety contest such as slogan & poster competition, quizzes organize by the
installation for the motivations of the employees.

The literature on safety and health is available for the employees. Installation
publicized safety and health in installation through Bulletin boards, Posters, wall
writing etc.

Installation subscribed Operation & Safety bulletin, which is published every
month.

Installation celebrated Safety day on 4th March 2014. On this occasion installation
management organizes safety quizzes, essay, fire drill ,awareness training
programs etc.
10.6 SAFETY MANUALS AND RULES

The BPCL Management has a “Comprehensive Safety Manual”, which is
prepared for all BPCL installations.
(IS-14489: 1998)
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10.7 COMPLIANCE WITH STATUTORY REQUIREMENT
The management was found committed to comply with all statutory requirements as
per the respective Acts and Rules made there under of the concerned authorities. A
brief assessment report of the same is as under:
SN
1.
Details of inspections
Statutory
requirements
Haryana
Factories
Status in Installation
of Factory License valid up to 2016
Rules-
1952.
Copy of application for the renewal is enclosed as Annexure-3
2.
Statutory
requirements
of License to import and store petroleum in
Petroleum & Explosives Safety installation valid up to 31/12/2015
Organization (PESO)
Copy of license from explosive department is enclosed as Annexure -4.
3.
Statutory
requirements
Haryana
State
of Air Consent valid up to 31/03/2015
Pollution Water Consent valid up to 31/03/2015
Control Board.
Hazard Authorization valid up to 31/03/2015
Copy Air, Water Consent & Hazardous Authorization is enclosed as Annexure-5
4.
Statutory requirements under Public Liability Insurance Valid up to 31/03/2015
public liability insurance act-
1991
Copy of Public Liability Insurance enclosed as Annexure-6
10.8 NEW EQUIPMENTS REVIEW/INSPECTION

The BPCL management has a tendency of reviewing and inspecting the efficacy
of all new equipment and ensures all safety requirements for any change in the
process, equipment or facility.
10.9 ACCIDENT
REPORTING,
ANALYSIS,
INVESTIGATION
AND
IMPLEMENTATION OF RECOMMENDATIONS

All the accidents resulting in either minor or major injuries which have the
potential of causing human injury and/or property damage are reported and
investigated as per the specified procedures framed based on Haryana Factories

Act and Rules & record is maintained.
All near miss accidents are investigated promptly and recommendations are
given to concerned officer for implementation to prevent recurrence of such
incidents/accidents.
(IS-14489: 1998)
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
PAGE: 14
Accident data of reportable as well as non-reportable for last three years is
available in the Installation. In last three years there was no major accident occur
in the installation in last one year total 17 nos. of near miss accident reported.

The investigation report of accident retained at least five years. The safety officer
maintains accident statistics and data.

Remedial measures, if needed are taken to prevent accidents/incidents in
present & future. Such recommendations and implementations are also
discussed in the Safety Committee meetings and compliance is ensured.
10.10 RISK ASSESSMENT INCLUDING HAZARD IDENTIFICATION

The installation identified the hazards, which may arise in the factory, on the
basis of the chemicals being handled and any deviation in operational conditions.
The assessment of hazards identified, so far, has been assessed quantitatively
and keeping in mind the failure frequencies of respective equipment or
operational conditions.

All possible control measures have been taken by the installation to prevent
these hazards as per the guideline of manufactures concerned authorities.
10.11 SAFETY INSPECTIONS AND MAINTENANCE SCHEDULE
Inspection

The installation has a well-developed inspection schedules as given below:

Daily inspection conducted by Dy. Manager (HSSE) & Installation In-charge.

Yearly inspection conducted by Multi Disciplinary Group (MDG) headed by
Chief Manager HSSE (Retail North) and member of corporate HSSE.

OISD audit conducted once in three year.

Once in a year safety audit conducted by third party.
Testing of pressure /vacuum vessel and storage tanks

There are no major pressure vessels existing in BPCL, Piyala Installation except
Air receiver. Air receiver are provided with pressure gauge and pressure rupture
disc and pressure safety valves, which keep the pressure below the maximum
working pressure.
(IS-14489: 1998)
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
PAGE: 15
All the Factory Rules are followed in operation and maintenance of pressure
vessels.

In addition, respective department and in-plant engineers inspect these. The
internal testing records are maintained in logbook.

Periodical testing is carried out by the competent person for physical inspections,
Safety relief valve test. The test report is enclosed as Annexure-7.

Storage tank is being tested once in five years.
Maintenance schedule

The installation has well-developed inspection and maintenance schedules and
system for all critical equipment viz. pipelines, pumps, generators, safety valves,
house keeping, trips & alarms.

Apart from them the installation management has an operator’s maintenance
guide for the operators to maintain the engines for the satisfactory working
condition. The engine operators also maintain a logbook so that reference can be
made to total engine hours and particulars of engine performance.

Overhauling of machines such as pumps etc. done more or less as per schedule
recommended by the respective vendors or depending upon the requirement of
operations in practice.
10.12 HEALTH AND SAFETY IMPROVEMENT PLAN

The installation has no separate First Aid Center but the facilities of first aid are
available in Administrative Building and the facility of a visiting doctor twice in a
week is available.

03 nos. of vehicle available in the installation, which can be used in case of
emergency. The other medical facilities available from outer agencies are as
follows:
-
BPCL, Piyala Installation has mutual aid with the M/S BPCL LPG Plant, M/s
Avi-Oil, M/s IOCL Lube Blending Unit & M/s Balmer Lawire, M/s Gateway
Rail, M/s.GAIL –Piyala ,GAIL –Chhainsa, NTPC which is adjacent to BPCL,
Piyala Installation has sufficient medical & fire fighting facilities and which
may be utilized/provided on occurrence of any emergency.
-
Sarvoday Hospital, Faridbad is situated at 14 Km. way from the installation,
which can provide adequate first aid facilities in case of emergency.
(IS-14489: 1998)
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10.13 FIRST AID FACILITIES

The installation has provided the necessary first aid facilities throughout the
installation. There is 08 number of first aid boxes available in the installation.

Total 30 nos of trained first aider available in the installation.
10.14 PERSONAL PROTECTIVE EQUIPMENTS (PPES)

The Personal Protective Equipment such as Safety Helmet, Safety Belt,
Gumboot, Hand Gloves used regularly in installation. The availability of PPEs in
the installation is as under:
Sn
Facilities
Quantity
1.
Safety Helmets
Provided to each employee.
2.
Safety Shoes
Provided to each employee
3.
Hand Gloves (Electrical Use)
02 Pairs
4.
Hand Gloves (Cold/Low Temp.)
04 Pairs
5.
Breathing Apparatus (40 Minute)
03 set.
6.
Emergency Escape Set (15 Minute)
02 set.
7.
Fire Proximity Suit
02 nos.
8.
PVC Suit
02 nos.
9.
Flame Proof Torch
04 nos.
10.
Hand Siren with Stand
07 nos.
Petroleum Product Cleanup material
Boom-5”&3” dia 3 m long
06 nos.
Granular Particle
20 kg.
12.
Leak Control Kit
Pillows-12 nos.
13.
Oil Spill Dispersant with back sprayer
40 Liter
14.
Manual Resuscitator
02 nos.
15.
Chemical Splash Proof Goggles
04 nos.
11.
(IS-14489: 1998)
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10.15

PAGE: 17
HOUSE KEEPING
Installation has well-developed drainage system in the installation with pits and
sump.

The sufficient numbers of disposable bins are provided.

Where required dip tray are provided all over the installation.

There are no any working conditions, which make the floor slippery.

The walkways are clearly marked and free from obstructions.

Within installation all roads are made-up of bitumen so no road dust is generated.

For the achievement of installation neat and clean management follow the below
given exercise:
-
Daily round of the Dy. Manager (HSSE) to ensure the good house keeping.
-
Regular washing and cleaning of inter-sectional pathways, staircases etc.
-
Periodic cutting/removal of the vegetation growth in storage area as well as in
the other area.
10.16 MACHINE AND GENERAL AREA GUARDING

As per section 21, 22, 26 of The Factories Act and rules made there under in
respect of safeguarding of dangerous parts of machinery is a measure in accident
prevention, which receives considerable attention. The high severity rate of
accidents caused by dangerous parts of machinery justifies the importance
attached to machine guarding.

While taking the audit round, it was observed that all the moving parts of the
machines and storage area of hazardous chemicals are well guarded/fenced in
the installation.
10.17 ELECTRICAL AND PERSONAL GUARDING

ISI marked rubber mats are provided in front of the electrical panel throughout the
installation.

Wherever necessary flameproof fittings is provided through out the installation as
per the requirement of the statutory authorities.

The audit team marked that the processes and equipment capable of generating
and accumulate static charge have been identified. All such equipment are
properly bounded and earthed.

Electrical earth resistance measurement and continuity tests are carried out
periodically and record is maintained (Annexure-8).
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PAGE: 18
10.18 MATERIALS HANDLING EQUIPMENT
Lifting machines
There is no lifting machine in the installation. Chain Hoist system is used for High
masts -04 nos. and is being tested by competent person as per required frequency.
Mobile equipments and vehicular traffic
Proper road and de-marked place are available for tankers.
10.19 VENTILATION, ILLUMINATION AND NOISE
Ventilation

All the shops are well-ventilated types.

The workers do not feel any discomfort condition of heat and humidity in the shop
floors.

Office, control rooms are provided with effective ventilation system such as
exhaust fan.

No ventilation systems re-circulate the exhaust air in the work areas.
Illumination

All work environments are found adequately illuminated.

Sufficient and suitable lighting, natural or artificial or both have been provided.

All light fittings are periodically checked and cleaned.
Noise

It was observed that the noise level in the generator room is high but no
continuous employment in this area. Other wise there is no objectionable noise
making in the entire installation.
10.20 WORK ENVIRONMENT MONITORING SYSTEM

So far, there has been no work environment monitoring required. however
ambient air, water monitoring system exists and six monthly checking by NABL
approved lab are available.
10.21 PREVENTION OF OCCUPATIONAL DISEASES

Every employee of the Company at the time of recruitment is subjected to preemployment medical examination and is recruited only when he has been
declared medically fit by the competent Medical Authority.
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PAGE: 19
Every employee declared medically fit would conform to the medical fitness
norms in accordance with the rules and standards, as prescribed by the

company.
All health-screening examinations are aimed at evaluation of general as well as
occupational health status of employees. These examinations will include
screening and diagnostic tests as may be deemed necessary from the
occupational exposure point of view. All the employees are encouraged to report
any adverse symptoms immediately to Installation In-charge/safety officer.
10.22 SAFE OPERATING PROCEDURE
Technical aspects

The “Operating Manual” of various equipments installed in the installation is
available.

This manual also highlights safety procedure for installation operation and
maintenance, which highlights need of work permit requirement, training in use of
Personal Protective Equipment, preparation for maintenance work, opening of
malfunctioning equipment, entry into equipment.

The Do’s and don’t were properly displayed at various equipment in both English
as well as in Hindi for proper and safe operation.

All workers engaged in installation operation know the failure consequences of
safe operating procedure.
Access

Where necessary adequate safe access, portable access platforms are provided
all over the installation.

All accesses are regularly inspected. For replacement of portable access plateform is used which is regularly checked and kept in good condition.

Oiling and greasing points are located at safe places not liable to drip into
walkways.

All drain covers are in good condition.
10.23 WORK PERMIT SYSTEM
Online Work Permit system for Hot Work /Cold Work is being used. Electrical work
permit is given manually.
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PAGE: 20
10.24 FIRE FIGHTING ARRANGEMENTS AND FACILITIES

All the fire fighting system and equipment are approved tested and maintained as
per the standard laid down by OISD and CCE, Nagpur. The design and
standards adopted in the fire protection system are as per the OISD standard.

The safety officer maintains the records of all the fire extinguishers and fire
engines are inspected periodically.

The frequency of inspection of fire fighting installation is monthly and record is
maintained on a pre-designed format as per OISD 142

However there is no separate fire department in the installation but every
employee is trained in fire fighting.

All the pipelines, valves and fittings in the installation are colour coded as per
IQCM manual Standards.

The details of fire fighting arrangement is as follows:
SN
FACILITIES
QUANTITY
1.
Double headed hydrants
106 nos.
2.
Single headed hydrants
04 nos.
3.
UL/FM approved water cum Foam monitors
76 nos.
4.
Fixed Type, MEFG
04 nos.
5.
Portable Type, MEFG
04 nos.
6.
Jet Nozzle
60 nos.
7.
Foam Branch Pipe
04 nos.
8.
Fog Nozzle
04 nos.
9.
Universal Nozzle
04 nos.
10.
Water Sprinkler System
On all A/G Tanks
11.
Foam Pourer System
On all A/G Tanks
12.
Curtain nozzles
04 nos.
13.
Hose pipes
160 nos.
14.
HVLR 2000 GPM
04 nos.
15.
HVLR 1000 GPM
02 nos.
16.
Trolley mounted HVLR 2000 GPM
01 no.
17.
Rim seal fire protection system (MS TanK)-WIP
04 nos.
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PAGE: 21
Portable Fire fighting Extinguishers:
SN
FACILITIES
QUANTITY
1.
10 Kg Fire Extinguishers
129 nos.
2.
06 nos.
3.
25 nos.
4.
07 nos.
5.
04 nos.
6.
CO2 Type Fire Extinguishers
66 nos.
Emergency Kit consisting of the following emergency equipments:
S.No.
1
2
3
Item
Fire proximity suit
PVC suit
Leak control kit
Quantity
2 set
2 sets
Consisting of 1 no each of leak arresting
pad, leakage control of external pipes,
internal pipes, large external pipes upto
20 inch, drums / containers leakages,
general purpose leakages, large hole
leakages in storage tanks.
4
Petroleum product cleanup
chemical
Boom(5 inch dia , 3 mtr. Long) : 6 nos.
Boom(3 inch dia , 3 mtr. Long) : 6 nos.
Granular particles to absorb Oil : 20 Kg.
5
Oil spill dispersant (water
based) along with hand held
spray nozzle.
Dispersant :40 litres
Spray Gun with back pack : I set.
6
Non sparking tools
One Set.
7
Breathing apparatus set (40
minute duration)
Emergency escape sets (15
minutes duration)
3 sets
9
Flame proof search light
2 nos.
10
11
Mega phone ex-proof
1 set
7 nos.
12
First aid box
1 no.
13
14
15
16
Manual resuscitator
Folding stretcher
Mechanical tool kit
Cold / low temperature hand
gloves
Electrical rubber hand gloves
Electrical tester
Chemical/oil splash proof
1 no
1 no
1 set
4 Pairs
8
17
18
19
Hand siren with stand
2 Sets
2 pair
1 no
4 nos.
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PAGE: 22
goggles

The installation has sanctioned power available form HSEB is 11 KV, 3 Phase, 50
HZ. 1950 KVA sanctioned load have been provided for distributing power to
different moving machine and lighting etc.

In case of grid power failure from HSEB, the installation has sufficient D.G. sets
with adequate capacity to maintain uninterrupted power supply to all critical
equipments.
10.25 EMERGENCY PREPARREDNESS PLAN (EPP)

Plant has a detailed Emergency Response and Disaster Management Plan
(ERDMP), which is prepared as per guideline given by ‘Petroleum and Natural
Gas Regulatory Board (Codes of Practices for Emergency Response and
Disaster Management Plan (ERDMP) Regulations, 2010.

The fire drill conducted every month and mock drills as per ERDMP are
conducted once in six months and record is maintained.

The Emergency control center is located at a safe place in the control room, away
from hazardous area. All the operations will be directed and co-oridinated from
the Emergency Control Centre.

The emergency team and key personnel have been identified in the existing
ERDMP.

Suitable numbers of adequate protective and rescue equipments are available.

The mode of communication with in the installation is V.H.F. Hand Sets and
intercom telephone. Installation has external P&T line with STD facility and
personnel mobile phone for out side communication.
10.26 PROCESS/INSTALLATION MODIFICATION PROCEDURE

The modification is defined as change in equipment or process, temporary or
permanent, which may affect the safety of the process or integrity of the
installation. The need of such changes/modifications may come out at various
times during the installation life as a need-based change or as a statutory
requirement.

The installation management has a formalized procedure for modification in
process as well as in the installation.
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PAGE: 23
10.27 TRANSPORTATION OF HAZARDOUS SUBSTANCES

Only MS, HSD, SKO, ATF and Ethanol as a hazardous material are transported
at BPCL, Piyala Installation. The mode of transportation is pipeline, road and rail
for out side of installation and with in installation oil is transported by pipelines, all
pipelines of oil with in the installation are above grounded and all the pipelines
follow standard colour code practices.


The frequency of testing of the pipelines is 03 years.
Installation has a separate place (Tank Lorry Parking area) for loaded/Unloaded
Tankers. All Tank Lorry driver carry Transport Emergency Card (TERM CARD)
and Green card. All Tank lorry drivers and cleaners are undergoing training in
handling emergency during transport.
10.28 HAZARDOUS WASTE TREATMENT AND DISPOSAL

Installation has not any source of generation of hazardous waste except the
sludge from the cleaning of the oil storage tanks. Which is disposed off through
the State Pollution Control Board authorized vender.
10.29 SAFETY IN STORAGE AND WARE HOUSING
General/Central store

The storage areas are clearly marked/ defined. Over grounded Pipeline are used
for transportation of oil from storage tank to Tank lorry filling area. The installation
has adequate equipments for material handling. The workers, handling the
material, are acquainted with the hazardous associated with the material. Also,
they are trained in safe procedure of handling the material.
Tank storage and vessel area

The storage facilities available at the installation comprises of 30 tanks in total, of
these 11 are “Under Ground Tanks” (UG Tank) and remaining 19 are “ Above
Ground Tanks” (AG Tank). The Under Ground Tanks are ground buried and
cylindrical shaped while Above Ground Tanks are also cylindrical type. Details of
tanks are given in Para 8.3. All the tanks are on ambient temperature and at
ambient pressure.
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
PAGE: 24
The Tanks have the necessary in built safety devices such as Vent valves,
ROSOV,MOV sprinkler system etc.
10.30 CONTRACTOR SAFETY SYSTEM

Contract workers are involved in installation operations. The contractor workers
are hired for variety of jobs.

The responsibilities of contract labour are as follows:
-
All contractors/sub contractor labour engaged in all kinds of jobs shall adopt
safe and healthy work practices as described by the company from time to
time.
-
The contractors/sub contractors shall be responsible for the safe working and
safety of their employees. They shall designate a person to be responsible for
the safe working and he shall maintain regular liaison with Dy. Manager
(HSSE).
-
The contract labour shall subject to such medical examination as required by
the law and/or by the company.
-
Suitable clauses shall be incorporated in all contracts to ensure safe working
including use of appropriate safety appliances.
10.31 SAFETY FOR CUSTOMERS (INCLUDING MATERIAL SAFETY DATA
SHEET)

The material data sheet of the all-hazardous materials is available in the
installation viz. MS, HSD, SKO & Ethanol.
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PAGE: 25
11.0 RECOMMENDATIONS
1. During round It was observed that outlet valve of tank lorry was dripping during
filling operation. In this regards, management is advised to check the proper
closing of valves of tank lorry before filling operation.
2. Management is advised to display the test & due date of earth pit at each earth
pit.
3. In TLF shed wooden wheel chock was used by the installation. It was observed
that wooden chock was smooth at the bottom surface, which may slip. In this
regard management is advised to replace wooden chock by rubber chock or
make grove (rough) on the bottom of wheel chock.
4. Management is advised to ensure proper continuity of earthing of pipeline
specially on the joints where jumpers are provided.
5. Management should ensure the proper earthing of cable tray installed inside the
dyke area.
6. Management is advised to display the emergency contact number of railway at
railway siding for the stoppage of Delhi-Bombay route in case of emergency.
7. Management is advised to place fire extinguisher near the sample store at railway
siding.
(IS-14489: 1998)
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Annexure
1. Health, Safety & Environment Policy
2. Minutes of Safety Committee Meeting
3. Factory License
4. PESO License
5. Air Consent, Water Consent & Hazard Authorization
6. Public Liability Insurance
7. Pressure Vessel Test Report
8. Earth Test Report
PAGE: 26
 Status note on implementation of MB Lal Committee
recommendation on safety. RECOMMENDATIONS OF M B LAL COMMITTEE - COMPLIANCE
(Note : Sl no. is the serial no. mentioned in the original report
POINT
COMPLIANCE STATUS AT PIYALA
IMMEDIATE
The pad lock on the hammer blind on the Not applicable for Piyala as product being
outlet line should not be removed before received from own multiproduct pipeline.
the tank joint dipping is completed
However receipt SOPs are followed
1
10.2
viii
2
10.2
xi
3
10.2
xiv
4
10.2
xv
5
10.2
xvi
6
10.2
xviii
7
10.2
xix
The company should approach and Yes, system is in vogue.
coordinate with the district authority for
conducting “Off Sites Mock Drills".
8
10.2
xxi
9
10.2
xxii
Any bad practice of HOV being opened first Hammer blind already replaced with double block
before opening of hammer blind should be and bleed valve (DBBV)
done away with and conveyed throughout
the organization.
Control room should be manned on Yes, during operations. Log book being
continuous basis.
maintained.
10
10.2
xxiv
11
10.2
12
10.2
13
10.2
14
10.2
15
10.2
16
10.2
Supervisor should be present to oversee Not applicable for Piyala as product being
the pipeline transfer line up and related received from own multiproduct pipeline.
However receipt SOPs are followed.
operation
Check list for operators for checking safety Yes
system and equipment should be prepared
and check records kept in safe custody
Mock drill whenever conducted should Yes, done with full shut down system activation.
include the full shut down system activation
also
Shift
manning
should
always be Yes, log being maintained
maintained. Only in serious exigencies,
permission can be granted by Terminal
Manager subject to obtaining a reliever
forthwith
The person leaving site should only be
allowed on avalid gate pass issued by the
immediate officer.
The security supervisor at the gate should Yes, Provided
be provided with external telephone. The
supervisor shall be provided with telephone
numbers of all officers.
A board displaying the names, address and Yes, Provided
phone numbers of the emergency contact
points of the company as well as the local
authorities shall be provided there in.
The pipeline transfer should preferably be Pipeline receipt from refinery is 24x7. Adequate
commenced during day light hours
manpower (officers) are deputed in pumping
location and terminals.
xxviii All PPEs required during emergency shall Yes, system in vogue
be located in designated safe areas.
xxxii Regular inspection of pipelines including
thickness survey and pipeline support
systems shall be carried out and records
maintained
xxxiii All terminal operating personnel including
regular contractors and security personnel
should be given safety and fire fighting
training with the help of reputed training
institutes
xxxiv The security staff should be trained as first
responders for fire fighting and rescue
operations along with plant operating
personnel.
xxxv Near miss reporting system should be
immediately implemented.
Yes, system in vogue
Yes
Yes
Yes, system in vogue
xxxvii Manning level in the shift should be Yes
reviewed to have adequate coverage in the
emergencies.
17
10.2
18
10.3
19
10.11
20
10.21
RECOMMENDATIONS OF M B LAL COMMITTEE - COMPLIANCE
POINT
COMPLIANCE STATUS AT PIYALA
xxxviii Vehicles with spark ignition engine should Yes, system in vogue.
not be allowed inside the Installation area
except up to the Administrative Block and
also to ensure continuous manning at the
control room
g
Design, inspection and repair as per latest Yes, Being done for all tanks.
API Codes.
The certifications such as ISO, NSC Being done. Safety audit for 2015 conducted by
awards, Greentech awards, Ministry of consultant M/s Earth Protection Group.
Labour awards etc., are all based on
documentation
submitted
by
the
organizations and not on field verifications
and safety practices. The awards /
recognitions
mesmerize
the
higher
management besides giving wrong signals
about safety management systems leading
to complacencies. It is, therefore,
recommended that time and efforts be
directed towards annual safety audits by
involving non-company experts so as to
have unbiased reports. The companies
should be cautioned to be circumspect
about utilizing agencies and organizations
who claim to be providing expert safety
During the interactions with the site security
personnel the Committee learned of the
exemplary courageous action taken by the
Head of the security of the Terminal, Shri
Sher Singh, who risked his life and made
valiant efforts to save the lives of the two
operators who perished in this accident.
The Committee recommends that the
efforts of Shri Sher Singh be recognized
through appropriate bravery award.
21
POINT
INDUSTRY DECISION
IMMEDIATE
WITHIN 1 - 6 MONTHS
10.2
vi
Main emergency shut down switch Yes.System in vogue. Separate SIL 2 /
which should be located in the 3 standard system being provided for
control room should also activate safety in operation and activation of
ESD in case of emergency.
the MOVs to close.
22
10.2
vii
A
separate
pad
locking Hammer blind already replaced with
arrangement on each of the double block and bleed valve (DBBV)
hammer blinds on the inlet and
outlet lines should be provided so
that they can be independently
locked as required.
23
10.2
ix
If any MOV is observed to be Yes, being done through a well planned
passing, it should be immediately maintenance schedule.
attended and records maintained
24
10.2
xix
A system should exist for Yes, Memorandam has been prepared
informing neighbouring industries and agreed by all nearing industries for
mutual help.
about impending danger
25
10.2
xxv
Personal protective equipment Yes, being complied
such as safety glasses must be
worn while carrying out all
operations
26
10.2
xxxvi
Management of change procedure Yes, OISD standard is being followed.
should
be
immediately
implemented.
27
10.3
e
Dyke should be constructed and All dykes have been made impervious
tested to be leak proof
and tested for leakproof.
28
10.2
x
VHF handsets to be provided to Yes, already provided to the operating
each of the operating crew.
crew as per operations’ need.
29
10.2
xii
Site specific, Standard Operating
Procedures (SOPs should be
prepared which not only give what
the procedures are, but also why
they are needed. These must be
made with the involvement of
procedure users and approved by
Yes, SOPs approved by operation and
safety team were prepared and
displayed in all relevent locations. All
manpower were being trained on
periodic basis for compliance of SOP.
30
POINT
INDUSTRY DECISION
10.2
xiii
Emergency procedures should be Yes, gist of emergency procedures
written and available to all already provided in the form of a
personnel in the installation booklet to all employees. Procedure
outlining the actions to be taken by being provided to visitors also till they
are inside installation. They are breifed
each during a major incident
abiut the dangers inside installation.
31
10.2
xx
The critical operating steps should Yes, SOPs approved by operation and
be displayed on the board near the safety team were prepared and
displayed in all relevent locations.
location where applicable.
32
10.2
xxvi
All other PPEs should be available Yes, maintained
at location and easily identified
33
10.2
xxvii
All PPEs as well as safety Yes, maintained
equipment required for emergency
use such as breathing apparatus,
fire
suit, fire
extinguishers,
monitors and sprinklers should be
regularly tested in presence of
safety officers
and records
maintained.
36
10.3
i
For floating roof tanks, roof drain Existing articulated drain system was
to be of more robust design to replaced with robust (Pivot master) roof
prevent oil coming out when roof drain system.
drain is open for water draining
operation.
37
10.3
j
39
10.4
d
Piping design inside tank dyke Complied
area
should
ensure
easy
accessibility for any operations
inside dyke in the tank farm.
Site specific “Standard Operating Yes, SOPs approved by operation and
Procedure (SOP” to be developed safety team were prepared and
displayed in all relevent locations.
75
10.3
POINT
INDUSTRY DECISION
IMMEDIATE
WITHIN 6 - 12 MONTHS
o
Tank Dyke Valves should be provided with position Yes, all dyke valves were provided with
indicator (open or close in control room and necessary position indicator. Audio visual
hardware and instrumentation should be provided for indicators installed in control room for
this.
effective monitoring. Syatem checked
on periodical basis and log
maintained.
76
10.2
i
Push buttons on the MOV should be brought just Yes, complied
outside the dyke
77
10.2
ii
Push button operation should be modified so that
action required for opening is different than action
required for closing (e.g. pull type and push type.
78
10.2
iii
The push button assembly should be mounted at a
place where it is easily visible to the operator.
79
10.2
iv
Lighting adequacy should be checked so that visibility
is adequately ensured at the push button of MOV &
HOV location
80
10.2
xvii
A dedicated, qualified and experienced officer should 1. Designated Safety Officer with
be designated as ‘Safety Officer’ of the Terminal after engineering degree and adequate
training. He should be given exposure to Hazop, risk experience already posted at location.
assessment, safety audit and upkeep of fire fighting
facilities and conducting safety meetings.
2. He has been be given exposure to
Hazop, risk assessment, safety audit
and upkeep of fire fighting facilities
and conducting safety meetings.
81
10.2
xxx
Medium expansion foam generators shall be provided Yes, Installed in MS dyke. MEFG
to arrest vapour cloud formation from spilled volatile being used for fire fighting at other
places also. Exposure provided to all
hydrocarbons.
employees during fire drill.
82
10.3
n
Wherever PLT transfers take place, to avoid pilferages, Flow meter installed in pipeline.
a Mass Flow Meter with Integrator shall be provided on Complete pipeline is in survillance of
SCADA system
delivery pipelines.
83
10.3
p
The TFMS system should be upgraded and integrated Yes, Location provided with complete
with SAP and provision for recording of all critical automation system. All tanks are
events in SAP as well as TFMS (such as critical valves monitored through Radar gauses and
position, start/stop of pumps, levels in tanks, alarms pumps are controlled automatically.
There is provision / interlocks for hietc..
level / low-level for closing and
opening of the valves / pumps.
84
10.3
q
A CCTV should be installed covering tank farm areas
and other critical areas. The CCTV can nowadays
provided with an alarm to provide warning in case of
deviation from any normal situation. The CCTV
monitoring station should be provided both in the
control room as well as in the Security cabin/office.
86
10.3
l
Thermal Safety Valve (TSV should be provided at the Yes, thermal expansion release line is
operating manifold (outside dyke.
existing inside the dyke wall
CCTV already provided at location and
all strtegic locations are kept under
contineous survellance. The CCTV
monitoring was provided in the control
room as well as in the Security cabin /
in-charge room.
87
10.3
POINT
INDUSTRY DECISION
m
The dyke volume has been revised to 110% of largest Yes, existing standard takes care.
tank in certain international standards. This should be
reviewed by OISD for tank terminals and refinery
tankage.
88
10.4
a
Carry out HAZOP and Quantitative Risk Assessment Yes, Risk Analysis is in vogue. Further
(QRA on large sized installations through well qualified HAZOP / QRA carried out on periodic
basis.
agency and implement recommendations forthwith.
89
10.4
b
The Terminal Managers should be trained in Hazard Yes, system in vogue.
Identification techniques and be familiarized with risk
assessment and risk mitigation methods.
93
10.6
d
Wherever there is a cluster of terminals of different Yes, memorandum have been
companies, an emergency response centre equipped finalsied and signed by the nearing
with advanced fire fighting equipment viz. fire tenders industries.
and trained manpower shall be considered on cost
sharing basis or on outsourcing basis.
94
10.6
e
All terminal operating personnel should be given safety Yes
and simulated fire fighting training based on simulated
modules of live fires in tanks, pipeline manifold and
pumps, process platforms etc., in reputed training
institutes equipped with these facilities. These training
performances should be linked to their KRAs and
promotions. Personnel from security services should
be trained fully for fire fighting and rescue operations
using Personal Protective Equipment.
95
10.8
a
Training for Safety is currently based on OISD 154 for Training is being imparted in line with
all categories. Safety training for operators should be OISD 154.
based on the needs of the operation, the procedures
and why these are needed. Fire training will always be
an important part of his training, which is best provided
by realistic fire fighting exercises in an area designated
for this purpose.
Training should also be given to prevent operational
malpractices such as shortcuts, on safety provision
being bypassed and how they can create
unmanageable risks to life and property. Training
should be based on the needs of the job, and relevant
to the trainee.
96
10.8
b
97
10.8
c
For Supervisors, intimate knowledge of the operator’s
job is essential and this should be ensured. In addition
Leadership Training should be provided on Manpower
management and motivation, and also on
Communication which should enable them to give
t k i Managers,
t ti
t safety
th
t
For Terminal
training
should include
areas like
- Basics of Safety Management System
-The causes and effects of accidents
- Hazard identification
- Risk Assessment and risk mitigation
- Controlling risks and Preventing Accidents
- Emergency preparedness
- Critical Task Analysis
- Crisis Management
POINT
INDUSTRY DECISION
- Importance of trip/alarm and Safety Procedures and
systems
Learnings from case histories
Training activities should include Safety Training for
contract employees since a number of activities have
been outsourced.
For Maximum Accident Hazard sites, MSHIC Rule Yes, Covered in the Risk Analysis thru
requires the preparation Of both on-site and off-site OISD recommended parties.
emergency plans to minimise as far as possible the
consequences of a major incident. The Company
should revise the emergency plans to take into account
scenarios such as vapour cloud explosions (before first
Buncefield and now Jaipur, VCE had not been
considered credible by the sector or Controlling
Authority.and severe multi-tank fires.
98
10.16
106
10.6
h
During all operations even after the general shift a In view of all employees are trained for
dedicated fire fighting team should be present.
fire fighting, dedicated team is not
necessary.
107
10.6
i
There should be a minimum level of manning Always manned by highly professonal
maintained apart from the security personnel for officers.
monitoring the facilities even during non operational
hours.
110 10.3
k)
111 10.2
v)
112 10.2
RECOMMENDATIONS OF M B LAL COMMITTEE - COMPLIANC
POINT
INDUSTRY DECISION
IMMEDIATE
BEYOND 1 YEAR
Adequate lighting in operational areas should be ensured.
Yes, adequate lighting have been
provided in all operation area as
per the lux level required to be
maintaied as guided by OISD 244.
A technical group should study the feasibility of providing a limit switch on Hammer Blind already replaced
the hammer blind with interlocking for MOV operation
with double block and bleed valve
(DBBV)
xxiii) Immediatelythe feature of remote shut off of the MOV from the control room Yes, Complied
should be restored. The cable leading to the control room should be fire safe.
113 10.3 xxxix) Advancements in technology make it possible to automate tanks and Yes, Installation have been
terminals with sophisticated systems both in hardware and software. This provided with robust TAS system
enhances the safety and can greatly reduce possibility of human error by being monitored on contineous
having interlock permissive and recording and measurement of events like basis from control room. Systems
valve opening or closing and measurement of flow rate/level etc. Existing are provided with interlocks to
Terminal managements should review the technology for retro-fitment which nullify the humen errors.
can reduce risk levels
114 10.3
a) Avoid hammer blind as an equipment in the plant design. Only a closed Hammer Blind already replaced
system design should be adopted. It is understood that other OMCs/MNC’s with double block and bleed valve
are already using such designs in their installations. Using a Plug valve or a (DBBV)
Ball Valve in place of the Hammer Blind should be an acceptable option.
115 10.3
b)
The first body valve on the tank should be Remote Operated Shut Off Valve Yes, existing tank body valves
(ROSOV) on the tank nozzle inside the dyke with Remote Operation only (gate) were already replaced with
from outside the dyke as well as from the control room. ROSOV should be ROSOV which are fire safe and fai
fail safe and fire safe. It should have only ‘close’ feature and not ‘open’ and safe. Operation strtegy have been
‘stop’ from control room. However, it should have ‘close’, ‘open’ & ‘stop’ followed as per the guidelene.
operation from the panel located outside the dyke.
Compliance details on M B Lal recommendation at Piyala Terminal
S.No
Facility
Status
1
Fire water Tanks
Water capacity was designed for double contigency
scenario and 1x4600 KL new fire water tank was
constructed in addition to 2x2950 KL existing fire
water tank for increased demand as per the M B Lal
recommendation
2
Fire Hydrant Network
Fire hydrant network was redesigned and provided
with higher dia based on the double contegency
scenario as per the M B Lal recommendation
3
Fire water pump
6x615 KL fire water pumps were installed to take
care 4 hours fire fighting as per the M B Lal
4
Jockey Pump
5
UL Monitors
2x80 KL jockey pumps were installed to keep
hydrant system in pressurised mode as per the M B
Lal recommendation
500 GPM fixed type (05 Nos) and 500 GPM-750 GPM
UL approved water cum foam monitors (68 nos)
were installed as per the M B Lal recommendation
6
CS Valves
7
Butterfly Valve
8
HVLR - 2000 GPM
9
HVLR - 1000 GPM
2x1000 GPM high volume long range monitors were
installed for fire fighting during roof sinking case in
Slop tank farm as per the M B Lal recommendation
10
Trolley mounted 2000 GPM
HVLR
11
Rim seal fire protection
system
One no trolley mounted high volume long range
monitor has been made available at location for fire
fighting during roof sinking case in 'B' class tanks as
per the M B Lal recommendation
Rim Seal fire protection system has been provided in
all MS FR tanks as per the M B Lal recommendation
CI Valves in hydrant lines were replaced with CS
valves as per the M B Lal recommendation
All sprinklers and foam system have been provided
with quick opening valve as per the M B Lal
recommendation
4x2000 GPM high volume long range monitors were
installed for fire fighting during roof sinking case in
MS tank farm as per the M B Lal recommendation
S.No
Facility
12 Robust roof drain system for
floating roof tank
13
14
15
16
17
18
19
20
21
22
23
Status
Existing articulated roof drain system has been
replaced with new robust roof drain system in all FR
tanks as per the M B Lal recommendation
Liquid seal in loating roof tank All existing vapour seals were replaced with liquid
seal as per the M B Lal recommendation
Tank gauging system
Two types of level gause have been provided as per
the guideline. Necessary modification done on tanks
to install the new gauges as per the M B Lal
recommendation
Level switch
Level switches have been provided in all tanks with
interlock to check overflow of tank as per the M B
Lal recommendation
ROSOVs on In / Out of AG
Automatic Remote Operated Shut Off Valves
tanks
(ROSOV) have been provided on In/out nozzles of AG
tank as per M B Lal Recommendation
DBBV
Existing Hammer blind valves have been replaced
with new Double Block and Bleed Valve (DBBV) as
Hydo carbon detectors at
Point type (02 NOS) and Open path type (07 nos )
sensitive location
hydrocaron detectors have been installed in class A
tank farms and pump houses as per M B Lal
Recommendation
Impervious Dyke in tank farm All tank farms are provided with impervious layering
to prevent ingress of hydrocarbon to soil inside dyke
area as per M B Lal Recommendation
Illumination
Adequate lightings have been provided to meet the
minimum lux level in operation area as per M B Lal
Recommendation
Medium Expension Foam
4 nos MEFG have been installed in MS dyke walls as
Generators
per the guideline. Additionally 2 nos of mobile MEFG
has been provided for class B tanks as per the M B
Lal recommendation
Limit switch
Limit switches have been installed in dyke drain and
audio visual annunciation was provided in control
room for the status as per the M B Lal
recommendation
SIL 2 PLC
SIL2 standard PLCs have been provided in control
room for actuation of emergency / safety devices as
S.No
Facility
Status
24 Emergency Shut Down System 12 nos of ESD switches have been provided at
stretegic location to actuate ESD system in case of
any emergency as per the M B Lal recommendation
 Conduct two weeks air quality monitoring for CO,
VOC, methane and non-methane hydrocarbon etc.
Envirotech East Pvt. Limited
An ISO 9001:2008, 14001:2004 & OHSAS:18001:2007 Company
Laboratory Recognised by Ministry of Environment & Forests, Govt. of India
CIN NO : U74210WB1989PTC047403
BengalAmbuja Commercial Complex,
UN-F 13, 1050/1, Survey Park, Kolkata – 700 075
 – 2418 8127/8128/8601; Fax – 2418 8128; email: [email protected],[email protected]
Web :www.envirotecheast.com
AMBIENT AIR QUALITY MONITORING RESULTS
Name of Industry
Address
Sl. No.
1)
2)
3)
4)
Piyala, Hariyana, India.
Date of
Monitoring
27.07.2015
30.07.2015
03.08.2015
06.08.2015
Sl. No.
1)
2)
3)
4)
Date of
Monitoring
27.07.2015
30.07.2015
03.08.2015
06.08.2015
Sl. No.
1)
2)
3)
4)
M/s. Bharat Petroleum Corporation Limited.(POL Terminal)
Date of
Monitoring
27.07.2015
30.07.2015
03.08.2015
06.08.2015
Location: Project Site (A-1)
Non-Methane
Hydrocarbon
Hydrocarbon
(ppm)
(ppm)
0.93
0.15
1.32
0.24
1.19
0.21
1.53
0.31
Location: Kaligaon (A-2)
Non-Methane
Hydrocarbon
Hydrocarbon
(ppm)
(ppm)
0.81
0.13
1.13
0.21
1.01
0.17
1.36
0.25
Location: Ladpur (A-3)
Non-Methane
Hydrocarbon
Hydrocarbon
(ppm)
(ppm)
0.79
0.12
1.09
0.17
1.23
0.19
0.91
0.14
Hydrocarbon
Method of Gas
Measurement Chromatography
CO
(mg/m3)
0.61
0.86
0.56
0.72
CO
(mg/m3)
0.59
0.52
0.63
0.45
CO
(mg/m3)
0.57
0.41
0.56
0.46
Non-Methane
CO
Hydrocarbon
Gas
Non Dispersive Infra
Chromatography Red (NDIR)
For ENVIROTECH EAST (P) LTD.
(Authorized Signatory)
Envirotech East Pvt. Limited
An ISO 9001:2008, 14001:2004 & OHSAS:18001:2007 Company
Laboratory Recognised by Ministry of Environment & Forests, Govt. of India
CIN NO : U74210WB1989PTC047403
BengalAmbuja Commercial Complex,
UN-F 13, 1050/1, Survey Park, Kolkata – 700 075
 – 2418 8127/8128/8601; Fax – 2418 8128; email: [email protected],[email protected]
Web :www.envirotecheast.com
AMBIENT AIR QUALITY MONITORING RESULTS
Name of Industry
Address
Sl. No.
1)
2)
3)
4)
Sl. No.
1)
2)
3)
4)
Sl. No.
1)
2)
3)
4)
M/s. Bharat Petroleum Corporation Limited.(POL Terminal)
Piyala, Hariyana, India.
Location: Brick Kiln Near Asawati (A-4)
Non-Methane
Date of
Hydrocarbon
Hydrocarbon
Monitoring
(ppm)
(ppm)
28.07.2015
0.86
0.16
31.07.2015
0.72
0.13
04.08.2015
0.83
0.15
07.08.2015
1.13
0.19
Date of
Monitoring
28.07.2015
31.07.2015
04.08.2015
07.08.2015
Date of
Monitoring
28.07.2015
31.07.2015
04.08.2015
07.08.2015
Location: Asawati (A-5)
Non-Methane
Hydrocarbon
Hydrocarbon
(ppm)
(ppm)
1.07
0.16
1.30
0.21
1.19
0.18
1.01
0.14
Location: Dhig (A-6)
Non-Methane
Hydrocarbon
Hydrocarbon
(ppm)
(ppm)
0.83
0.12
0.76
0.14
1.04
0.18
0.62
0.11
Hydrocarbon
Method of Gas
Measurement Chromatography
CO
(mg/m3)
0.93
0.59
1.06
0.63
CO
(mg/m3)
0.53
0.62
0.44
0.51
CO
(mg/m3)
0.42
0.58
0.64
0.38
Non-Methane
CO
Hydrocarbon
Gas
Non Dispersive Infra
Chromatography Red (NDIR)
For ENVIROTECH EAST (P) LTD.
(Authorized Signatory)
 Details w.r.t. Emergency preparedness plan.
EMERGENCY RESPONSE AND DISASTER
MANAGEMENT PLAN (ERDMP)
[as per PNGRB Guideline]
OF
M/s BHARAT PETROLEUM CORPORATION LTD.
PIYALA INSTALLATION
PIYALA P.O. ASAOTI, TEHSIL BALLABHGARH,
DISTRICT FARIDABAD (HARYANA)
Prepared under guidance of:
EARTH PROTECTION GROUP
ENVIRONMENTAL CONSULTANT PVT. LTD.
2104, IInd FLOOR, LEKHRAJ DOLLAR, INDIRA NAGAR, LUCKNOW
Telefax: 0522-2347075, 4002009, Mobile: 9839016959
E-mail: [email protected], Website: epgec.com
MONTH/YEAR: February/2014
Ref No.
BPCL/PYL/OSEP
EMERGENCY RESPONSE AND DISASTER MANAGEMENT PLAN
OF
M/s BH ARAT PETROLEUM CORPORATION LTD.
BALLABHGARH, DISTT. FARIDABAD (HARYANA)
MONTH/YEAR: FEBRUARY/2014
REVISION No. 0
PAGE: i
CONTENTS
Particulars
1.0 INTRODUCTION
1.1 Name and Address of the Person Furnishing the Information
1.2 About the Installation
1.3 Manpower and timing of shifts
1.4 Process description
Page no.
01-03
01
01
02
02
02
02
03
03
03
03
2.0 TERMS & DEFINITIONS
04-06
3.0 APPLICABILITY
07-07
4.0 SCOPE AND INTENT
08-08
4.1 Scope of ERDMP
4.2 Intent/Objective
08
08
5.0 CONTENTS OF ERDMP
09-09
6.0 CLASSIFICATION OF EMERGENCIES
10-11
7.0 IMPLEMENTATION SCHEDULE
12-12
8.0 CONSEQUENCES OF DEFAULT OR NON-COMPLIANCE
13-14
9.0 REQUIREMENTS UNDER OTHER STATUTES
15-15
10.0 PRE-EMERGENCY PLANNING
17-30
10.1 Hazard Identification
10.2 Risk Analysis & Risk Assessment
10.3 Causes of Disaster
10.4 Consequences
11.0 EMERGENCY MITIGATION MEASURES
11.1 Basic requirements of ERDMP
11.2 Resource Mobilization
11.3 Incident preventing measures and procedures:
17
20
28
29
31-35
31
32
33
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BPCL/PYL/OSEP
OF
REVISION No. 0
PAGE: 1
1.0 INTRODUCTION
1.1 Name and Address of the Person Furnishing the Information
Sr. Manager I/C
M/S Bharat Petroleum Corporation Ltd.,
Piyala Installation, Village Piyala
P.O. Asaotipur, Tehsil Ballabhgarh
District Faridabad, Haryana-121001
(Signature & Seal of Occupier)
1.2 About the Installation
The Piyala Installation of Bharat Petroleum Corporation Limited was commissioned in the
year 2007 and it is constructed as per the latest OISD norms. The installation is center for
collection, storage and distribution of petroleum products such as MS, HSD, SKO, ATF etc.
the product is stored in floating & fixed roof above ground tanks & cylindrical shaped
underground tanks. The supply of fuels comes mainly through pipeline from Mumbai
refinery. Details of storage facility are as under:
SN
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
Tank No.
TK-2
TK-3
TK-4
TK-5
TK-6
TK-7
TK-8
TK-9
TK-10
TK-11
TK-12
TK-13
UT-1
UT-2
UT-3
UT-4
UT-5
UT-6
UT-7
UT-8
UT-9
Type
FLOATING ROOF
FLOATING ROOF
FLOATING ROOF
FLOATING ROOF
FLOATING ROOF
FLOATING ROOF
FLOATING ROOF
FLOATING ROOF
FLOATING ROOF
FIXED ROOF
FIXED ROOF
FIXED ROOF
NA
NA
NA
NA
NA
NA
NA
NA
NA
Product Name
MS-IV
MS-III
MS-III
HSD-III
HSD-III
HSD-IV
HSD-IV
SKO
SKO
MS Slop
HSD Slop
HSD-IV
MS
MS
HSD
SKO
MS/ETHANOL
HSD
HSD
SLOP
SLOP
TANK TYPE
AG
AG
AG
AG
AG
AG
AG
AG
AG
AG
AG
AG
UG
UG
UG
UG
UG
UG
UG
UG
UG
Capacity (KL)
26750
26750
26750
15600
15600
15600
15600
8200
8200
890
890
890
200
200
200
200
200
15
15
20
20
Ref No.
BPCL/PYL/OSEP
OF
REVISION No. 0
PAGE: 2
1.3 Manpower and timing of shifts
The total manpower will be 26 nos. (Management 13 nos., Non Management 13 nos.), and
security staff is 25 nos.. The Shift Timing is as under:
Shift A
Shift B
Shift C
General Shift
:
:
:
:
06:00 AM – 02:00 PM
02:00 PM – 10:00 PM
10:00 PM – 06:00 AM
09:00 AM – 05:30 PM
1.4 Process description
The Operations and activities carried out at BPCL, Piyala Installation mainly involve
collection, storage and distribution of fuel(s) from the Supply Sources to the Catered Region.
Installation rarely receive product in TL from other locations. However facility is in place for
unloading tank lorry. It is done by gravity. Following procedure to be followed:
1.
2.
3.
4.
5.
6.
7.
8.
9.
TL for unloading is to be parked on the bay no. 1.
Earthing clamp to be fixed on unpainted surface of TL.
Front and rear tyres are to be secured by putting wooden wedge.
Master switch to be put off for disconnecting electric supply from the battery to the rest of
tank lorry.
TL to be parked in neutral gear.
Fire extinguishers to be kept in front of the tank lorry.
Invoice should be shown to the gantry officer before unloading.
After checking temperature/density of the product and tallying with invoice, proper hose
to be connected to appropriate sump for unloading.
After unloading, TL to be checked for emptiness by the officer.
Installation having facility for loading MSII, MSIII, HSDII, HSDIII, SKO, SPEEDII, SPEEDIII,
HISPEEDII and HISPEEDIII. Installation are loading average 50 TLs daily.
1.
2.
3.
4.
5.
Park the TL on the allotted bay.
TL crew has to follow all safety norms as listed above.
Start loading by punching card.
Gantry officer shall check and punch his card to allow TL to move out.
Operation shall lock it and punch his card. It will lift electric barrier and allow TL to move
out of the gantry area.
6. Pumps shall be operated automatically.
Ref No.
BPCL/PYL/OSEP
OF
REVISION No. 0
PAGE: 3
Installation can load complete rake comprises of 48 BTPN wagons at a time. Installation
having adequate pumping facility to load rake within free time. Following procedure to be
followed:
1. Security shall inform about the placement of rake to the concern officer.
2. Lines from the tank to be prepared for loading wagons.
3. All wagons are to be checked for emptiness.
4. Top and bottom valves are to be closed.
5. Proper loading arm to be put in the filling pipe of wagon and bonding clip to be fixed.
6. All wagons are to be located as per loading sheet and checked.
7. Release memo to be sent after the loading is completed.
Whenever TXR staff of railway failed to repair loaded wagon for leakage, product is required
to be unloaded. Installation having facility to unload sick wagon. Discharge pipe of sick
wagon is to be connected to appropriate sump. It is to be unloaded in the same tank using
pump in the sick wagon pump house. Installation having one pump for each product.
Installation storing MS, HSD & SKO in above and underground tanks. Detail of tanks are
given as above. Quantity of product in the tanks is measured by taking dips. Dips are taken
before and after the operation. Weekly dips are taken for monitoring. Quality of product is
monitored by taking samples once in a month. It is called as monthly monitoring samples.
Installation receives MSII, MSIII, HSDII, HSDIII & SKO through cross country pipeline.
Quantity monitoring to be done daily operating tanks and once in week of idle tanks. Quality
monitoring to be done by taking monthly monitoring samples and sending it to lab for testing.
Receipt operation is supervised and controlled by MMBPL.
Ref No.
BPCL/PYL/OSEP
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REVISION No. 0
PAGE: 4
2.0 TERMS & DEFINITIONS
Terms & Definitions in this ERDMP document are same as given in PNGRB Act &
Regulations G.S.R. 39(E). Definitions are reproduced below:
Definitions
(1) In this ERDMP document, unless the context otherwise requires
(a) “Act” means the Petroleum and Natural Gas Regulatory Board Act, 2006;
(b) ‘‘Board” means the Petroleum and Natural Gas Regulatory Board established under
sub-section (1) of section 3 of the Act;
(c) “boiling liquid expanding vapour explosion
pressure vessel containing saturated liquid
atmospheric boiling point and the resulting
superheated liquid which produces a large
large rising fireball due to ignition;
(BLEVE)” means the violent rupture of a
or vapour at a temperature well above its
flash evaporation of a large fraction of the
vapour cloud which burns in the form of a
(d) “chief incident controller” means the person who assumes absolute control of the unit
and determines action necessary to control the emergency;
(e) “codes of practice” means the codes of practice for emergency response and disaster
management plan notified by the Board;
(f) “disaster” means an occurrence of such magnitude as to create a situation in which the
normal patterns of life within an industrial complex are suddenly disrupted and in certain
cases affecting the neighborhood seriously with the result that the people are plunged
into helplessness and suffering and may need food, shelter, clothing, medical attention
protection and other life sustaining requirements;
(g) “disaster management plan“ means a well-coordinated, comprehensive response plan to
contain loss of life, property, environment and provide speedy and effective recovery by
making the most effective use of available resources in case of a disaster;
(h) “emergency” means a situation or scenario which has the potential to cause serious
danger to persons, environment or damage to property and which tends to cause
disruption inside or outside the premises and may require the help of outside resources;
(i)
“emergency response vehicle (ERV)” means a vehicle for handling emergencies having
necessary equipment meant for rescue and relief operations and ERV can be put to use
within installation, outside of installation including road incident;
(j)
“hazard” means an event related to the property of substance or chemicals with a
potential for human injury, damage to property, damage to the environment, or some
combination thereof;
(k) “incident” means an unplanned or unintended or intended event having potential to
cause damage to life, property and environment;
(l)
“ incident record register” means a register containing complete information pertaining
to all incidents covering near miss, and all other incidents leading to Level-I, Level-II
and Level-III emergencies;
Ref No.
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REVISION No. 0
PAGE: 5
(m) “installation” means facilities, namely, gaseous product pipeline, liquid Product pipeline,
hydrocarbons processing installation, oil and natural gas terminals and commercial
storage and transportation, hydrocarbons gas bottling Installations including CNG, city
gas distribution facilities and retail outlets;
(n) “ leak” means release or discharge of a dangerous chemicals or substances or material
into the environment;
(o) “Level-I emergency” means an emergency as defined under sub regulation 6 (a);
(p) “Level-II emergency” means an emergency as defined under sub regulation 6 (b);
(q) “Level-III emergency” means an emergency as defined under sub regulation 6 (c);
(r) “Mutual aid association” means an industrial mutual aid association in which
participating industries as a community shall assist each other in case of emergency.
Mutual aid associations supplement a site’s emergency control plan. Services of
member industries shall be requested only when the emergency threatens to exceed
the capability of otherwise available resources;
(s) "occupier” of an installation means the person who has ultimate control over the affairs
of the installation;
(t) Off-site emergency” means an emergency that takes place in an installation and the
effects of emergency extends beyond the premises or the emergency created due to an
incident, catastrophic incidents, natural calamities, etc. It no longer remains the concern
of the installation management alone but also becomes a concern for the general
public living outside and to deal with such eventualities shall be the responsibilities of
district administration
(u) “Off site emergency plan” means a response plan to control and mitigate the effects of
catastrophic incidents in above ground installation (AGI) or underground installations
(UGI) or road transportation. This plan shall be prepared by the district administration
based on the data provided by the installation(s), to make the most effective use of
combined resources, i.e. internal as well as external to minimize loss of life, property,
environment and to restore facilities at the earliest;
(v) “On site emergency” means an emergency that takes place in an installation and the
effects are confined to the Installation premise’s involving only the people working inside
the Terminals and to deal with such eventualities is the responsibility of the occupier
and is mandatory. It may also require help of outside resources;
(w) “On site emergency plan” means a response plan to contain and minimize the effects
due to emergencies within the installations which have a potential to cause damage to
people and facilities within the installation premises;
(x) “risk” means the chance of a specific undesired event occurring within a specified period
or in specified circumstances and it may be either a frequency or a probability of a
specific undesired event taking place;
(y) “risk analysis” means the identification of undesired events that lead to the
materialization of a hazard, the analysis of the mechanisms by which these undesired
events could occur and, usually, the estimation of the extent, magnitude, and likelihood
of any harmful effects;
Ref No.
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REVISION No. 0
PAGE: 6
(z) “risk assessment” means the quantitative evaluation of the likelihood of undesired
events and the likelihood of harm or damage being caused by them, together with the
value judgments made concerning the significance of the results;
(aa) “Risk management” means the program that embraces all administrative and
operational programs that are designed to reduce the risk of emergencies involving
acutely hazardous materials. Such programs include, but are not limited to, ensuring the
design safety of new and existing equipment, standard operating procedures,
preventive maintenance, operator training, incident investigation procedures, risk
assessment for unit operations, emergency planning, and internal and external
procedures to ensure that these programs are being executed as planned;
(ab)“Site incident controller” means the person who goes to the scene of the emergency and
supervises the actions necessary to overcome the emergency at the site of the incident;
(ac) ‘‘Spill” means an unintended release or discharge of hydrocarbon or any other
dangerous liquid into the environment;
(ad) “transport emergency (TREM) card” means a card containing details about the nature
of hazards, protective devices, telephone numbers and actions related to spillage, fire,
first aid and other details of national and international (UN) numbers or signage which is
common in India and abroad;
(ae) “ unconfined vapour cloud explosion (UVCE)” means the formation of vapour cloud due
to release of significant quantity of liquefied hydrocarbons into the atmosphere and its
explosion due to ignition which may cause high over pressure and low pressure that
cause very heavy damage.
(2) Words and expressions used and not defined in these regulations, but defined in the Act or
rules or regulations made there under, shall have the meanings respectively assigned to
them in this Act or in the rules or regulation, as the case may be.
Abbreviations:
API - American Petroleum Institute
ASME - American Society of Mechanical Engineering
ASTM - American Society for Testing and Material
BLEVE - Boiling Liquid Expanding Vapour Explosion
CIC - Chief Incident Controller
CDM - Chemical Disaster Management
DHO - District Health Officer
DMI- Disaster Management Institute, Bhopal
ECO - Emergency Coordinating Officer
ERDMP - Emergency Response and Disaster
Management Plan
ESD- Emergency Shut down
ERV - Emergency Response Vehicle
HAZCHEM - Hazardous Chemicals
HAZOP - Hazard & Operability Study
HSD - High Speed Diesel
HSE - Health, Safety and Environment
LFL - Lower Flammability Limit (same as LEL – Lower
Explosive Limit)
LOPA - Layers of Protection Approach
MAH- Major Accident Hazard installation
MSDS- Material Safety Data Sheet
MSIHC- Manufacture Storage and Import of
Hazardous Chemicals
NDMA - National Disaster Management Authority
NDRF - National Disaster Response Force
OIC - Officer In- Charge
OISD- Oil Industry Safety Directorate
PCV- Pressure Control Valve
PNGRB - Petroleum and Natural Gas Regulatory
Board
SCADA - Supervisory Control and Data Acquisition
SDRF - State Disaster Response Force
SDV- Shut down valve
SIC - Site Incident Controller
TREM - Transport Emergency Card
UVCE - Unconfined Vapour Cloud Explosion
ROU/ROW : Right of Way USE not included in the
manual
Ref No.
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PAGE: 7
3.0 APPLICABILITY
This ERDMP is prepared based upon PNGRB regulations G.S.R. 39(E) titled ‘Petroleum
and Natural Gas Regulatory Board (Codes of Practices for Emergency Response
and Disaster Management Plan (ERDMP) Regulations, 2010’. Following regulations
are applicable for ERDMP of BPCL, Piyala Installation:
(a)
(b)
(c)
(d)
Hydrocarbons processing installation (refinery, gas
processing, LNG Re- gasification installations etc.);
Pipeline such as natural gas, propane, butane etc. and
the hydrocarbons products which remain in gaseous
state at NTP;
Liquid petroleum product pipeline;
(f)
Commercial petroleum storage facilities, gas
storage
facilities
and terminals including LNG
terminals;
Hydrocarbons gas bottling Installations having
receiving, storage and handling facilities including
storage for LPG, propane and butane;
City or local natural gas distribution facilities;
(g)
Dispensing stations and POL retail outlets;
(e)
(h)
(i)
Not Applicable
Not Applicable
Applicable
Applicable
Not Applicable
Not Applicable
Not Applicable
transportation of petroleum products by road
Applicable
any other installation as may be notified by the Board Not Applicable
from time to time;
Emergency Response and Disaster Management Plan (ERDMP) describes the
organizational structure, facilities, equipment, services and infrastructure necessary to
respond to the emergency situation which could have on-site as well as off-site implications
at Receipt, Storage & Dispatch points. Emergency Response Plan covers all emergencies
relating to Operation & Maintenance, personnel, properties including serious accidents,
explosions, floods, fire and bomb threat etc.
This plan also applies to those Governmental Agencies that are responsible for emergency
response within the immediate area surrounding the facilities and those agencies,
organizations, contractors, and facilities providing assistance to Piyala Installation in the
event of an emergency. Piyala Installation shall maintain liaison with concerned
governmental agencies to ensure proper understanding and interfaces regarding aspects of
notification, responsibilities of personnel and resources of state and local agencies to be
deployed in case of actual emergency situation.
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4.0 SCOPE AND INTENT
4.1
Scope of ERDMP
The scope of ERDMP is as under:
i.
the identification of emergencies;
ii.
the mitigation measures that attempt to reduce and eliminate the risk or disaster;
iii.
the preparedness that to develop plan for action when disaster or emergencies occur;
iv. the response that mobilize the necessary services including responders like fire
service, police service, medical service including ambulance, government as well as
non-government agencies;
v.
the post disaster recovery with aim to restore the affected area to its original
conditions;
4.2 Intent
(a) Intent of this Emergency Response and Disaster Management Plan (ERDMP) document
is to formulate action plan for all necessary functions that are required to be carried out
towards preparedness, response & management of emergencies. It describes the
emergency response organization, the resources available (internal as well as external)
and specific response actions required for various types of emergencies that could occur
in BPCL, Piyala jurisdiction.
(b) ERDMP is not just to use as reference material for training. The ERDMP prepared with
the following objectives:
i. to minimize the effects due to :
a. spillage of petroleum products during storage and handling within the premises.
b. release or escape of flammable petroleum products
c. fire or explosion
ii. to prevent causalities- both on-site and off-site;
iii. to reduce damage to property, machinery, public and environment;
iv. to develop a state of readiness for a prompt and orderly response to an emergency
and to establish a high order of preparedness (equipment, personnel) commensurate
with the risk;
v. to provide an incident management organogram with clear missions and lines of
authority (incident command system, field supervision, unified command);
vi. to ensure an orderly and timely decision making and response process.
vii. To maintain good public relations;
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PAGE: 9
5.0 CONTENTS OF ERDMP
Contents of this ERDMP documents have been listed under Table of Contents. For better
correlation, same Clause No’s have been retained in the Contents as in PNGRB regulations
G.S.R. 39(E).
(a)
classification of emergencies;
(b)
implementation schedule;
(c)
consequences of defaults or non-compliance;
(d)
statutory requirements;
(e)
pre-emergency planning;
(f)
emergency mitigation measures;
(g)
emergency preparedness measures;
(h)
emergency response procedures and measures;
(i)
emergency organization and responsibilities;
(j)
infrastructure requirements;
(k)
declaration of on-site and off-site emergency;
(l)
resources for controlling emergency;
(m)
demographic information;
(n)
medical facilities;
(o)
evacuation;
(p)
public relations and information to public;
(q)
reporting of the incident;
(r)
emergency recovery procedures;
(s)
ERDMP for tank trucks and pipelines carrying petroleum products
(t)
integration of the ERDMP with National Disaster Management Authority (NDMA)
guidelines and action plan on Chemical Disasters (Industrial);
(u)
Security threat plan and action plan to meet the eventualities.
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PAGE: 10
6.0 CLASSIFICATION OF EMERGENCIES
Emergency in industry may be defined as one or more emergencies, which can affect
several or all plants/departments, can cause serious injury to personnel and can result in
extensive damage to property and loss of life and disruption both inside and outside the
works. It requires the use of outside resource to handle it effectively.
As per Rule-2 (f) of The Chemical Accidents (Emergency Planning, Preparedness and
Response) Rules, 1996 the Chemical emergency is defined as:
“Major Chemical Accident (Chemical emergency) means an occurrence including any
particular major emission, fire and/or explosion evolving one or more hazardous chemicals
and resulting from uncontrolled developments in the course of industrial activity or
transportation or due to natural events leading to serious effects both immediate or delayed,
inside or outside the installation likely to cause substantial loss of life and property including
adverse effects on the environment.”
In Bharat Petroleum Corporation Ltd., Piyala Installation premises, probable emergencies
can be categorized into three broad levels on the basis of seriousness and response
emergencies can be categories into following three level:
a.
Level-1: this is an emergency or an incident whichi. Can be effectively and safely managed and contained within the site, location or
installation by the available resources;
ii. Has no impact outside the site, location or installation.
b.
Level-2: this is an emergency or an incident whichi. cannot be effectively and safely managed or contained at the location or
installation by available resources and additional support is alerted or required;
ii. is having or has the potential to have an effect beyond the site location or
installation and where external support of mutual aid partner may be involved;
iii. is likely to be danger to life, the environment or to industrial assets or reputation.
c.
Level-3: this is an emergency or an incident with off-site impact which could be
catastrophic and is likely to affect the population, property and environment inside
and outside the installation and management and control is done by district
administration. Although the Level-III emergency falls under the purview of District
Authority but till they step in, it should be responsibility of the unit to manage the
emergency.
Level-1 & 2 emergencies are considered in preparation of ERDMP of BPCL, Piyala
Installation.
Based on the nature of emergency & severity the levels of type of emergency to be declared
will be decided by the location in charges (Sr. Manager I/C). Various possible types of
emergencies are tabulated as below:
Ref No.
BPCL/PYL/OSEP
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PAGE: 11
SN
Type of
Applicable Emergency
Emergency
Action Plan
Description of Emergency

1
Level-1
On site






2
Level-2
On site




3
Level-3
Off Site






Oil spills from the
flanges/Pipeline/Hammer Blinds/Gate
Valves.
Pinhole leakage from Pipelines
Failure of gasket resulting in leakage
Spillages from tank truck due to over
flow while loading.
Spillages from storage tank during
receipt.
Floating roof getting struck in the tank.
Tank containment failure and release
of flammable petroleum Product.
Leakage from pipeline due to damage
by external sources, sabotage,
pilferage.
Failures caused by corrosion defects,
Failures caused by miscellaneous
factors such as pipe material defects,
natural hazards.
Burst of product Pipelines inside &
siding area.
Failure of storage tanks.
Pool fires
Vapour cloud explosion.
Agitation / forced entry by external
group of people.
Natural Perils – Earthquake, flood,
tsunami
Sabotage, Bomb explosion / Threat
Note: - The emergency classification as per OISD-117 has been substituted by
classification of emergency as per PNGRB Regulation- 2010 as given below.
OISD-117 classification
Small Fire
Major Fire
Disaster
ERDMP Regulation-2010 classification
Level-1 Emergency
Level-2 Emergency
Level-3 Emergency
Hereafter in this plan, terminology used for emergency is Level 1, Level 2 & Level 3 and
words like Small fire, Major fire and Disaster as per OISD-117 have been omitted.
Ref No.
BPCL/PYL/OSEP
OF
REVISION No. 0
PAGE: 12
7.0 IMPLEMENTATION SCHEDULE
Schedule-1
Schedule of implementation of Code of Practice for ERDMP
Sl.
No.
Activity
Implementation
Time (from the
notification date)
1
On-Site Emergency Plan
03 Months
2
Off-Site Emergency Plan
(Submission of
Information to District
Authority)
03- Months
Prepared by District Authority
(District Crises Group)
3
Resources in Position
06-Months
Yes
4
Accredited Third Party
Certification of ERDMP.
01-Year
5
Testing and Mock Drills
(On-Site)
03-Months
6
Testing and Mock Drills
(Off-Site)
12 months
** To be coordinated with District Authority
Compliance status
Yes. Current On-Sire
Emergency Plan modified as
per regulation.
Under process
Yes, Six Monthly
Yes, Yearly **
Ref No.
BPCL/PYL/OSEP
OF
REVISION No. 0
PAGE: 13
8.0 CONSEQUENCES OF DEFAULT OR NON-COMPLIANCE
8.1 There shall be a system for ensuring compliance to the provision of these regulations
through developing a well defining emergency response and disaster management plan
and conduction of mock drill and safety audit during the construction, commissioning
and operation phase, as well as an on-going basis. There shall also be system of do’s &
don’ts regarding safety, mock drill or real emergencies for visitors before entering and
establishment. This should be supported by written instruction sheet for visitor and
ensured the visitor is accompanied by Installation representative on forward visit and
return gate.
Following emergency drills being conducted in BPCL, Piyala Installation:
i. Emergency Drills and Mock Exercises:
Off-site emergency plan – Yearly conducted by District Authorities.
On-site emergency plan – Once in three months.
iii. Fire drill / emergency handling drill – Monthly.
iv. Safety Briefing is compulsory for contract personnel in Piyala Installation once every
fortnight. For visitors, Safety Information sheet is given while issuing gate pass.
DO'S AND DON'TS
Any One Noticing
An Emergency
Situation
Contractor
Personnel
Security
Visitors
All other
Employees
On Site
DO'S
Actuate nearest fire alarm
manual call point and /or inform
Fire Station on telephone or
inform the supervisor. Wait till
arrival of Emergency Team and
direct them to the site of
emergency. Then report to the
assembly point.
Stop work on hearing alarm.
Assemble at the nearest /
designated ASSEMBLY POINT
and be ready to evacuate.
Keep the gate manned; Keep the
road clear for movement of
Emergency
Vehicles/
Fire
Tenders/Ambulance.
Control
traffic at gates.
Leave the place and assemble at
assembly point.
DON'TS
DO NOT panic and avoid
running all over the place,
prevent other from doing so.
DO NOT enter the site unless
instructed
or
all
clear
siren/message is heard.
DO NOT enter the site, till it is
cleared for the normal work by
site incident controller.
DO NOT allow unauthorized
visitors free to enter.
DO NOT enter the site if
emergency alarm is heard.
DO NOT panic
On hearing FIRE alarm, go to DO NOT go to the site of
assembly point and wait for emergency unless specifically
further instruction.
instructed by site main/ incident
controller.
Ref No.
BPCL/PYL/OSEP
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REVISION No. 0
PAGE: 14
8.2 The Board shall monitor the compliance of ERDMP, Technical Standards and
Specifications including Safety Standards either directly or indirectly by
accredited third party through separate regulations on third party conformity
assessment.
8.3 In case of any deviation or shortfall, in achieving the recommended
standards the entities are liable to penal provisions under the provisions of the
technical standards, specifications including safety standards
8.4 Mutual Aid Association not responding as per memorandum of Understanding (MOU) or
written agreement on request of assistance shall attract penalty as per mutual Aid
agreement are as under. However details are elaborate in clause no-12.3 and check
list -3:
a. In the event of first default in response, the defaulting entity with the application and
its management shall have to submit written explanation to affected mutual aid
members.
b. for the second and successive failure, the defaulting entity shall have to pay the
double of the billed amount of expenses incurred by affected mutual aid
members in case of any eventuality occurs in the premises of affected mutual aid
members.
Ref No.
BPCL/PYL/OSEP
OF
REVISION No. 0
PAGE: 15
9.0 REQUIREMENTS UNDER OTHER STATUTES
Implementation of ERDMP is primarily governed & complying with following regulations as
per Schedule – II of PNGRB regulations G.S.R. 39(E).









The Environment (Protection) Act, 1986 (amended 1991) and following Rules there
under:
 The Environment (Protection) Rules, 1986 (amended 2004).
 The Manufacture, Storage and Import of Hazardous Chemicals Rules, 1989
(amended, 1994 and 2000).
 The Hazardous Wastes (Management, Handling and Transboundry) Rules, 2008.
 The Environment Prior Clearance Notification, 2006.
 The Chemical Accidents (Emergency Planning, Preparedness and Response)
Rules, 1996.
 Bio-medical Wastes (Management and Handling) Rules. 1989- N/A.
The Factories Act, 1948 (amended 1987).
 Haryana State Factory Rules.
The Inflammable Substances Act, 1952.
The Motor Vehicles Act, 1988 (amended 2001).
 The Central Motor Vehicles Rules, 1989 (amended 2005).
The Public Liability Insurance Rules, 1991 (amended 1992).
 The Public Liability Insurance Rules, 1991 (amended 1993).
The Petroleum Act, 1934.
 The Petroleum Rules, 2002.
The Insecticide Rules, 1968 (amended 2000). – N/A
 The Insecticide Rules, 1971 (amended 1999).
The National Environment Tribunal Act, 1995.
The Explosives Act, 1884 (amended till 1983).
 The Gas Cylinder Rules, 2004,
 The Static and Mobile Pressure Vessels (Unfired) Rules, 1981 (amended 2002).
 The Explosives Rules, 1983 (amended 2002).
In compliance of the Rule-13 of the Manufacture Storage and Import of Hazardous
Chemicals Rules 1989 (amended in 1994 and 2000), under The Environment Protection Act,
1986; and Chemical Accidents (Emergency Planning, Preparedness, and Response) Rules,
1996 under The Environment Protection Act, 1986, Factories Act - 1948 (amended in 1987),
Section 41-B (4). M/s Bharat Petroleum Corporation Limited, Piyala Installation, prepare an
Emergency Response and Disaster Management Plan (On Site Emergency Plan) as per
Codes of Practices for Emergency Response and Disaster Management Plan (ERDMP)
Regulations, 2010 of Petroleum and Natural Gas Regulatory Board Act, 2006 and
Guidelines on Emergency Preparedness Plan (EPP) for locations of oil industry (OISD-GDN168).
Ref No.
BPCL/PYL/OSEP
OF
REVISION No. 0
PAGE: 16
Current compliance status with above rules / permissions as per Schedule – II is
given below.
As of DATE: 17.04.2014
SL.
NO
Description
1
Factory
2
Explosive
3
Prohibited Area
4
VHF License For Main
Station Hand Sets
Public Liability Insurance
5
6
Handling Of Hazardous
Waste
7
Pollution Control Board
( Water & Air Consent)
8
Contract Labour
Registration
Calibration of Flow
Meters and Tank Etc by
W&M
Calibration of weigh
bridge by W&M
Calibration of Explosive
Meter
9
10
11
License No.
FBD/B/546/3280
Renewed
/Applied
On
05.04.2012
Valid Up to
Remarks
31.12.2016
P/HQ/HN/15/2125(P
138253)
29.11.2013
31.12.2014
30/2/2008-5 J.J.(I)
19.08.2010
----
FL-162/1-21
26.02.2014
31.03.2014
021000/49/14/60/
00000002
HSPCB/Consent/:28
14714FDBBCTOHW
M695197
HSPCB/Consent/:28
14714FDBBCTO695
197
46(R-02)/2005-ALK
01.04.2014
31.03.2015
25.03.2014
31.03.2015
25.03.2014
31.03.2015
08.01.2014
------
000314/78
21.11.2013
01.11.2014
R/29/1904 (968)
31.01.2014
30.01.2015
RSSPL/13-14/022
(Sr.No.-181-143972)
26.12.2013
25.06.2014
ONE TIME
APPROVAL
Waiting for
Renewal
ONE TIME
APPROVAL
Ref No.
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REVISION No. 0
PAGE: 17
10.0 PRE-EMERGENCY PLANNING
10.1 Hazard Identification
This shall involve a detailed study of areas and operations of storage, handling, transfer,
filling of petroleum products in the plant with a view identifying potential hazards, which could
bigger loss causing event such as fire and explosion etc.
The identification of hazards and degree of hazard associated with various chemicals and in
operation units carried out by relative ranking method.
As per Petroleum Rules, Petroleum products are divided into three classes based on their
flash points as follows:
Class A - Flammable liquids having flash point below 23oc.
Class B - Flammable liquids having flash point of 23oC and above but below 65oC.
Class C - Flammable liquids having flash point of 65oC and above but below 93oC.
Excluded - Liquids having flash point of 930C Petroleum and above.
As per Manufacture Storage and Import of Hazardous Chemical Rules (as amended to
date), the flammable chemicals are divided into five categories, which are as under:
(i)
Flammable Gases: - Gases which at 20 0 C and at standard pressure of 101.3 Kpa
are;
(a) Ignitable when in a mixture of 13% or less by volume with air, or
(b) Have a flammable range with air of at least 12 percentage points regardless of
the lower flammable limits.
(ii)
Extremely Flammable Liquids: Chemicals, which have flash point, lower than or equal to 23o C and boiling point less
than 35oC.
(iii)
Very Highly Flammable Liquids:Chemicals, which have flash point, lower than or equal to 23o C and initial boiling
point higher than 35oC.
(iv)
Highly Flammable Liquids
Chemicals, which have flash point, lower than or equal to 60o C but higher than 23oC.
(v)
Flammable Liquids
Chemicals, which have, flash point higher than 60o C but lower than 90oC.
As per the NFPA classification the hazard rating of petroleum, products are as under:
S. N. Chemical
Max. Capacity
A. NFPA Hazard Classification
Ref No.
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PAGE: 18
KL
1.
2.
3.
4.
MS (A)
HSD (B)
SKO (B)
Ethanol (A)
82430
92090
16600
200
Flammability
3
2
2
3
Health
1
1
1
0
Reactivity
0
0
0
0
The explanation of the NFPA hazard rating is as under:
A. Health Hazard Classification
4
Materials which on very short exposure could cause death or major residual
injury even though prompt medical treatment were given
3
Materials, which on short exposure could cause serious temporary or
residual injury even through prompt medical treatment, were given.
2
Materials, which on intense or continued exposure could cause temporary
incapacitation or possible residual injury unless prompt medical treatment, is
given.
1
Materials, which on exposure would cause irritation but only minor residual
injury, even if no treatment is given.
0
Materials, which on exposure under fire conditions, would offer no hazard
beyond that of ordinary combustible material.
B. Flammability Classification
4
Materials, which will rapidly or completely vaporize at atmospheric pressure
and normal ambient temperature, or which are readily dispersed in air and
which will burn readily.
3
Liquids and solids that can be ignited under almost all ambient temperature
conditions.
2
Materials that must be moderately heated or exposed to relatively high
ambient temperatures before ignition can occur.
1
Material that must be preheated before ignition can occur.
0
Materials that will not burn.
C. Reactivity Classification
4
Materials, which in themselves are readily capable of detonation or of
explosive decomposition or reaction at normal temperature and pressures.
3
Materials which in themselves are capable of detonation or explosive
reaction but require a strong initiating source or which must be heated under
confinement before initiation or which react explosively with water
2
Materials, which in themselves are normally unstable and readily undergo
violent chemical change but do not detonate. Also materials, which may react
violently with, water or which may form potentially explosive mixtures with
water.
1
Materials which in themselves are normally stable, but which can become
unstable at elevated temperature and pressure or which may react with water
with some release of energy but not violently.
0
Materials which in themselves are normally stable, even under fire exposure
conditions, and which are not reactive with water.
Ref No.
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PAGE: 19
The following conclusions drawn with respect to toxic, flammable, and reactivity criteria’s:
(i) TOXICITY HAZARD
(a) Health hazard for the ATF is equal to two (Nh=2) and chemicals (MS, HSD, SKO) is
equal to one (Nh=1). Adequate safety arrangements are provided to facilitate a Quick
First Aid for the worker exposed to the chemicals.
(b) Health hazard rating for Ethanol is zero.
(ii) FLAMMABILITY HAZARD
(a) The highest flammability rating is reported for MS, & Ethanol i.e. Nf =3, according to
NFPA.
(b) Flammability hazard rating for HSD, ATF & SKO is equal to two (Nf=2). Adequate
safety arrangements are provided to facilitate a Quick First Aid for the worker
exposed to the chemicals.
(iii) REACTIVITY HAZARD
Reactivity hazard rating for MS, HSD, ATF & Ethanol is zero.
Location of hazardous substances
The hazardous chemicals stored or handled in the Installation and their Hazardous Property
and nature of hazard is given below and their storage location is shown in the map enclosed
as Annexure-2.
The Material Safety Data Sheet of all the hazardous chemicals, which are stored/handled at
Installation site, is enclosed as Annexure-3.
All chemicals as given in above table are hazardous in nature [as defined under Rule 2 e (i,
ii, iii) of “The Manufacture, Storage and Import of Hazardous Chemicals Rules, 1989”,
amended in 1994 and 2000], which are either stored or handled in the plant.
As per Rule 2 j (a) of “The Manufacture, Storage and Import of Hazardous Chemicals Rules,
1989” (amended in 1994 & 2000), the quantity of hazardous chemical in the BPCL, Piyala
Installation is equal to or in excess of the threshold quantities specified in Column 3 of
Schedule 2 & 3 respectively, so BPCL, Piyala Installation is qualify as “Major Accident
Hazard” (MAH) Units.
Ref No.
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PAGE: 20
The hazardous chemicals handled in the BPCL, Piyala Installation is given below in table
along with their hazardous properties:
SN
Hazardous chemical
handled
Hazardous Properties
Motor Sprit (MS)
Hazard Involve
(Toxic/Flammable/
Explosive)
Flammable/Explosive
1.
2.
High Speed Diesel (HSD)
Flammable
LFL= 1.3%
UFL= 6.1%
Flash Point= 37.7-51.70C
Boiling Point=110-4000C
3.
Superior Kerosene Oil (SKO)
Flammable
LFL= .7%
UFL= 5-7%
Flash Point= 380C
Boiling Point=149-3250C
4.
Ethanol
Flammable
LFL= 3.3%
UFL= 17%
Flash Point= 120C
Boiling Point=78.30C
LFL= 1.4 %
UFL= 7.4%
Flash Point= -38 to -480C
Boiling Point=30-215 0C
Only Flammable and explosive chemicals stored in plant as listed in above table. No major
toxic chemical stored in the plant.
Check Points for hazard identification are given at check list-1.
10.2 Risk Analysis & Risk Assessment
The basic procedure in a risk analysis shall be as follows:
(a)
(b)
(c)
(d)
identify potential failures or incident s (including frequency) ;
calculate the quantity of material that may be released in each failure, estimate
the probability of such occurrences;
evaluate the consequences of such occurrences based on scenarios such as
most probable and worst case events;
the combination of consequences and probability will allow the hazards to be
ranked in a logical fashion to indicate the zones of important risk. Criteria should then
be established by which the quantified level of risk may be considered acceptable to
all parties concerned
Ref No.
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(e)
(f)
OF
REVISION No. 0
PAGE: 21
after assessing the risk, the "maximum tolerable criterion" must be defined and
above which the risk shall be regarded as intolerable. Whatever be the benefit level
must be reduced below this level;
the risk should also be made "as low as reasonably practicable" (ALARP)
and
least impacting
the neighbourhood. While
conducting
the
risk
analysis, a quantitative determination of risk involves three major steps:IRPA (Individual Risk per Annum)
NOTE- a risk of 10 per million per year, or 10 -5/Year, effectively means that any person
standing at a point of this level of risk would have a 1 in 100 000 chance of being
fatally injured per year
SN Scenario
1. Catastrophic failure of HSD,SKO & MS storage tank
2. Catastrophic failure of HSD, SKO & MS Railway
wagon
3. Maximum length of HSD, SKO & MS pipeline failure
(Line Rupture)
*Basic Failure frequency are taken from Purple Book (CPR 18 E).
Failure frequency*
5 x 10-6 year-1
1 x 10-5 year-1
1 x 10-7 m-1 year-1
Damage criteria due to incident radiation intensity & overpressure
In the events of an explosion taking place within the complex due to hydrocarbon and airmixing and catching fire the resultant blast wave may have damaging effect on equipment,
structures, building and piping coming inside the overpressure distance of the blast.
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The effects of thermal radiation, on humans are most relevant in the immediate vicinity of an
incident and the progressive effects resulting are:
 Pain
 First degree burns
 Second degree burns
 Third degree burns
 Fatality
Depending on the duration, intensity and area of exposure, the effects of fire range from
pain, through 1st, 2nd and 3rd degree burns, to fatality.
These effects are commonly linked to the intensity of the incident thermal radiation and given
below table provides the typical consequences of exposure to various levels of intensity and
the expected time to each effect.
Damage due to Thermal Radiation Intensity
Incident radiation
0.7 kw/m2
1.6 kw/m2
4.0 kw/m2
9.5 kw/m2
12.5 kw/m2
37.5 kw/m2
Type of damage expected
Equivalent to solar radiation
Will cause no discomfort to long exposure
Sufficient to cause pain to personnel if unable to reach cover
within 20 sec, however blistering of skin (2nd degree burns) is
likely; with no lethality.
Pain threshold reached after 8s; second degree burns after
20 seconds
Minimum energy required for piloted ignition of wood, melting
plastic tubing etc.
Sufficient to cause damage to process equipment and human
death.
Explosions generate overpressures and drag forces that in turn result in damage to buildings
and structures, and generate missiles (fragments of damaged structures, window glass
shards, or loose objects). The effects of overpressure on humans are normally categorized
as follows:



Direct or Primary: injury to the body as a result of the pressure change
Secondary: injury as a result of fragments or debris produced by the overpressure
impacting on the body
Tertiary: injury as a result of the body (especially the head) being thrown by the
explosion drag and impacting on stationary objects or structures
For QRA, lethality is not typically estimated independently for these effects; instead, an
overall lethality is estimated based on the combination of these effects.
Damage effect of blast overpressure
Blast Over pressure (Bar)
0.30
Damage Type
Major damage to structures (assumed fetal to the
people inside structure)
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0.17
0.10
0.03
0.01
Eardrum rupture
Repairable Damage
Glass Breakage
Crack of Window
Consequence analysis of various major accident scenarios will yield a range of hazard
distances specifying different damage levels. With the help of damage criteria discussed
above, it is possible to judge the type of damage to man and material due to realization of
any of the accident scenarios.
The assessment of the consequences of maximum identified credible accident scenarios in
terms of:
a)
b)
c)
d)
e)
Pool fire Radiation Hazard
Flash Fire
Jet fire hazard
Boiling liquid expanding vapour explosion hazard (BLEVE)-Fire ball Radiation Hazard
Vapour Cloud Explosion Hazard
i. Unconfined Vapour Cloud Explosion Hazard
ii. Confined Vapour Cloud Explosion Hazard
a) Pool fire Radiation Hazard
To estimate the radius of zone in which fatality and second degree burn may be expected if
a pool of flammable liquid should ignite.
In case of release of petroleum products from the storage tank or pipeline it would spill on
the ground and form pool. When it finds a source of ignition it results into pool fire. Petroleum
products burn with a smoky flame over the total area of pool radiating intense heat to the
surrounding equipment, tanks or buildings. The flame may tilt with the wind speed in the
direction of wind. Damage of fire is restricted in the plant areas only. Due to domino effect
nearby tanks, other equipments containing flammable materials may ignite and catch fire.
In case of plants having good layout maintaining safe separation distances between tanks
and equipments the loss due to pool fire is minimum.
b) Flash Fire
Hydrocarbons vapours release accidentally will normally spread out in the direction of wind.
If finds an ignition source before being completely dispersed below lower flammable limit
(LFL), a flash fire is likely to occur and the flame may travel back to the source of leak. Any
person caught in the flash fire is likely to suffer fetal burn injury. Therefore, in consequence
analysis the distance of LFL value is usually taken to indicate the area, which may be
affected by flash fire.
c) Jet fire hazard
Escaping jet of MS/HSD/SKO from pressure vessels/piping, if ignited, causes a jet flame.
The jet flame direction and tilt depend on prevailing wind direction and velocity. Damage, in
case of such type of jet fires, is restricted within the plant boundary. However, the ignited jet
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can impinge on other vessels and equipment carrying petroleum oil and can cause domino
effect.
d) Boiling liquid expanding vapour explosion hazard (BLEVE)-Fire ball Radiation
Hazard
Fireballs are short-lived flames which generally result from the ignition and combustion of
turbulent vapour/two-phase (i.e., aerosol) fuels in air. Releases that fuel fireballs are usually
near instantaneous and commonly involve the catastrophic failure of pressurized
vessels/pipelines. Fireballs could dissipate large amounts of thermal radiation, which, away
from their visible boundaries, may transmit heat energy that could be hazardous to life and
property. As such, in the evaluation of the hazard posed by fireballs, the accurate
determination of the likelihood of object engulfment and/or the amount of radiant
energy received by objects at a distance from the flame is of primary importance.
The term “BLEVE” is an acronym for boiling liquid expanding vapour explosion and may be
defined as any sudden loss of containment of a liquid above its normal boiling point at the
moment of vessel failure. Failure may result from the development of cracks which are
mainly caused by impact on the vessel, corrosion, internal overheating and construction
defects. A common cause of failure leading to BLEVE is due to fire engulfment of a vessel
containing liquid under pressure. As the liquid heats up, the vapour pressure rises which
may actuate the safety valve causing the liquid level in the vessel to fall as vapour is
released.
Because the heat capacity of vapour is lower than liquid, the portion of the
vessel walls in contact with the vapour increases in temperature as heat is transferred from
the fire while that in contact with the liquid remains relatively cool. This may result in nonuniform expansion and sufficient loss of strength of the vessel walls to rupture.
Boil over hazard result BLEVE occurs in pressurized vessel. In BPCL, Piyala Installation all
tanks are at atmospheric pressure and so consequences of BLEVE may not occur. The
possible consequences are Late Pool fire and Tank Fire may possible.
e) Vapor Cloud Fire Hazard
Ignition of a cloud of flammable vapour in air, which can result in flash fire or explosion. The
results look at downwind hazard distance, hazard zone width and weight of air born
flammable vapors in air, when such a cloud is formed.
i)
Unconfined Vapour Cloud Explosion (UVCE)
Clouds of flammable vapours and gases with concentrations within their lower and upper
explosive limits may explode when it finds a source of ignition. Such explosions may
occur within the plant area or slightly displaced area depending upon how the vapours or
gas has drifted before it finds the source of ignition. The explosions radiate intense heat
during the short time that it may cause secondary fires. In addition to radiation the
explosions create pressure waves, which cause damage at considerable distances from
the explosion. These explosions are called unconfined vapour cloud explosions.
ii) Confined Vapour Cloud Explosion (UVCE)
A confined explosion occurs in a confined space, such as a vessel or a building. A
confined explosion is a result of a rapid chemical reaction, which is constrained within
vessels and buildings. A basic distinction between confined explosions and unconfined
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explosions is confined explosions are those which occur within some sort of
containment. Often the explosion is in a vessel or piping, but explosions in buildings also
come within this category. Explosions, which occur in the open air, are unconfined
explosions.
In BPCL, Piyala Installation Confined Vapour Cloud Explosion Hazard may not possible
because all the storage tanks are place in open air.
The worst scenario as per risk analysis will be catastrophe failure of HSD, SKO and MS
Tank and flooding of dyke. Pool fire is possible in case of ignition source. The material
released in each failure case is as under:
SN
1.
2.
3.
4.
Scenarios
Catastrophic failure of HSD tank (TK-5)
Catastrophic failure of MS tank (TK-2)
Catastrophic failure of SKO tank (TK-9)
Catastrophic failure of LPG storage vessel at
neighboring BPCL, LPG plant
Quantity of material released
15600 KL
26750 KL
8200 KL
1350 MT
Small Spills
o
o
o
o
Small spills which pose no safety and health dangers are not likely to adversely
affect the environment, are to be handled by trained personnel.
Eliminate the source of the spill by closing valves
Recover the spilled products
Avoid migration of product into the external drain
Large Spills
Large spills contained inside the tank bund will be recovered manually /
using sorbent pads. Ensure closure of drain valves.
mechanically
by
Pipeline leak during Tank Truck loading




Suspend pumping, avoid naked light / source of heat
Close all valves at either end.
Rectify the defect and Salvage the spill, clean the site by spreading sand, check the
explosive limit vapour.
Get external assistance to avoid crowding of unauthorized persons
Product leakage / seepage inside Installation
This is possible in the operating area of the Installation. The man on the spot to control leak /
spill. Block and arrange for recovery of spilled Oil.
The Hazard, Severity, Population and precautions taken are tabulated Area-wise herein
below:
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AREA
HAZARD
SEVERITY
H
1. Foam pourer provided as per
requirement of OISD.
2. Sprinkler system installed on
tanks.
3. Remote operated valves for
emergency shutdown.
4. Continuous monitoring and
maintenance.
5. Area maintained as per CCOE
requirement.
6. Proper earthing of Tanks.
L
emergency shutdown.
2. Automated processes to enhance
safety & reduces human error.
maintenance.
1. SOP followed to avoid vapour
formation.
2. Explosive meter always kept in
control room in case of need.
1. Hydrant system made available
with foam monitor.
2. Sprinkler system installed on
tanks.
emergency shutdown.
maintenance.
5. Area maintained as per CCOE
requirement.
6. Proper earthing of Tanks.
1. Automated processes to enhance
safety & reduce human error.
emergency shutdown.
3. Continuous
monitoring
and
maintenance
Pool Fire
Class - A
(MS)
Storage
Spill or Leak
due to
containment
failure
H
Vapour Cloud
Explosion
H
Class – B
(HSD & SKO)
Storage
PRECAUTIONS TAKEN
Pool fires
L
Spill or Leak
due to
containment
failure
M
Tank Truck Loading
Gantry/ Loading of
Rake
1. Protection against static electricity
is kept mandatory, while loading is
done by providing earth clips to
TT, which will conduct and
discharge the charges generated
from the body (compartment) of
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Pool fire
L
Spill or leakage
the TT.
2. Adequate portable fire extinguisher
DCP carried in TT for
extinguishing any petroleum fire in
TT or loading gantry.
3. All equipments fitted/used in TLF
gantry are of flameproof
4. All petroleum pipelines entering
tank vehicle loading or unloading
area are to be electrically
continuous and efficiently earthed.
5. An earthing with a flexible cable
having robust clamping device
provided adjacent to the loading
point.
6. Engine air intake is fitted with
flame-arrester, capable of
preventing emission of flame from
the side of the engine in the event
of back firing.
7. Exhaust system of TT fitted with
spark arrestor that prevents
flammable contents outside TT.
8. TT is checked for any flammable
substance before entering.
9. TT should have Material Safety
Data Sheet (MSDS) and Transport
Emergency Card (TREM).
1. Adequate lighting made available.
2. Adequate arrangement for
containment made (Pump, Flexible
pipes, containers, etc.)
3. Proper communication through
VHF Sets among various teams
working at different work station.
L
Pipeline
Spill or Leak
1. Hydrotesting of all pipes done as
per requirement.
2. Continuous supervision.
3. SOP followed.
4. Emergency Shutdown which will
immediately stop all motors in
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M
Pump house
case of emergency.
1. Emergency Shutdown which will
immediately stop all motors in
case of emergency.
H – High, M – Moderate, L - Light
Severity mapping
The entire licensed area of this Installation may be considered as the Area of Hazard. In line
with petroleum rules, the areas are mapped as under:
1. Area where inflammable gases or vapour are likely to be present under normal
operating times.
(a) Tank truck filling shed
(b) Loading of Rake area
(c) TLF Pump house
2. Area where inflammable gases or vapour are likely to be present under abnormal
operating conditions.
(a) Product tank farm
(b) Tank farm Manifold area
(c) TLF Manifold area
(d) Loading of Rake Manifold area
Hazardous area classification drawing prepared as per Explosive rules is attached as
Annexure-2.
10.3 Causes of Disaster
Following reasons can cause an industrial emergency:
Man made
Heavy Leakage
Fire
Explosion
Critical
Failure
of
Control system
Design deficiency
Unsafe acts
In-adequate
maintenance
Natural Calamities
Flood
Earth Quake
Cyclone
Outbreak of Disease
Excessive Rains
Tsunami
Extraneous
Riots/Civil Disorder/
Mob Attack
Terrorism
Sabotage
Bomb Threat
War / Hit by missiles
Abduction
Food
Poisoning/
Water Poisoning
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Faridabad district comes under seismic zone ‘4’ as per list of BMTPC 2006 (Building
Materials & Technology Promotion Council). It means that there is always a probability of the
earthquake in the district. Earthquake cannot be stopped, while the impact of the event could
be minimized through creating awareness, preparedness and pre-management. Map of
India showing earthquake zones enclosed as Annexure-4.
10.4 Consequences
To study the flammable chemicals three radiation levels corresponding 1st , 2nd and 3rd
degree have been considered. In case of explosion peak over pressure 0.02, 0.14 and 2.0
bar have been considered.
Neutral weather (class D) and wind speed 3 m/s and extremely stable (Class F) and low
wind speed 1.5 m/s have been considered in consequences analysis.
Catastrophic failure of HSD, SKO and MS Storage tanks, Railway wagon and maximum
length of pipeline (between two valves) failure scenario has been conducted in
consequences analysis. The results of consequences analysis is as under:
Summary late pool fire
S
Scenario
N
1.
2.
3.
4.
Catastrophic failure of HSD
tank (TK-5)
Catastrophic failure of MS
tank (TK-2)
Catastrophic failure of SKO
tank (TK-9)
Catastrophic failure of LPG
storage vessel at neighboring
BPCL, LPG plant
Maximum Downwind distance (m)
Stability Class D (3 m/s)
Stability Class F (1.5 m/s)
5.0
10.0
2.0
5.0
10.0
2.0
Kw/m2
Kw/m2
Kw/m2
Kw/m2
Kw/m2
Kw/m2
186.31
124.47
73.08
179.69
115.30
70.05
266.25
160.86
89.85
251.68
147.98
86.59
160.59
102.64
56.55
152.19
93.17
53.83
2014.87
1304.22
906.47
2210.33
1421.39
988.08
Summary late explosion
S
N
Scenario
1.
Catastrophic failure of MS tank
(TK-2)
Catastrophic failure of LPG
storage vessel at neighboring
BPCL, LPG plant
2.
Maximum Downwind distance (m)
Stability Class D (3 m/s)
Stability Class F (1.5 m/s)
.02 Bar .14 Bar .20 Bar .02 Bar .14 Bar .20 Bar
624.47
386.63
380.60 1065.85 602.12
567.71
2675.69
692.802
536.075
2675.69
692.802
536.075
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It may be seen from the vulnerable zone plotted on the layout plan enclosed as Annexure-5
that the hazard distance due to pool fire of catastrophic failure of largest capacity of HSD,
SKO and MS tank does not goes beyond the plant boundary for 2 kw/m2 corresponding to
First degree burn within 60 sec and for 5 kw/m2 corresponding to Second degree burn & 10
kw/m2 corresponding to Potentially lethal within 60 sec is also within plant boundary for all
the scenarios.
It may be seen from the vulnerable zone plotted on the area map enclosed as Annexure-5
that the hazard distance due to fire ball of catastrophic failure of LPG bullet of largest
capacity (1350 MT filling capacity 85%) goes up to 2.5 Km for the 2 kw/m2 corresponding to
First degree burn within 60 sec. The hazard distances are also reached up to BPCL Oil
installation for the 10 kw/m2 corresponding to Third degree burn within 60 sec.
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11.0 EMERGENCY MITIGATION MEASURES
11.1 Basic requirements of ERDMP
Schedule–III
1.
Location Plan of the Installation indicating sitting of the installation at
neighboring details up to a distance of 2 kms from the installation in
each direction.
Annexure-1
2.
Site plan of the installation showing a complete layout of the
installation indicating boundary walls, exit and entry gates and
location of various facilities
Annexure-2
3.
Layout of Fire Water Systems and Fire Fighting Equipment details
Annexure-6
4.
Line block diagram of manufacturing process and Process Flow
Diagram (PFD) of each unit
Annexure-7
5.
Material Safety Data Sheet (MSDS) for all hazardous chemicals
stored, handled, produced and transported in the installation
Annexure-3
6.
Internal Emergency Contact Numbers.
Annexure-8
7.
External Emergency contact numbers and addresses of police, fire
station, hospitals, mutual aid industry, factory inspectors, Board,
State Pollution Control Board, Petroleum and Explosive Safety
Organization (PESO), etc.
Annexure-9
8.
Pipeline route map and details of various facilities such as
sectionalizing Valve (SV), intermediate Pigging (IP) stations,
intermediate pumping stations (IPS) across pipeline route.
Annexure-11
9.
Addresses and Telephone Directory of Technical Support Services
such as Environmental Laboratories, fire fighting chemical suppliers,
public and private consultant associated with emergency handling
and Aviation Medical Services
Annexure-10
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11.2 Resource Mobilization
Schedule IV
Resource Mobilizations (Men and Equipment)
S.N. Total Requirement
Available with
Installation
BPCL, IOCL,
LPG
Lube
Plant Blending
Unit
MANPOWER
Regular employees – shift
wise
Security staff
Personnel Trained in first
aid
Others ( Technicians /
Helpers )
FIRE
FIGHTING
APPLIANCES/
EQUIPMENT/
CHEMICALS
Fire Tenders/ Fire fighting
engines
Water storage capacity
1
2
3
4
5
6
GAIL
Piyala
Balmer
Lawire
District
Fire
Service
28
113
87
40
150
20
1
11
4
30
22
42
94
26
30
15
08
35
30
19
20
8
5
16
5
Nil
12
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
3
1 /6
Nil
Nil
3
Nil
Nil
Nil
3
Nil
Nil
3 KL
Nil
Nil
Nil
Nil
Nil
12
2
Nil
Nil
Nil
Nil
Nil
Nil
Nil
3 KL
12 KL/
5KL/
3
KL
12
8
4
Nil
0.500
5900 KL +4600
10,300
(Under Construction
KL
2200 KL
300 KL 90,000KL
(Reservoi
rs)
32
60
32
8
Nil
4
Nil
Nil
5 KL
Fire Hoses
Jet/Fog/Spray Nozzles
Foam Branch
Jumbo Jet Nozzles
Foam Compound ( KL )
SAFETY EQUIPMENTS
PVC Suit
130
60/4/4
4
NIL
28 KL
205
100/5
Nil
Nil
Nil
50
30
Nil
Nil
Nil
2
Nil
Nil
10
Nil
1
Nil
Nil
Compressed air B.A. Set
Refill Cylinders for B.A.
Set
Cascade B.A Set
Fire Proximity Suit
COMMUNICATION
Walkie-Talkie
Public Address System
Megaphone
TRANSPORT
Jeeps
Cars
Ambulance
Trucks
Buses
Tractors
Boats
Mobile Cranes
MISCELLANEOUS
Ropes ( Metres )
3
6
1 (Low
Temp.
Suit)
1
2
1
1
Nil
Nil
12
12
Nil
Nil
1
1
Nil
Nil
Nil
Nil
Nil
2
Nil
1
Nil
2
Nil
Nil
Nil
6
Nil
Nil
Nil
1
Nil
Nil
Nil
Nil
21
1
1
21
1
2
16
1
1
Nil
Nil
Nil
5
2
1
7
Nil
Nil
2
Nil
Nil
Nil
Nil
Nil
Nil
3
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
3
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
1
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
300 25
60
100
1
Nil
Nil
Nil
100
50
200
5
Nil
1
1
10
20
Nil
Nil
Nil
Nil
Nil
30
15
Nil
Nil
Nil
Nil
Nil
60
90
100
1
Nil
Nil
Nil
10
4
20
Nil
Nil
Nil
Nil
5
5
10
Nil
Nil
1
Nil
20
10
Nil
Nil
Nil
Nil
Nil
5
Nil
Nil
Nil
Nil
Nil
Nil
Empty drums
Buckets
Sand bags
Dewatering pump
Pneumatic pump
Photo Camera
Video Camera
7
Available with
Neighbouring Units
AviNTPC
Gateway
Oil
Rail
EQUIPMENTS FOR
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CORPS DISPOSAL
Light Metal Stretchers
Tarpauline 12‟ X 12”
Nil
Nil
Nil
2
Nil
Nil
Nil
1
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Rope fibre 3/8”
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Bucket
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
4
2
Nil
Nil
Nil
Nil
Nil
Nil
6
Rubber gloves
8
Nil
Nil
LIST OF EMERGENCY
DRUGS and
APPLIANCES
Canvas Stretcher
1
5
1
1
2
Nil
1
Nil
Nil
Oxygen Cylinder
Nil
Nil
Nil
Nil
2
Nil
1
Nil
Nil
Sterlite Bandages
7
10
8
5
30
3
Cotton Sterilised
10 Pkt.
20 Pkt.
5 Pkt
3 Pkt
10 Pkt
3Pkt
1
1 Pkt
5
3
3 Pkt
6 Pkt
Antibiotics
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Analgesties
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Sedatives
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Tetanus Toxoid
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
7 sets
10 Sets
Nil
Nil
10 Sets
Nil
Nil
Nil
3 sets
Sterilisers
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Autoclave for sterlising
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Dressing Instruments
Instruments, dressing
B.P. Apparatus
Nil
1
Nil
Nil
1
Nil
Nil
Nil
Nil
Suction Apparatus
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
I.V.Set
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Antishock drugs
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Gluco Saline Set
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Gluco Saline Bottle
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Nil
11.3
Incident preventing measures and procedures:
i.
Safety Policy:
As per the legal requirement of section 7-A (3) and 41-B (2) of Factories Act 1948 (as
amended to date). Installation has a written Safety, Health and Environment policy at
corporate level. This policy as such adopted at Installation level. The policy has been
prepared as per the guideline of the statuary requirement. All the workers known the policy,
it is also displayed in various conspicuous places to ensure that policy is well drawn and
known to all employees
ii.
Design of the Installation is such that no significant amount of material arises from
the loading operations, storage tanks, filling gantry and administrative blocks are
designed as per the latest and standard of Oil Industry Safety Directorate (OISD).
Installation is reasonably far away from as possible from public road and population
area. The location plan of the Installation enclosed as Annexure-1.
The layout of the Installation and tank form is accordance with the Petroleum Act and the
design is approved by the Chief Controller of Explosive (CCE). It is based on the vast
experience collected over the years for petroleum Installations and provides for generous
margin of safety. The layout specifies aspects such as the maximum capacity of tankage
within a bound enclosure, the bound wall design, the inter distances, tank to boundary wall
distance, area classification etc. In addition, the following point is also considered:
-
Adequate spacing is provided for maintenance, operations, and fire fighting.
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Storage tanks are reasonably far away from as possible from the Installation boundary,
public road and population area.
Bound wall is provided around sides of the storage tanks with concrete flooring of the
ground with some slope. Grading of the ground under meat is leveled so as to direct
spillage away to a shallow sump away from the tanks.
Only piping associated with the storage tanks is located within the storage areas or
between the storage area and the manifold system.
No pumps are located in the bounded enclosure. All lighting and electrical fixtures in the
hazardous areas are flameproof.
The inter distance between facilities in the Installation is as under:
SN
Facilities
1.
2.
3.
4.
5.
6.
7.
8.
Between tanks
Between tank & pump house
Between tank farm & TLF
between tank and fire water pump house
Between storage tanks & dyke wall
Between pump house & sub station
Between storage tanks & compound wall
Between TLF & office
Recommended as
per OISD (m)
06
08
30
60
08
15
20
60
Actual (m)
10
50
60
175
10
200
60
150
iii. Safety committee:
Plant has safety committee having equal numbers of members of workers and management.
Safety Committees meeting are held in once in every three-month. The recommendations of
the Safety Committee meeting are implemented through the respective concerned officer.
The progress is discussed in the next meeting and checked in the daily round. The minutes
of the safety committee meetings are circulated among the members both ‘management
representatives’ as well as ‘workers representatives’.
iv. Safety audits:
Safety audits is a well recognized tool to improve the effectiveness of safety program and
loss prevention measures by carrying out systematic and critical appraisal of potential safety
hazards involving personnel, plant and equipment.
General guidelines on safely audit methodologies and techniques are also given in OISD (Oil
Industry Safety Directorate) standards. The frequency of audits is given below:


Daily inspection conducted by Sr. Manger I/C
Weekly safety round conducted by the Dy. Manager (HSE), the observations is noted in
a set format “Weekly Safety Round Check List”.
 OSID and BPCL Regional Office and State office also carried out periodic safety audit of
the Installation.
 Annual external safety audit conducted by outside expert agency
v.
Work permit system:
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A work permit system is followed in the Installation for covering hot work, cold work, tank/
vessel entry, excavation, and related maintenance work. The permit is approved by an
authorized person, prior to carrying out the hot jobs in the hazardous areas of the
Installation. The permit details out the precautionary measures to be taken to complete the
job safely. The permit is initiated by, approved by and carried out and signed off by
authorized representatives of the Installation.
vi.
Early warning alarm system:
High Level alarms, High Pressure alarm, High temperature alarm and other safety
instruments are installed at conspicuous places with indication in the control room.
vii.
Inbuilt interlocks system:
Tripping and interlocking devices such as non-returning valve (NRV), remote operated
valves (ROVs) and other various emergencies tripping system such as high pressure & high
temperature etc. installed at conspicuous places with indication in the control room.
viii.
Fire Protection & HSE Management system:
Installation has a well-organized fire & safety management system. The entire fire & safety
provisions made available in the plant such as hydrant lines, fire extinguishers, backup
power etc. All the fire fighting system and equipment are designed as per the OISD
standard. Availability of resources in the Installation as per schedule-IV of PNGRB,
Regulations 2010 under Regulation 11.2 & 17.
ix.
Do’s and don’t, map showing escape route & assembly point displayed at the main
entry gate. Instructions for visitors in case of emergency/drill also displayed at main
gate. All the standby equipments and DG set are checked periodically and record is
maintained in log book.
x.
Safety MIS system is established. Unit sends monthly safety reports including
Exception reports to Corporate SHE department who issues monthly HSE report for
whole organization.
xi.
All standby equipment’s are operated periodically and checked as per specified
schedule. Warning system, first aid & definitive treatment methods, evacuation
procedures are tested periodically.
xii.
Check list points for incident prevention measures as per Check list – 2.
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12.0 EMERGENCY PREPAREDNESS MEASURES
Following emergency preparedness measures are followed by the Installation to handle
emergency
12.1 Emergency drills and mock exercises
(a) To evaluate t h e thoroughness a n d effectiveness o f this ERDMP, Emergency
drills and mock exercises conducted periodic table top exercises
full-scale
or
announced, and unannounced drills. Drills may conduct on the night shifts, change
shifts as well as during the day as mandated under regulation 12.1 (e).
(b) In emergency management time is very important, the initial few minutes are critical and
timely action may contain the emergency. For persons to perform quickly their assigned
roles, it is essential that each individual should be made aware of emergency rehearsals
which will impart procedures and their individual roles through proper training. In each
fire and mock drill emergency scenarios and area are different to cover maximum
scenario of emergency e.g. fire, explosion, or toxic agent release.
(c) The warning system, first aid, evacuation procedures and the definitive treatment
procedures would all be tested periodically.
(d) In on site emergency drill out site observers and participation such as police, fire bridge
ambulance service, civil defence and mutual aid group are invited.
(e) Testing and mock drills for onsite emergency plan will be carried once in three months
and for offsite emergency plan twelve months.
(f) Mock Drills on “Off-site emergency action” has been conducted with the consent of and
under the guidelines of District Collector for surrounding MAH industries.
(g) On completion of the mock drill rehearsal, the debriefing meeting chaired by Officer Incharge (Sr. Manager I/C) of the unit is conducted to ensure the efficacy of the rehearsal
and to discuss the observations. Recommendations/observations received from the
observers in this regards are complied with time bound schedule.
(h) Fire drill will be conduct every month and mock drill as per on site emergency plan is
conduct once every quarter. Observation of mock drill are recorded and rectified within
24 hours. Mock drill results are reviewed by Officer In-charge and reports communicated
to Factory Inspector.
(i) Check Points for mutual aid and mock drills are given at Check list - 3.
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12.2 Training
1) An ERDMP shall be easier to use if training material and general philosophy
on emergency prevention and control are kept separate from the working plan.
(2) (i) Monthly training will be imparted to all the personnel likely to be involved directly
or indirectly to the emergencies including employees, contract workers,
transport crew and security personnel.
(ii) Contract personnel and contract labour will be allowed to start work only after
clearance of attending safety training.
Critical Safety Campaigns are being conducted monthly on various safety topics circulating
by Dy. Manager-HSE by involving all Employees, Contract Employees and Security
Personnel.
(3) Refresher training shall be conducted at regular intervals.
(4) Special training for tank truck crew will be imparted for the fulfillment of requirement
Central Motor Vehicles Rules, 1989 pertaining to dangerous or hazardous good
transport.
12.3 Mutual Aid
We have written mutual aid scheme with neighboring industries viz. M/s BPCL Piyala LPG
Plant, Piyala, M/s Indian Oil – Lube Blending Unit, Piyala, M/s Avi-Oil, Piyala, M/s Balmer
Lawire, Piyala. The list of mutually agreed equipment and material as per schedule-IV of
PNGRB Regulations 2010 given in this report at Clause No 11.2.
We are committed to attend any incidents involving road transport vehicle near our
installation on getting information by civic authorities even in absence of mutual aid
agreement with the consignor.
To make the emergency plan a success, the following exchange of information amongst the
member organizations of mutual aid association is considered essential:
(i)
The types of hazards in each installation and fire fighting measures.
(ii)
List of all the installations or entities falling along the routes of transport vehicles
carrying petroleum or petroleum products.
(iii)
The type of equipment, that would be deployed and procedure for making the
replenishment.
(iv)
Written procedures which spell out the communication system for help and response.
This is also required to get acquainted with operation of different firefighting
equipment available at mutual aid members and compatibility for connecting at users
place.
(v)
Familiarization of topography and drills for access and exit details carried out by
mutual aid members.
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13.0 RESPONSE PROCEDURES AND MEASURES
(a) Zoning and Maps
The Site Plan and layout plan enclosed as Annexure-1& 2 showing the Incident prone area,
assembly points and emergency control room.
(b) Layout/Flow Diagram
Layout plan enclosed as Annexure-2 and Flow diagram & P&I diagram for different activities
such as lines, filling system shows isolation valves, NRV etc. enclosed as Annexure-7.
(c) Manpower data
The total manpower will be 26 nos. (Management 13 nos., Non Management 13 nos.), and
security staff is 25 nos.. The Shift Timing is as under:
Shift A
Shift B
Shift C
General Shift
:
:
:
:
06:00 AM – 02:00 PM
02:00 PM – 10:00 PM
10:00 PM – 06:00 AM
09:00 AM – 05:30 PM
Check points on ERDMP response measures are given at Check list- 4
Emergency and disaster response of Level I & II will be conducted according to established
operating procedures will be used to manage the event. For this purpose the plan will be
identify an emergency response organization with appropriate lines of authority with
succession planning and actuating the response management. Following emergency
organization structure will be established for tackling any emergency of Level-I & II. In case
emergency goes beyond the plant premises immediate inform to District Authority/District
Crises Group for the actuation of Offsite emergency plan.
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14. EMERGENCY ORGANIZATION & RESPONSIBILITIES
Detailed information on roles and responsibilities of various coordinators and other
employees and action to be taken in case of emergency in BPCL Piyala Installationis
provided in this clause. The success of control of an emergency situation depends upon the
timely action by the key personnel of the organization.
Emergency Response Organization:
Overall objectives of an emergency response organization shall be such as to:
a)
b)
c)
d)
e)
f)
Promptly control problems as they develop at the scene.
Prevent or limit the impact on other areas and off-site.
Provide emergency personnel, selecting them for duties compatible with their normal
work functions wherever feasible.
Follow Standard Operating Procedures (SOP’s) laid down for all types of
emergencies.
Employees must assume additional responsibilities as per laid down procedure of
ERDMP whenever an emergency alarm sounds.
In setting up the organization, the need for round-the-clock coverage shall be
essential. Shift personnel must be prepared to take charge of the emergency control
functions or emergency shutdown of system, if need be, until responsible personnel
arrive at the site of emergency. The organization should have an alternate
arrangement for each function.
14.1 Emergency organization Structure
Role of key personnel is clearly defined to avoid confusion and to meet the emergency
effectively. The Chief Incident Controller and the Site Incident Controller are two main
positions for effective control of an emergency at site. They shall be supported by
Emergency Management Team comprising of technical resources from Operations &
Maintenance, mechanical, electrical, instrumentation, civil, communications, technical
services etc. Fire & Safety, Security, HR (Personnel & Administration), Finance & Accounts,
personnel shall also take due roles & responsibilities.
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Affected Stake
Holders and
Government
Authorities
Municipal
transport rescue
and rehabilitation
team
Police Services Off-site Incident
Controller
(District
Collector)
Medical Services & Ambulance Fire Brigade Services CHIEF INCIDENT CONTROLLER
Sr Manager I/c Anil Srivastava Alternate: Manager‐Ops 1. Sh. Manoj Patoa 2. Sh. Vikas Rastogi
Mutual Aid SITE INCIDENT CONTROLLER Index Level‐I: Level‐II: Level‐III: Manager‐Ops 1. Sh. Manoj Patoa 2. Sh. Vikas Rastogi Alternate: Dy.Manager‐Ops‐ Sh. K.P.Singh Dy.Manager‐HSE‐ Sh. Yogesh Chinchole Administrative & communication Team In Charge: Assistant Manager-Ops
Sh. Rajinder Kanojia
Alt. In charge: Executive Ops
Sh. Swapnil Srivastava
Fire Combating Team In Charge: Dy.Manager-HSE
Sh.Yogesh Chinchole
Sh. Shobhit Kumar Yadav
Auxiliary Team In charge- Executive Ops
Sh. Anoop Kumar Sharma
Alt. Incharge : Executive Ops
Sh. Amber Zaidi
Following coordination functions are not nominated separately but assigned to members of
auxiliary services.
i.
ii.
iii.
iv.
Human resources and Welfare Services
Transport and Logistic Services
Media and Public relations
Operation and technical Coordination
Emergency organization Structure off office hours
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CHIEF INCIDENT CONTROLLER
Sr. Manager I/c SITE INCIDENT CONTROLLER Police Services Manager‐Ops Fire Services INCIDENT CONTROLLER
MAIN GATE SURITY GURAD
Communication Chief TT PARKING GUARD -
Fire Combating Chief PATROLING GUARD Auxiliary Chief SIDING GUARD On Holiday or after the closure of Installation or during the night incident controller (main
gate security guard) inform to SIC as well as CIC.
To inform local Police Station & police control room & fire service by phone/mobile.
Try to control the fire by operating fire extinguisher/hydrant.
14.2 Role and Responsibilities
14.2.1 Chief Incident Controller (CIC): Sr. Manager I/C (Sh. Anil Srivastava)
Alternate: Manager-Ops
1. Sh. Manoj Kumar Patoa
2. Sh. Vikas Rastogi
The Chief Incident Controller (CIC) will have overall responsibility to protect personnel,
site facilities, and the public before, during, and after an emergency or disaster. The CIC will
be present at the main emergency control centre for counsel
and
overall
guidance.
Responsibilities of the Chief Incident Controller will include the following:a. preparation, review and up-dation of the ERDMP a s p e r g u i d e l i n e o f
PNGRB Regulation 2010;
b. assessment of situation and declaration of emergency;
c. mobilization of main coordinators and key personnel;
d. activation of Emergency Control Centre;
e. taking decision on seeking assistance from mutual aid members and external
agencies like Police, Fire Brigade, Hospitals etc.;
f. continuous review of situation and decide on appropriate response strategy;
g. taking stock of casualties and ensure
timely medical attention;
h. ensuring correct accounting and position of personnel after the emergency;
i. ordering evacuation of personnel as and when necessary;
j. taking decision in consultation with District Authorities when an Off-site emergency to
be declared.
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14.2.2 Site Incident Controller (SIC): Manager-Ops
1. Sh. Manoj Kumar Patoa
2. Sh. Vikas Rastogi
Alternate:
Manager-Ops- Sh. Hirender Singh Negi
Dy.Manager-HSE- Sh. Yogesh Chinchole
The Site Incident Controller will directly report to Chief Incident Controller. Responsibilities
of the Chief Incident Controller will include the following:a. will maintain a workable emergency control plan, establish emergency control
centers, organize and equip the organization with ERDMP and train the personnel;
b. will take quick decisions and taking full charge at the time of emergency.
c. will communicate to the Emergency Control Centre where it can coordinate activities
among groups;
d. will be responsible for ensuring that appropriate local and national government
authorities are notified, preparation of media statements, obtaining approval from the
CIC and releasing such statements once approval received;
e. will also ensure the response to the incidents or the emergencies, as the case may be,
is in line with entity procedures, coordinating business continuity or recovery plan
from the incident. He must ensure next of kin are notified in a timely manner;
f. will also co-ordinate if any specialist support is required for the above purpose; and
g. will decide on seeking assistance of mutual aid members and external agencies
like police, fire brigade, hospital etc.
14.2.3 Administration and Communication Team:
In Charge:
Assistant Manager-Ops
Rajinder Kanojia
Rohit Lihite
Responsibilities of the administration and communication in-charge will include the
following:a. to coordinate with mutual aid members and other external agencies;
b. to direct them on arrival of external agencies to respective coordinators at
desired locations;
c. to activate the medical centre and render first aid to the injured. Arrange ambulance
and coordination with hospitals for prompt medical attention to casualties;
d. to ensure head counts at assembly points;
e. to arrange procurement of spares for fire fighting and additional medicines and
drugs;
f. to mobilize transport to various teams for facilitating the response measures;
g. to monitor entry and exit of personnel into and out of premises;
h. to ensure only authorized personnel enter into the premises;
i. to regulate the flow of traffic into and out of premises and control the mob outside, if
any, with the assistance of the police;
j. to provide administrative and logistics assistance to various teams; and
k. to arrange evacuation as directed by the chief incident controller, and in
coordination
with the civil
authorities
like
police, panchayat / municipal authorities etc.
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14.2.4 Fire Combating Team
In Charge:
Dy.Manager-HSE (Yogesh Chinchole)
Alt. In charge: Executive Ops ( Amber Zaidi)
Responsibilities of the in- charge of Fire Combating Team will include the following:a. to activate emergency sirens as per the practiced codes;
b. to take charge of all fire fighting and rescue operations and safety matters;
c. to ensure that key personnel are called in and to release crew of fire fighting operations
as per emergency procedure;
d. assess functioning of his team and communicate with the CIC and or administrative
controller for any replenishment or, replacement of manpower or firefighting
equipment;
e. direct the fire brigade personnel and mutual aid members to their desired roles as
also proper positioning of the manpower and equipment;
f. to decide the requirement of mutual aid and instruct fire station, who, in turn will
contact mutual aid members;
g. to coordinate with outside fire brigades for properly coordinated fire fighting operation;
h. to ensure that casualties are promptly sent to first aid centre /hospital;
i. to arrange requirement of additional fire fighting resources including help from mutual aid
partners;
j. ensure empty and loaded trucks are removed to safer area to the extent possible so as
not to affect emergency handling operations;
k. continually liaise with the SIC and or CIC and implement the emergency combat
strategies as communicated by him; and
l. ensure adequate hydrant pressure in the mains and monitor water level in the reservoir.
Note: In-charge of Fire Combating Team will wear identification jackets at the site of
disaster so that he is clearly distinguished among fire fighting personnel and is visible
from a distance.
14.2.5 Auxiliary Team
In chargeExecutive Ops (Anoop Kumar Sharma)
Alt. In charge- Executive Ops (Shobhit Kumar Yadav)
Responsibilities of the in- charge of Auxiliary Team will include the following:a. to take immediately information from the in- charge of Fire Combating Team for
required help (equipment, manpower etc.) and provide them;
b. to safely shutdown all the operation (safely shutdown all the pumps, remove the hose
pipe of TTs at TLF, remove the hose pipe of wagon and close the supply of electricity);
c. to ensure that the tankers are fully/half loaded shifted at a safe place;
d. to gather information regarding all personnel at the incident location and information
about any casualties and or missing persons;
e. to make arrangements for the timely notification of injured personnel at the incident site
and their condition;
f. to coordinate with first aider/ doctor, for making onward medical arrangement for
casualties who have been evacuated from the incident location.
g. to ensure that security guard to control the persons coming and going out from
Installation and keep the way clean.
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14.2.5.1 Security Coordinator : Main Gate Security Guard
The Security Co-ordinator reports to the Site Incident Controller and is responsible for
security of the installation during any incident or emergency situation and for implementing
the actions below:
a. Obtaining an approved visitor list from the reception at main gate and ensuring that
personnel on the list are escorted to Reception by security staff;
b. Maintaining security of the office in the event of an office evacuation;
c. Providing office security and assisting authorities in the event of civil unrest or when
required organizing additional security at the emergency scene;
d. Obtain initial briefing from Site Incident Controller and provide security information and
status reports to Site Incident Controller
e. Assume responsibility for any task delegated by Chief Incident Controller
f. Assess the emergency, identify security specific problems and recommend solutions to
Chief Incident Controller
14.2.5.2 (a) Maintenance of ERDMP Record
Dy. Manager HSE will be maintain ERDMP record for all kind of emergencies covering near
Miss, Level-I, Level-II and Level-III. He will also maintain an Incident Record Register for
the above purpose and post–disaster documentation like resources deployed, relief,
rehabilitation measures and lesson learned to avoid re-occurrence of any such
emergency.
Administration and communication In-charge will maintains good public relations during
emergency and gather accurate information and inquires from the media, government
agencies, local organizations and the general public to the Site Incident Controller (SIC).
After approval of CIC Site Incident Controller will Issue authorized statements to Press,
Radio, TV etc. regarding the emergency and its possible impact on the surroundings to
reducing the rumours and speculation.
14.2.5.2 (b) Recorder
Dy. Manager HSE will be maintain an accurate time record of key information received
from the incident or emergency location and to record the actions initiated by the site
incident controller and for implementing the emergency response actions below:
to record key incident events/actions on incident status board;
to maintain essential equipment checklist status;
to ensure all status and information is up to date and correctly displayed;
to take all necessary recorded material to the alternate ECC room in the event of
emergency in main ECC room; and
e. to maintain a log book.
a.
b.
c.
d.
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14.2.5.3 Communication Services
(1) Administration and communication in-charge will ensure the following actions below:
a. Ensuring the ECC equipment and systems are maintained to a high standard and
remain functional throughout the emergency;
b. Ensuring a back-up communication system is available such as mobile phones
for outside communication and walky-talky.
c. Providing quality and diverse communication systems for use in routine and
emergency situations.
COMMUNICATION FLOW CHART
First Responder SCADA System Administrative & Communication team Crises Mgmt Group Public
Employee/
Security Police
MANAGEMENT
TEAM (Head
Operations, Head
Maintenance, Head
Technical, Head
HSE, Head Security,
Head (HR)
Emergency Control Centre Fire Combating
Team Auxiliary Team Site Incident Controller Fire Bridge, Police, Medical & Govt. authorities
Chief Incident Controller Mutual Aid Members Index Level‐I: Level‐II: Level‐III: District Administration
(2) Flow of Information
a. Emergency Control Centre will receive the information form field either in person or
from the various systems available in the installation.
b. on receipt of information, the control room shift In-charge will actuate the ERDMP
and notify the emergency to site incident controller;
c. Control room shift in-charge will act as site incident controller till arrival of SIC/CIC.
d. SIC or CIC depending upon the level of emergency will actuate the ERDMP and inform
the concerned authorities as depicted above in the chart.
The followings are the Essential persons of the Installation and their duties are as under:
14.2.5.4 First Aiders
-
He will prepare plant dispensary readiness for emergency.
He will provide first aid to the injured personnel and arrange to transfer to nearby
hospitals, designated doctors & nursing homes.
He will ensure that all the medicines are available in the first aid boxes.
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14.2.5.5 Electrician
-
He will disconnect the electric supply of the affected area.
He will provide lighting in the affected area and keep generator ready, if required.
14.2.5.6 Fire pump attendants
On hearing the fire siren they will report at the pump house and will start activities as
directed by the In-charge Fire Combating Team.
14.2.5.7 Operators
-
He will shutdown the plant/equipment in a safe manner and will process to the
emergency control room for further instructions.
He will follow the instruction given by SIC/CIC.
14.2.5.8 Responsibilities of the Non- Essential Workers
The all non-essential workers, who have not been defined any role and duties in an
emergency situation should not gather around the accident/incident site as this would result
in a chaotic situation at the site. These people should remain at the assembly point and wait
for instruction from the SIS/CIC, and when he requires their service.
14.2.5.9 Siren Codes
1. The following Emergency siren/s will be located in the Installation to inform the people
of emergency. These would be tested once in a week to keep them in working condition
a. Electric siren 3 Km range: 01 no.
b. Electric siren 1 Km range: 01 no.
c. Hand operated siren: 07 nos.
2. Emergency siren code is as follows, namely
a. Emergency Level-I & II: A wailing siren for two minutes.
b. Emergency Level-III: Same type of siren as in case of Level – I and II but the same
will be sounded for three times at the interval of one minutes i.e.( wailing siren 2min
+ gap 1 min + wailing siren 2min + gap 1min + wailing siren 2min) total duration of
Disaster siren to be eight minutes.
c. ALL CLEAR: Straight run siren for two minutes.
d. TEST: Straight run siren for two minutes at frequency once a week.
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15.0 INFRASTRUCTURE
15.1 Emergency control centers (ECC)
(1) Sr. Manager I/C room of the Installation designated as Emergency Control room.
(a) ECC is away from potential hazard and provided maximum safety to personnel and
equipment.
(b) ECC will be constructed by reinforced concrete.
(c) The ECC have two exits and adequate ventilation.
(2) Following supplies and dedicated equipment are made available at the ECC
a.
b.
c.
d.
e.
f.
g.
h.
i.
A copy of the ERDMP is made available.
Maps and diagrams showing buildings, roads, process lines, drainage trenches, and
utilities such as air, nitrogen, water and electricity are displayed.
Maps showing the site, surrounding area, high-ways, rivers, etc. are displayed,
Names, addresses, and telephone numbers of employees displayed.
Updated lists of names, addresses, and telephone numbers of off-site groups and
organizations are made available that might have to be contacted during emergency.
Dedicated and reliable communication equipments are provided at the ECC.
ECC has emergency lights and back up UPS power so that operations can continue in
the event of power failure.
Logbooks for recording the sequence of events have been provided to assist in
investigating causes, evaluating performance, and preparing reports.
ECC also has dedicated computer with LAN / internet facility to access the installation
data and also it has the latest and updated soft copies of all standard operating
practices (SOP) etc.
15.2 Assembly points
1. Emergency Assembly Point near the Administrative Office is pre-designated areas in
safe zone as per quantitative risk assessment, where the personnel like workers, staff,
contractor workers etc. not involved in emergency operations (as per ERDMP) shall
assemble in case of an emergency.
2. Depending on the location of the emergency, the assembly point can vary. Accordingly
for each potential hazardous zone, a specific assembly point is identified and clearly
marked on the zones or maps.
3. All Designated assembly points are clearly marked with directional display board along
the route. Routes are well lighted with florescent marking.
4. During an emergency, pre-designated persons would take charge of this point and take
the roll call of the people reporting. Provisions are made for assembly points,
communication and headcount facilities at assembly points, and personnel to control the
movement of assembled employees.
5. Security coordinator will make head count for the persons present at the assembly points
and will inform the SIC/CIC.
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16.0 DECLARATION OF ON-SITE AND OFF–SITE EMERGENCIES
1. An emergency starts as a small incident which may become a major incident with
passage of time. At the initial stages, the emergency organization chart shall be put into
action. If the incident goes beyond control the on-site emergency plan will be actuated by
the chief incident controller at the appropriate stage as considered necessary.
2. During idle shift or holidays, the security personnel will combat the incident as per the
ERDMP organization chart.
3. When emergency becomes catastrophic and evacuation beyond the plant premises is
considered necessary by the chief incident controller, the situation will be handed over to
district authority for implementing the off-site emergency plan.
4. The management of emergency henceforth has to be controlled by the district crisis
management group under the supervision of the District Collector.
5. In addition to preparation of on-site emergency plan, furnishing relevant information to
the district authorities for the preparation of off-site emergency plan is a statutory
responsibility of the occupier of every industry handling hazardous substance
Who should report the fire disaster and how:
Any person in the pump station / tank farm who sees a fire or unsafe conditions anywhere in
the station/tank farm should report it at once to the Control Room. Person reporting the fire /
emergency should state the location at a prominent place to guide fire-fighting crew arriving
on the scene. The man should try to attempt to mitigate the emergency, extinguish the fire
with the equipment available nearby till arrival of fire fighting crew. He should draw the
attention of nearby people by shouting ‘FIRE, FIRE, FIRE’.
Declaration of the disaster
Level 1& 2 disaster- The disaster is declared by the Chief Incident controller.
Level 3 disaster- The disaster is declared by District Collector.
Any untoward incident/emergency has to be reported either by person or through
telephone/VHF or by any other means to the Location In-Charge (Sr. Manager)/Security
Gate. The Location In-Charge (Sr. Manager I/C) shall act as per Roles & Responsibility
defined in clause No.14.2.
Incident Controller shall decide the nature of emergency [Level-I, Level-II & Level-III] and
take appropriate action.
In the event of Emergency, the same will be communicated to all Coordinators. All
employees will report to nearest Assembly points as specified, on hearing the siren or
getting the message over telephone/VHF. Maintenance personnel/Contract workmen
working with machines also proceed for Assembly point after leaving the machine in safe
condition.
This plan has been developed to deal with emergency incidents which occur totally within
the BPCL, Piyala Installation premises and which do not endanger the outside community.
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Emergency incidents will be classified by the level of response that will be required. The
actual classification will be made by the Location-In-Charge (Sr. Manager I/C) or his
nominee as information first becomes available on an incident. The level of response may
change as more information becomes available or conditions change. Where information is
lacking the worst case scenario will dictate the level of response.
Level 1: Minor Emergency
Incidents with minor release or leak of products or other emergency, which amounts to
minimum spill or minimum release of volume, could poses a minor threat to the safety
of employees, residents, the environment or property and can be safely contained
On-Site, which doesn’t produce any off site impact and doesn’t seek any outside
involvement.
Level 2: Major Emergency
Incidents with moderate release or leak of petroleum products handled or other
emergency, which amounts to moderate spill or moderate release, could poses a
moderate threat to the safety of employees residents, the environment or property
which could have safely contained On-Site, could produce off site impact and could
seek any outside involvement and could require outside resources.
Level 3: Disaster
Incidents with major release or leak of hydrocarbon products or other emergency,
which amounts to large spill or large release of volume involved, could poses a total
threat to the safety of employees, residents, the environment or property which
produce off site impact and require large outside involvement & district outside
resources.
Termination of emergency period and restoration of normalcy period, which follows all clear
sirens, shall also be declared by the “Chief Incident Coordinator” in case of Level-I and II.
For level-III termination of emergency will be declared by District Authority through
appropriate mode of information transfer so as to reach each and everyone.
Emergency Action Plan for Emergency during Off- Shift Hours (Including Holidays):
1.
2.
3.
During other than office hours (including holidays) the Security In-charge shall perform
the duties of Site Incident Controller. Security at Visitor Gate shall also perform duties
of Communication, Welfare & Medical, and Material Coordinator in addition to his
normal duties till the arrival of the concerned coordinator.
The Security in-charge in consultation with the site incident controller shall act upon
depending on the situation till arrival of the concerned coordinators for effective
handling of emergency. They shall take care of the safety of personnel, installation
property etc. Safe operating procedures which are already in practice shall be followed.
All other non-essential personnel whose roll is not defined in the action plan shall
assemble at assembly points and wait for further instruction from CIC Control Room.
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17.0 RESOURCES FOR CONTROLLING EMERGENCY
17.1 In order to meet all possible emergencies, adequate number of resources and systems
has been provided as per identified Risk level and also in compliance with statutory
requirements under Factories Act, 1948 and other OISD regulations.
17.2 The available emergency control systems and facilities within the installation is as
under: (a) Fire and gas detection system
LEL Detectors and Manual Call Points are installed in the installation. Siren is kept in
auto mode and will sound in case of operation of break glass unit/MCP.
(b) Fire protection system (Active and Passive)
Fire is classified basically on the basis of the combustible material involved in it as
below:
Type of Fire
Class ‘A’ Fire
(Combustible Solid)
Materials Involved
Ordinary combustibles as Wood, Cloth, Rubbish,
Plastic, Paper.
Inflammable substances as Oil, Mob, Benzoyl,
Class ‘B’ Fire
Solvent etc. And also all the fires, which occur in
(Combustible Liquid)
fast and vapour.
Fire involving gases i.e. LPG, CNG, Synthetic
Class ‘C’ Fire
(Combustible Gases & Energized gas, Hydrocarbon Gases etc. and energized
electrical equipment.
Electrical Equipment )
Class ‘D’ Fire
All Combustible metallic fire, Potassium,
(Combustible Metal)
Magnesium, Sodium etc.
For Fires of:
1. Electric Origin, use only CO2 or dry chemical fire extinguishers to extinguish fire on or
around electrical equipment. Do not use water or foam.
2. Do not extinguish a gas fire until the source of fuel has been cut off to avoid an
explosive mixture being formed.
Suitability of Fire Extinguishers:
Types of
Extinguishers
Water Type
Fire Extinguishers
Foam Type
Fire Extinguishers
CO2
Fire Extinguishers
Dry Powder
Fire Extinguishers
*Special type of DCP
Class ‘A’
Suitable
Unsuitable but will
control small fires
Unsuitable but will
control small fires
Unsuitable but will
control small fires
Class ‘B’
Class ‘C’
Class ‘D’
Unsuitable
Unsuitable
Unsuitable
Suitable
Unsuitable
Unsuitable
Suitable
Suitable
Unsuitable
Suitable
Suitable
Suitable*
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All Tanks are provided with fixed water & Fixed Foam Pourer system for cooling as well
as combating tank fire during emergency as per OISD-117 &118 requirements for Oil
installations.
(c) Fire fighting systems
Following fire fighting system available in the installation:
SN
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
FACILITIES
Double headed hydrants
Single headed hydrants
Water Monitor
Foam Monitor
Fixed Type, MEFG
Portable Type, MEFG
Jet Nozzle
Foam Branch Pipe
Fog Nozzle
Universal Nozzle
Water Sprinkler System
Foam Pourer System
QUANTITY
68 nos.
04 nos.
34 nos.
38 nos.
04 nos.
02 nos.
60 nos.
02 nos.
02 nos.
02 nos.
On all A/G Tanks
On all A/G Tanks
Wind Socks:
Wind socks are installed for knowing wind direction during emergency. Adequate number of Wind
Socks has been installed in at strategic locations such as Tank Form areas; TLF Shed etc.
Portable Fire fighting Extinguishers:
All the strategic location/areas of the installation, are covered with portable fire
extinguishers for tackling fires at their incipient stage. The details of Fire Extinguishers is
as under:
SN
1.
2.
3.
4.
5.
FACILITIES
CO2 Type Fire Extinguishers
QUANTITY
121 nos.
25 nos.
07 nos.
07 nos.
64 nos.
Hydrants, Monitors & Hose Boxes:
Entire installation premises & strategic processing areas are covered with hydrant point;
water Monitor & Water Cum Foam Monitor System. Every hydrant point is provided with
one hose box having two delivery hoses and one branch/Nozzles.
Fire Water Network:
Entire installation premise is covered with fire water Network to meet the emergency
along with Monitors, High Range Monitors, Fire Hydrant points and water cum Foam
Monitors at strategic points as per OISD-117 requirements.
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Installation has two verticals fire water tanks of capacity 5900 KL each & one
underground tank of capacity 4200 KLas per OISD requirement for 4 hours capacity.
Three fire engine of capacity 615 KL/Hr & 105 Meter head each and two numbers of
jockey pump of capacity 20 KL/Hr. The fire engine header is kept pressurized with tank
head. The remotest point on the water header has pressure of close to 7 Kg/cm3g.
In case of power failure Installation has 04 nos. of D. G. sets of capacity 625 KVA, 250
KVA, 125 KVA & 25 KVA.
(d) Ambulance facility in house, if not available then should be available on
urgent call basis.
One emergency vehicle available round the clock in the Installation used to shift injured
person in nearest hospital on occurrence of any emergency. Ambulance shall be
available on urgent call basis from the nearest hospital.
(e) Rescue facilities and personal protective equipments (PPEs)
Emergency Kit consists of listed emergency equipments required for rescue and
control/arresting leakage in case of emergency in oil terminals & depots. The equipments
shall be mounted on a compact light weight trolley.
Emergency Kit shall be consisting of the following emergency equipments:
S.No.
1
2
3
Item
Fire proximity suit
PVC suit
Leak control kit
4
Petroleum product
cleanup chemical
5
6
7
8
Quantity
1 set
2 sets
Consisting of 1 no each of leak
arresting pad, leakage control
of external pipes, internal
pipes, large external pipes upto
20 inch, drums / containers
leakages, general purpose
leakages, large hole leakages
in storage tanks.
Boom(5 inch dia , 3 mtr. Long)
: 6 nos.
Boom(3 inch dia , 3 mtr. Long)
: 6 nos.
Granular particles to absorb Oil
: 20 Kg.
Oil spill dispersant
(water based) along
with hand held spray
nozzle.
Non sparking tools
Dispersant :40 litres
Spray Gun with back pack : I
set.
Breathing apparatus
set (40 minute
duration)
Emergency escape
sets (15 minutes
2 sets
One Set.
2 Sets
Specification
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duration)
9
10
11
Flame proof search
light
Mega phone ex-proof
Hand siren with stand
12
2 nos
1 set
1 no
1 no.
First aid box
13
14
Manual resuscitator
1 no
1 no
Folding stretcher
15
16
17
18
19
Mechanical tool kit
Cold / low temperature
hand gloves
Electrical rubber hand
gloves
Electrical tester
Chemical/oil splash
proof goggles
Approx. range of
1.6 KMS
nose, mouth, face
plate, air bulb with
oxygen inlet
connection, nonreturn, nonbreathing human
valves and first
aid charge packed
in a plastic bag
Size 6 feet X 3
feet with tying
belts & blanket.
1 set
4 Pairs
2 pair
suitable for
Electrical jobs
upto 33000 Volts
1 no
4 nos.
ANSI/CE marked
Personnel protective equipment
Sn
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Facilities
Quantity
Safety Helmets
Provided to each employ.
Safety Shoes
Provided to each employ
Hand Gloves (Electrical Use)
02 Pairs
Hand Gloves (Cold/Low Temp.)
04 Pairs
Breathing Apparatus (40 Minute)
03 set.
Emergency Escape Set (15 Minute)
02 set.
Fire Proximity Suit
02 nos.
PVC Suit
02 nos.
Flame Proof Torch
04 nos.
Hand Siren with Stand
05 nos.
Petroleum Product Cleanup material
11.
Boom-5”&3” dia 3 m long
06 nos.
Granular Particle
20 kg.
12.
Leak Control Kit
Pillows-12 nos.
13.
Oil Spill Dispersant with back sprayer
40 Liter
14.
Manual Resuscitator
02 nos.
15.
Chemical Splash Proof Goggles
04 nos.
(f) First aid and medical facilities round the clock with availability of
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minimum one nurse (24X7) and doctor in the first aid room.
No separate first aid centre in the Installation. Facility of first aid available in
administrative building. 02 numbers of first aid boxes are available in the Installation. A
panel doctor available for all the employees
(g) Communication facilities
Installation equipped with communication facilities such as walkie-talkies and intercom
telephone for communication within premises and P&T line with STD facility and
personnel mobile phone for outside communication.
(h) Escape route and evacuation zones
Map showing escape route & assembly point are identified and displayed at the main
entry gate.
(i) Emergency shutdown system
In case of emergency Installation will be shut down as per Standard Operation
Procedure.
17.3 In case of emergency not handled by the plant personnel and required help of local
agencies, SIC & CIC will communicate to following local agencies for assistance as per
requirement and severity of emergency:
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
l.
Fire Department
Police
Municipal and Provincial agencies
Hospitals
Doctors
Other relevant company facilities
Mutual aid organizations
Co-operatives
Helicopter and air transport services
Surface transport services
Safety and monitoring equipment suppliers
Spill response and/or cleanup services
Contact numbers is enclosed as Annexure-9. The mutual aid members are as follows:
1.
2.
3.
4.
M/s BPCL Piyala LPG Plant,
M/s Indian Oil – Lube Blending Unit,
M/s Avi-Oil &
M/s Balmer Lawire
17.4 Installations also determined type of resources such as equipment, personnel,
technology, expertise, etc. provided by the respective governments under different
conditions, in case Level-II emergency.
17.5 Availability of resources (internal/external) is attached as Check list – 6.
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18.0 DEMOGRAPHIC INFORMATION
a. Neighboring population in 5 Km radius
There is no major population residing around the Installation. The neighboring villages
around the Installation are village Sagarpur, Jajru, Kali Goan, Sikri, Piyala, Sunped, Malerna,
Softa, Dheeg, Khadholi, Bhanakpur. The approximate population around 5 km radius from
the Installation is approximate 50,000.
b. Housing colonies of industries
BPCL, Piyala Installation is situated near Village Piyala. It is located on National Highway-2
(Delhi-Mathura Road) at a distance of about 2.5 Kms. in District. Faridabad, Haryana and
about 45 Kms. from New Delhi. The main nearby town is Ballabhgarh.
c. Sensitive institutions such as Schools, Old-age homes, Hospitals, religious
establishments
There are no such as Schools, Old-age homes, Hospitals, religious establishments around
the Installation.
d. Cattle & Livestock
The major cattle found in this are area are cows, buffaloes and other live stock are goat, pigs
and dogs.
c. Flora & Fauna
Mulberry, eucalyptus, pine, kikar, shisham and babul are some of the trees found here. The
species of fauna found in this area are, nilgai, panther, fox, mongoose.
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19.0 MEDICAL FACILITIES
(a) Facilities available at first aid centre
Facility of first aid centre is 02 numbers of first aid boxes and a Panel doctor. One
emergency vehicle available round the clock in the Installation used to shift injured person in
nearest hospital on occurrence of any emergency. Details of first aid facilities available in
first aid centre is as under
I
1
2
3
II
1
3
4
5
III
1
2
3
Medical Staff
Doctor
Compounder
Nurse
Emergency Facilities
Ambulance
Beds
Stretcher
Wheel Chair
Lab/ Test Equipment
X-Ray Unit
ECG
Audiometer
Spirometer
Oxygen, Pulse
Oxymeter
Blood Analysis
Equipment
Qty
1
0
0
1
0
1
0
Remarks
General Shift (9AM – 11.00AM) Weekly Twice
Emergency Vehicle
0
0
0
0
0
0
(b) Details of trained persons in first aid in the plant
All the employees of the Installation are trained in first aid.
(c) & (d) Facilities available at identified hospitals and at other local hospitals
The nearest medical facilities available in Faridabad District. The other medical facilities
available from outer agencies are as follows:
SN
Name of Hospital
1.
Sarvoday Hospital, Faridbad
Approx. Distance
from the Installation
14 Km
2.
Government Hospital, Faridabad
15 Km
3.
Escort Hospital, Faridabad
14 Km
The contact numbers of hospitals is given in Annexure-9.
Facilities available
O.T. Burn Ward,
Pathology etc.
O.T. Burn Ward,
Pathology etc.
O.T. Burn Ward,
Pathology etc.
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(e) Antidotes and emergency medicines
No specific antidotes of petroleum product exposure, general medicine such as antiseptic,
analgesic, Anti-Snake Venom etc available in the first aid centre.
(f) & (g) Details of specialist doctors in the town and Details of hospital in nearby cities
The other local hospitals available in nearby cities are given below and specialist doctors
are available in these hospitals.
SN
1.
Name of Hospital
Kalra Child Care Centre
2.
QRG Central Hospital &
Research Centre
3.
Centre for Sight-Faridabad
4.
Metro Heart Institute
5.
7.
Asian Institute of Medical
Sciences
Sun Flag Hospital &
Research Centre
Gupta Hospital
8.
Handa Medical Centre
9.
R. K. Hospital
10.
S.V.Nursing Home
11.
Nagpal Maternity &
Orthopaedic Hospital
6.
Address
1485,Sector-15,
Opp.Telephone Exchange,
Faridabad
Vivekananda Hospital
Campus, Sector-16,
Faridabad
At Sunflag Hospital, Sector16 A, Faridabad
SEC-16A, Faridabad
Sector-21 A, Near Badkal
Flyover, Faridabad
Sector-16A, Faridabad
Mohna Road, Ballabgarh,
Faridabad
site no:1, sector-16,
Faridabad
3c/59, Near ESI Hospital,
Faridabad
1-G, 49, B.P.NIT, Opp. Bal
Bhawan NIT. Faridabad
1-C-62 N.H., N.I.T
Faridabad
Contact nos.
0129- 2280265
0129- 4280300
0129-4004441/2
0129-5002517-18,
2263590, 4277777
0129- 4253020
01294199000,2263584/85/86
0129- 2248439
0129-2291847
0129-2413430,2423430
0129-2416240/
98104 45953
0129- 3293066
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20.0 EVACUATION
20.1 Planning and training on evacuation techniques are important in preventing
injuries. Evacuation of local communities or people near the site may be
prudent depending on the situation and down-wind dispersion information etc.
Although this action will normally be initiated and handled by district
authorities, the
affected
installation shall help to
implement
such evacuation
20.2 Evacuation Plan
(a) Basis for recommending on-site or off-site actions
CIC continuous monitor the situation and assume and take decision of evacuation if required.
Evacuation of the communities or people near the site depending on the situation are handled
by the district authorities, in-charge administration and communication team coordinate with
district authorities in such evacuation.
(b) Authorize person for area or site evacuation
In case situation is beyond the control of plant personals CIC take decision to evacuate plant
personnel at safe place (assembly point) for further direction. SIC give instruction to In-charge
of all the team members to go to designated assembly point for further action. SIC will decide
the evacuation route depends on wind direction. Security coordinator will make head count
for the persons present at the assembly points and will inform the SIC/CIC for any missing
person. SIC will organize the rescue team for the person left behind, which will go from
section to section with proper protective appliance in order to remove entrapped person.
Rescue operation will be carried out by the Incident Control personnel immediately attending
to the emergency. The above operations will be led by the Site Incident Controller. The list of
casualties etc. shall be reported to the Chief Incident Controller at site. Casualties will be
shifted to hospital.
Evacuation of those personnel who are not required to be present will be carried out in
consultation with site incident controller. When required, all personnel shall proceed to
assembly points through designated routes.
All team coordinators will ensure that the employees nominated by them from their
respective Sections must report at emergency site to extend their support to Team
Coordinators
(c) Mode of communication
The Installation has developed the communication system for making the emergency to the
following personnel:
-
Those inside the works
The outside emergency services
Key personnel outside normal working hours
To authorities/contact persons of the
neighbouring factories
By PA System/Walkie Talkie
By Telephone (P & T)/Mobile Phone
By Telephone (P & T) /Mobile Phone
By Telephone (P & T) /Mobile Phone
(d) Training in locating exits from buildings, areas and the site
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Escape route, exist and marking towards exist are shown on the map and displayed at the
main entry gate. Before entry in the installation contract labour, drivers and cleaner and
visitors will be trained and all the company employee also trained. When officially told to
evacuate, leave by the nearest exit and alert others to do the same.
(e) Location of escape equipment
Installation does not have escape equipment it can be arrange from outside agencies if
required.
(f) Provisions for flashlights or other supplemental lighting
Installation has the provision of battery operation emergency lighting system for the
Emergency Control Centre and for critical equipment. Installation also has portable battery
operated flashlight and torch.
(g) Which areas can function as safe area.
Emergency Control Centre and assembly points are the safe area in the installation.
(h) Moving crosswind from gas or fume releases, etc.
Wind shocks are provided for the monitoring of wind direction.
(i) Provision of food and drinking water at assembly point and transfer point.
Auxiliary team makes arrangement of Food and water at Assembly points for assembled
persons
20.3 If evacuation takes place after initial head counts are reported, means for
recounting may be necessary. Where it is safe to do so, areas being evacuated
should be thoroughly searched to ensure everyone has departed safely.
Portable mobile vehicle for announcement should be available in the
emergency.
All Team In-charges/Security will provide the exact head count details (Installation
Employees) during the emergency. Accounting for site personnel, visitors and contractors,
particularly those known to have been in the affected area will be done.
Figures of contract labor may vary depending upon day and time, but the exact figure (inside
Installation) will be available at main gate (Security Department keeps record of contract
person/ visitor etc. who have entered inside Installation). Total number of persons available
at site shall be calculated from above.
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21.0 INFORMATION TO PUBLIC
Installation has Electrical operated Emergency siren/s, which gives an immediate warning
to the people inside and outside the factory premises and informs the people of emergency.
General Dos & don’ts as well as in case of emergency displayed at the main gate. Slogans
and instruction for the outside public and neighboring population are displayed on the
boundary wall of the Installation.
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22.0 ROLES AND RESPONSIBILITIES OF STAKEHOLDERS
INCLUDING EXTERNAL AGENCIES
22.1 The role and responsibilities of stakeholders including external agencies such as
District Authority, police, fire service, revenue department, health department, pollution
control board, National Disaster Response Force (NDRF) and State Disaster Response
Force (SDRF), have been detailed in Off site emergency Plan, which will be developed
by the District authority.
CIC will provide all the required information such as list of hazardous chemical and systems
which have potential to cause danger to human, environment and property and a copy of
On Site Emergency Plan and report of periodic mock drill to the district authority for the
development and updation of Off Site Emergency plan.
22.2 In brief the role and responsibilities of stakeholders a s p e r s c h e d u l e - V a r e a s
under:
a. The district authority is responsible for the Off-Site emergency plan and it will be
equipped with up-to-date Major Accident Hazard units, website, control room etc., with
provisions for monitoring the level of preparedness at all times. Regular meetings of
various stakeholders of Chemical Disaster Management will be conducted by district
administration/District Disaster Management Authority to review the preparedness of
Chemical Disaster Management.
b. The police will be an important component of all disaster management plans as they
will be associated with investigation of incident s/disasters. Police take overall charge of
the Off-Site situation until the arrival of the district collector or its representative at the
scene.
c. The fire services are one of the first responders and will be adequately trained and
equipped to handle chemical emergencies. Fire services are to acquire a thorough
knowledge of likely hazards at the incident site and the emergency control measures
required to contain it.
d. In a chemical emergency, the revenue department shall coordinate with other
agencies for evacuation, establishment of shelters and provision of food, etc.
e. When required for evacuation purposes in a chemical emergency, the department of
transport would made transport promptly available.
f.
The health department needs to assure that all victims get immediate medical attention
on the site as well as at the hospitals/health-care facility where they are shifted. In
addition, the department needs to network all the health-care facilities available in
the vicinity for effective management and also take effective measures to prevent
the occurrence of any epidemic.
g. Pollution control boards need to ascertain the developing severity of the emergency in
accordance with responsive measures by constant monitoring of the environment. If and
when an area is fit for entry will depend upon the results of the monitoring. A
decontamination operation would be required to be carried out with the help of other
agencies and industries.
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h. The NDRF and SDRF are the specialized forces to manage these disasters in a
longer run according to the severity and nature of the disaster. Their specialized training
is an effective measure that needs to be built up and maintained with time for achieving
a higher standard of preparedness. They need to coordinate with other local agencies
such as the Central Industrial Security Force that may be responsible for security at the
industrial site.
i.
The role of civil society and private sector in the Off- site plan is as under:
Assistance may be required from outside agencies during the course of an emergency &
SICs will be responsible for establishing liaison with these agencies for effective assistance.
Deputy Collector, Police & Fire Brigade
 To inform BPCL about leak / burst on the Mainline when the Public brings it to their
notice.
 In case of Oil or Product Spillage, to ensure security at site to cordon off the areas and
post guards for preventing the villagers going near the site of the spillage.
 In case of fire, mobilization of Foam Tenders and Crew from local Fire Stations.
 For deployment of Home Guards , if necessary
 Traffic Control and Diversion
 Wireless Communication facilities.
 Evacuation of Civilian Population, if necessary
 Maintenance of communication with the public
Assistance required from irrigation authorities
 Stopping of the water flow in case of the mainline leak / burst of the pipeline in the area
of his jurisdiction.
 To make available earth-moving equipments like bulldozers, drag line etc. for making
approach road and constructing bunds in the canal / river for containing the spread of
products for reclaiming the same.
Assistance required from PWD authorities
 For constructing any temporary diversion.
 For repair of any damage to Roads or Bridges.
 Assistance for mobilizing equipment labour contractors (s) for de-watering the canal,
exposing the line and digging Bore-wells etc. for carrying out of the repairs.
Assistance required from railways
 Equipment like mobile Crane etc. for the repair of the pipeline across the Railway Bridge
shall be provided.
 Re-scheduling of the train movement to facilitate the repair of the line.
 Stoppage of the movement of trains driven by stream or diesel engines if there is Oil or
product spillage around the track.
 Information to public /BPCL about the leak / burst on the mainline when the train staff
bridges it to the notice of Railway Station Master.
 Railway communication facilities to convey important message at the time of crisis.
Assistance required from neighbouring industry (mutual aid partners)
Mutual Aid Members will render the help at the time of emergency. They will mobilize the
Equipments, Manpower, etc. to mitigate the loss due to disaster or accident. They will
provide support to combat the disaster situation in an efficient way and will provide.
 Fire Tender and Crew
 F/F material, First Aider, their hospital facilities if any.
 Technical expertise, communication facilities, vehicles as required.
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23.0 REPORTING OF THE INCIDENT
i).
All the incident of level-I will be maintained by the Dy. Manager (HSE) for inspection
whenever called for inspection and Level-II and Level-III including miss incident report
send to the Board in the specified format (Schedule-VI) with in 48 after occurrence of
incident or any other reason triggering major incident.
ii). Investigation report of all major incidents will be submitted to the Board. An incident
will be treated as Major if any of the following occurs:
(a.)
(b.)
(c.)
(d.)
(e.)
(f.)
(g.)
fire for more than 15 minutes
explosion / blowout
fatal incident
loss above Rs. 10.0 Lac
cumulative man hours lost more than 500 hrs.
plant shutdown / outage due to the incident
Level-III incident
Any incidents in the location has to be reported to the concerned authority based on the
guidelines of the regulation & the format as given below:
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SCHEDULE – VI
Incident reporting format
1. Organisation
3. Location
5. Date of Incident
7. Major / Minor / Near
miss
9. Fire / Incident
2. Sector
4. Incident Sr. No.
6. Time of Incident
8. Report Preliminary / Final
10. Duration of fire Hrs / Min
11. Type of Incident with loss of life / injury, Fire, Explosion, Blowout,
Electrocution, Fall from Height, Inhalation of Gas, Driving, Slip / Trip,
Others, NA
12. Location of Incident ( Name of Plant / Unit / Area / Facility / Tank farm
/
Gantry / Road / Parking area etc )
13. Whether plant shutdown / caused outage of the facility? Yes / No
14. Fatalities nos.
a) Employees =
b) Contractor =
15. Injuries nos.
a) Employees =
b) Contractor =
16. Man - hours Lost
a) Employees =
b) Contractor =
17. Direct Loss due to the incident ( Rs. In Lacs ). Loss to equipment /
Machinery as per Insurance claim etc.
18. Indirect Losses : Through put / Production Loss, etc.
19. Status of the Facility : Construction / Commissioning / Operation /
Shutting
down / Turn around, Maintenance / Start up / Any other.
20. Brief Description of the Incident including post
incident measures.
( Attach details in separate sheet )
c) Others =
c) Others =
c) Others =
21. Whether similar Incident has occurred in past at
the
same location, If yes, give brief description of
the incident and attach details in separate
sheet.
22. Whether Internal Investigation has been
completed.
If no, likely date by which it will be completed.
23. Whether internal investigation report ( Major
Incident ) has been submitted to PNGRB. If no,
likely date by which it will be submitted.
24. Cause of the Incident ( Tick the most relevant cause preferably one, maximum two )
A) Deviation from Procedure
I) Not using the PPE
B) Lack of Job Knowledge
J) Equipment failure
C) Lack of supervision
K) Poor design / Layout etc.
D) Improper Inspection
L) Inadequate facility
E) Improper Maintenance. ( Mech. / Elec. / Inst )
M) Poor House Keeping
F) Improper material handling
N) Natural Calamity
G) Negligent Driving
O) Pilferage / Sabotage
H) Careless walking / climbing etc.
P) Any other (give details)
25. Cause of leakage - Oil, Gas or Chemical ( Tick one only )
A) Weld leak from equipment / lines
E) Leakage due to improper
operation
B) Leak from flange, gland etc.
F) Leak due to improper
maintenance
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C) Leak from rotary equipment
G) Normal operation Venting / draining
H) Any other
D) Metallurgical failure
26. Cause of Ignition leading to fire ( Tick only one cause )
A) Near to hot work
B) Near to Furnace / Flare etc.
C) Auto - ignition
D) Loose electrical connection
E) Near to hot surface
27. Was the incident Avoidable?
28. The incident could have been avoided by the use of / or by ;
( Tick the most relevant point preferably one, maximum two )
A) Better supervision
B) Adhering to specified operating procedure
C) Imparting Training
D) Giving adequate time to do the activity
through
proper planning.
E) Adhering to the work permit system
F) Static Electricity
G) Hammering / Fall of
object
H) Heat due to Friction
I) Lightning
J) Any other ( pyrophoric etc
)
( Yes / No )
F) Personal Protective
Equipment
G) Better equipment
H) Management Control
I) Adhering to specified
maintenance procedure
J) Adhering to specified
Inspection / Testing
procedures.
K) Any other information;
Guidelines for filling the Incident Report:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
All Major, Minor and Near miss incidents shall be reported in the quarterly report.
Incident Reporting form shall be filled up for all Major, Minor and Near miss Incidents.
Summary report shall be enclosed with every quarterly report.
Investigations shall be carried out for all Major, Minor and Near miss Incidents.
Investigation report of all Major incidents shall be submitted to PNGRB. An incident shall be
treated as Major if any of the following occurs
- Fire for more than 15 minutes
- Explosion / Blowout
- Fatal Incident.
- Loss above Rs. 5.0 Lac.
- Cumulative man hours lost more than 500 hrs.
- Plant Shutdown / Outage due to the incident
Loss time Incident shall be monitored till the affected person joins duty. In case the affected
person is yet to join the duty, then the status of report submitted will be preliminary. Final report
against the same incident shall be sent once he joins duty and the man - hours lost are known.
All columns must be filled up.
For any additional information use separate sheets as required.
Quarterly report shall be sent to PNGRB within 15 to 30 days of end of quarter.
Immediate reporting of incident through fax/telephone shall continue as per the prevailing system.
Signature
Name
Designation of the Occupier/Manager
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24.0 ACTION AFTER REPORTING OF INCIDENT BY THE ENTITY
After reporting of the incidents to Board, Nodal officer of the Board (Head of Technical
Standards
the
specifications and
safety group) will have responsibility
of
informing all the Members of the Board and w i l l coordinate with appropriate level in
National Disaster Management Authority (NDMA) till normalization of the situation.
All the incident of level-III will be maintained by the CIC. All these incident will be reported to
the National Disaster Management Authority (NDMA) with in 48 after occurrence of incident
or any other reason triggering major incident.
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25.0 TERMINATION OF EMERGENCY
(1) Termination activities should concentrate on giving accurate information to people who
need it most especially employees, neighborhood, District Authorities engaged in offsite
emergencies, and should begin as soon as the emergency phase of the operation is
completed.
(2) After confirmation of emergency will be fully coped CIC declared termination of
emergency through siren as per the siren code defined in para 14.2.5.9 in case of
Level-I and II. For level-III termination of emergency will be declared by District Authority
through appropriate mode of information transfer so as to reach each and
everyone.
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26.0 EMERGENCY RECOVERY PROCEDURES
a. Information to statutory authorities
(i) As per the Rule 5 (1) of Manufacture, Storage and Import of Hazardous Chemical
Rules, 1989 (amended in 1994 & 2000), in case of major accident occurs Occupier
of the Installation inform (within 48 hours) to following concerned authority as
identified in Schedule-5, if necessary information to be furnished regarding
notification of a major accident as per schedule-6.
- Chief Inspector of Factories appointed under the Factories Act, 1948.
- Chief Controller of Explosives appointed under the India Explosive Act and
Rules, 1983.
- District Collector or District Emergency Authority designated by the State
Government.
(ii) As per the State Factories Rules, when any accident which results in the death of
any person or which results in such bodily injury to any person as is likely to cause
his death or nay dangerous occurrence takes place in the Installation, the factory
manager of the Installation will forthwith send a notice thereof by telephone, special
messenger or telegram to the Inspector of Factories of the region concerned and the
Chief Inspector of Factories. He will also send the information to:
- the District Collector or Sub Divisional Officer;
- the officer-in-charge of the nearest police station, and
- the relatives of the injured or diseased person.
b. Incident investigation
The purpose of incident investigation is to determine causes of incident and to prevent
recurrence of same incident in future. Following main features will consider during incident
investigation that:
-
All incidents of level-I, II and III (including near misses) are investigated.
Corrective action are determined that identify the root cause
Corrective actions are tracked until they are completed
Trends are reviewed, gaps are identified and improvement plans are developed to
prevent future occurrences
In-charge of the location will form incident investigation team by the involvement of workers.
The role and responsibilities of committee members is as under:
-
Worker will report all work-related incidents in a timely manner.
If the incident was very recent, secure the scene of the incident to ensure the safety of
any emergency responders and other employees, and to preserve any evidence that
may contribute to the investigation in future.
Ensure management or other company personnel who require it are notified.
Ensure the investigation begins as soon as possible after the incident occurs.
Identify the potential sources of information, such as the injured person, witnesses and
any physical evidence.
Gather the facts about the incident.
Ensure the investigation identifies the root cause.
Make and/or implement recommendations to control or eliminate the hazard.
Perform any trend analyses of past incidents that may identify additional hazard
prevention methods (i.e. training, maintenance, procedures, etc.)
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c. Damage assessment
The incident investigation team also carried out the damage assessment during incident
investigation process. It will be included personnel, property, material, man hours’ loss,
penalty by statuary authorities, repairs and maintenance cost of property, equipment cost,
damage assessment also include potential erosion of reputation – from company, industry
and national perspectives.
d. Salvage of products, de-contamination, clean-up and restoration
Manager (Operation) and his team members will perform following role and responsibilities:
Salvage of product
-
He will transfer the spilled / accumulated product contents into Oil Water Separator
or collect in drums.
He will ensure that the quality and quantity estimation of extracted product from OWS
has been done and decide to for further disposal as per quality control guideline by either
transferring to service tanks or to nearest refinery for blending / reprocessing.
He will made correction of stock of spilled product in accounting system.
De-contamination
-
If spilled oil goes to soil and surface or underground water testing of soil/water will be carried
out by recognized laboratory for the assessment of contamination level to meet the norms of
State as well as Central Pollution Control Board.
Clean up and restoration
-
He will ensure that affected area has been completely cleaned and dried after
evacuation of spilled product.
He will declare that affected area after salvage operations is fully clean and safe for
movement of the working personnel.
He will ensure that all drains are not having any residual oil and are thoroughly
cleaned and dried.
He will ensure that all control valves on product lines and OWS lines outside dyke area
and drains are completely closed after removal of the spilled product.
He will ensure that that interlocking system of tanks / gantry has been reactivated
for normal operations.
He will ensure that heat detectors, high level alarms, in built safety systems (NRV, TSV
etc.) are fully functional after the disaster incident.
He will ensure that all fire fighting equipments like – hoses / nozzles / Fire Extinguishers
etc. have been put back at designated places and are fully ready for reuse.
He will ensure that clear procedures are in place to allow resumption of normal
operations.
e. Dy. Manager (HSE) will be prepared a detailed report based on the entire experience of
the incident, including restorations, limitations and lessons learnt.
f.
Dy. Manager (HSE) will arrange ambient air monitoring at the site as well as 5 km radius
of the installation by to determine the contamination level which may affecting the
health of neighboring population.
Check points on ERDMP recovery measures as given at Check list-7.
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27.0 ERDMP FOR PIPELINE CARRYING PETROLEUM PRODUCTS
AND RETAIL OUTLETS
Schedule –VII
(Refer Regulation 27.0)
ERDMP for pipelines carrying petroleum products
Pipelines are assuming importance as a means of transport of hazardous substances. Crude
oil, its derivatives and natural gas are among the main substances transported by pipelines.
The Guidelines, therefore, comprise:
i) Creation and maintaining an administrative framework to facilitate the development of a
safe and environmentally sound transportation infrastructure, including pipelines for
hazardous substances.
ii) The pipeline operator has the primary responsibility for the safety of the systems and for
taking measures to prevent incident s and to limit their consequences for human health and
the environment.
iii) Pipelines for the transport of hazardous substances will be designed and operated so as
to prevent any uncontrolled release into the environment.
iv) Risk assessment methods should be used in evaluating pipeline integrity and impact on
human health and the environment.
v) Land-use planning considerations will be taken into account both in the routing of new
pipelines (e.g. to limit proximity to populated areas and water catchment areas to the extent
possible), and in decisions concerning proposals for new developments/building in the
vicinity of existing pipelines.
vi)Pipeline operators and the authorities responsible for pipelines shall review and, if
necessary, develop and implement systems to reduce third-party interference, which is a
cause of incident including their effects.
vii) National legislation shall be clear, enforceable and consistent to facilitate safe transport
and international cooperation.
viii) Competent authorities should ensure that pipeline operators:
(a) Draw up emergency plans.
(b) Provide the authorities designated for that purpose with the necessary information to
enable them to draw up Off-Site emergency plans.
(c) Emergency plans shall be coordinated between pipeline operators and competent
authorities, as well as with fire brigades and other disaster control units.
ix) Pipelines shall be designed, constructed and operated in accordance with recognized
national and international codes, standards and guidelines, notified by the Board.
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x) Consideration will be given to the impact on the safety of a pipeline such as design and
stress factors, quality of material, wall thickness, and depth of burial, external impact
protection, markings, route selection and monitoring.
xi) The safety of the pipelines shall be demonstrated through a suitable risk assessment
procedure including the worst case scenario and including breakdowns and external
additional loads.
xii) The pipeline operator shall draw up a Pipeline Management System (PMS) to ensure
that it is properly implemented. The PMS shall be designed to guarantee a high level of
protection of human health and the environment. The following issues shall be addressed by
the safety management system.
(a) The pipeline will be inspected and maintained regularly. Only reliable trained staff or
qualified contractors may carry our maintenance work on a pipeline. Third party confirmatory
assessment bodies should inspect the pipeline at regular intervals as far as required by the
Board. These inspections are to cover in particular the proper condition of the pipeline and
the functioning of the equipment ensuring pipeline safety.
(b) Organization ability, roles and responsibilities, identification and evaluation of hazards,
operational control, and management of change, planning for emergencies, monitoring
performance, audit and review shall be duly addressed in the Pipeline Management System
BPCL, Piyala Installation is receiving products through pipeline from MMBPL pipe line as
well as Tankers. Since critical pipelines are running after due consideration of board
Regulation, OISD regulations and National Oil Spill Contingency Plan a separate Risk
Analysis and Disaster Management plan prepared.
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28.0 ERDMP FOR ROAD TRANSPORTATION
An effective response to a road transport emergency is essential to eliminate the hazards
and lessen their impact if an incident occurs. For handling emergency arising out of road
transportations is as under:
28.1 Resource mobilization for road transport emergency
Following in plant resources a s m e n t i o n e d i n Schedule-VIII will mobilization by the
Installation in adequate quantity in case of road transport emergency occur.
Mechanical Equipment:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
Gaskets (Carbon Asbestos Filled)
Studs and bolts.
Teflon tapes.
½” / ¾” crowbar (1 m long)
Spade / blind flange
Rope (Manila / Jute)
Spark arrestors.
1” tapered wooden pegs.
Chopper
Spare fan belt for tank lorry with P.T.O. unit
Wind sock
M-Seal / epoxy-base cold-welding compound.
Wooden slippers
Teflon-taped spanners, wrenches
Spark-proof wrenches, hammer and tools.
Barricading masts and ropes / tapes
hoses
Chain pulley blocks and stay pipes
Small valve keys for operating valves in the tank truck
5 nos
50 nos
20 nos
2 Nos
5 nos
3 nos
6 Nos
Prepared as per requirement
Nil
1 No
1 nos
5 nos
10 nos
Nil
2 sets
Nil
20 nos
1 no.
2 Nos
Electrical Equipment :
1.
2.
3.
Gas Explosi-meter
Flame-proof torches
Earthing wires (10 m long) with crocodile clips
1 Nos
2 Nos
2 nos
Personnel Protective Equipment :
1.
2.
3.
Gloves:
i) Rubber gloves
ii) Low Temperature Gloves
iii) Industrial gloves (with leather lining)
iv) Canvas gloves
2 Pair
Nil
2 Pair.
5 pair
Face shields
Ear muff / ear plugs
1 No
10 No
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Other Safety Items:
1.
1 roll of gunny / hessian cloth (about 10 mts. long)
Nil
2.
3.
4.
5.
6.
7.
First aid box (containing water gel compounds)
2 No
Soap
5 no
Blanket.
Nil
Water Gel Blanket
Nil
Breathing Apparatus (With spare filled cylinder and Canister gas masks) – 2 nos
Fire proximity suit
1 no
Fire Fighting Equipment :
1.
2.
3.
Portable Dry Chemical Powder Fire Extinguishers
Fire-water Hoses
Triple Purpose diffuser nozzle for use with fire hoses.
80 nos
20 Nos
1 nos
Communication Equipment :
1.
2.
3.
Hand operated sirens
Whistles
Megaphone, Mobile Phones, VHF sets.
3 nos
2 nos
Personal mobile phone
Traffic Control Equipment :
1.
2.
3.
Red lights (Battery operated) - for traffic diversion
Area maps
Diversion Boards
Nil
1 nos
3 nos
A comprehensive Emergency Management Plan f o r t h e incident involving Petroleum
Product Transportation is readily available with the Installation to handle emergencies in a
systematic manner with minimum response time. Copy of Plan will be made available to all
field location as well as district authority.
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28.2 TREM Card (Specific to Road Transportation)
TREM Card as per Schedule-IX and route map is issued by the Installation to the tank truck
crew.
SCHEDULE – IX
Transport Emergency Card Format
Nature of Hazard:
Protective Devices:
Emergency Action
Spillage
Fire
First Aid
Chemical Abstract Service (CAS) No
(For universal acceptance of material, both numbers should be mentioned on TREM Card)
Emergency Telephone Numbers/mobile numbers
Name and contact numbers of the control room/contact person of the supplying company
Name and contact numbers of the control room/contact person of the receiving company
Name and contact numbers of Transporter
Other important Name and contact numbers of civic authorities, fire and police
Note: The format is designed & provided in English, Hindi and local language where crews
are operating.
The following is the sample transport emergency card formatted & circulated to the
transporter by the company
Sample transport emergency card format
Nature of Hazard: Highly volatile and Inflammable.
Can cause Cold Burns
Inhaling vapour can cause nausea, breathlessness &headache.
Air / vapour mixture highly explosive.
Leakage can cause Vapour Cloud explosion and BLEVE.
Protective Devices: Hand gloves (Rubber / low temperature)
Safety Goggles
Self-contained Respiratory device to work in vapour-rich area
Low temperature / fire proximity suit
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Emergency Action:
Try to move the vehicle to open area. (In case of the LPG is leaking from a stationary
tanker whose engine is shut, don’t try to start the engine.)
Stop Engine.
Vehicle should not be left unguarded.
Contact Police, Fire Brigade, Sarpanch, nearest oil company by sending helper /passerby
Keep public and traffic away by displaying ‘Danger Boards’ at sufficient distance.
“No Smoking” and “No Naked Lights” within the cordoned off area.
Keep ready for action Fire Extinguishers and Safety Kit.
Stay Upwind.
Don’t park the vehicle blocking the route
Spillage: Check the valves and caps for tightness by hand and stop leak if possible
Fire: If minor, try to extinguish by suitable fire extinguishers
First Aid: Pour water in case of cold or hot burn Seek medical help, if necessary
Emergency Telephone Numbers/mobile numbers
IOC _______________ HPC_______________________
BPC _____________________ IBP________________________
FIRE 101 _______________ POLICE 100_________________
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28.3 Role of External Agencies for road transportation emergency
It is expected that the following roles shall be performed by various agencies:
28.3.1 Fire Brigade
On receipt of information from any source on incident of tank truck, fire brigade may
contact nearest installation and police station. After assessing the situation, it may:
(a.) rush fire tender to the incident site with all necessary fire fighting equipments;
(b.) prepare a contingency plan for removal of tank truck, if not leaking, in
consultation with installation personnel;
(c.) dispersal of vapours by water spray away from inhabited area, in case of leakage.
Extinguish the fire, in case leakage source cannot be stopped;
(d.) allow the fire to burn under controlled conditions if isolation is not possible;
(e.) save human lives and salvage material from incident affected truck;
(f.) liaise with fire brigade in the adjoining town for additional help, if necessary;
(g.) arrange water through municipal water tanker or any other source;
28.3.2 Role of Police
On receipt of information, police may take the following actions as per Schedule-V derived
from the National Disaster Management Guidelines Chemical Disasters (Industrial), April,
2007. However, the following points may also be taken care by the police authority:
(a.)
(b.)
(c.)
(d.)
(e.)
stop the traffic from both ends of the road;
warn the people living in adjacent area for stopping all fire, smoking, evacuation to
safe places, if necessary;
contact nearest district police headquarters and giving the situation report;
evacuate personnel from the area, if required;
extend help in removal of injured personnel to the nearest first- aid centre /hospital,
contacting highway patrol, completing legal formalities in case of any casualty.
28.3.3 District Administration
On receipt of information, District Administration may take the following actions as per
Schedule-V derived from the National Disaster Management Guidelines Chemical Disasters
(Industrial), April, 2007. However, on receipt of information, following actions should be
taken care:(a.)
(b.)
(c.)
(d.)
to keep watch on the overall situation;
rush ambulance to the incident site if casualties are reported;
direct cranes or any other such equipment to carry out rescue operations;
issue warning messages to people through public address system, if any evacuation is
required;
(e.) arrange emergency vehicles for evacuation purposes;
(f.) give direction to hospitals having burns injury ward for readiness to receive patient
in case of incident involving fire;
(g.) provide basic amenities, e.g., water, electricity, food and shelter to the affected
people as required.
In addition to the above, the Schedule-V shall be followed.
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29.0 INTEGRATION OF THE ERDMP WITH THE NATIONAL
DISASTER MANAGEMENT PLAN (NDMP)
29.1 National Disaster Management Plan (NDMP)
On 23 December 2005, the Government of India took a definite step towards NDMP by
enacting the NDMP ACT, 2005. The NDMP Act, 2005 covers all aspects of disasters from
prevention, mitigation, preparedness to rehabilitation, reconstruction and recovery.
National Disaster Management Guidelines Chemical Disasters (Industrial)
The growth of chemical industries has led to an increase in the risk of occurrence of
incidents associated with hazardous chemicals (HAZCHEM). Common causes for chemical
accidents are deficiencies in safety management systems and human errors, or they may
occur as a consequence of natural calamities or sabotage activities. Chemical accidents
result in fire, explosion and / or toxic release.
With formulation of National Disaster Management Guidelines—Chemical Disasters, There
has been a paradigm shift in the government’s focus from its rescue, relief, and restorationcentric approach to a planning, prevention / mitigation and preparedness approach. It has
been realized that effective Chemical Disaster Management (CDM) is possible by the
adoption of preventive and mitigation strategies as most chemical disasters are preventable
in comparison to natural disasters that are difficult to predict and prevent. With this renewed
emphasis, the National Disaster Management Authority (NDMA) took up the task of
strengthening CDM in recognition of the gravity of the risk posed by HAZCHEM.
The main stakeholders in the management of chemical disasters are Ministry of Environment
and Forests (MoEF; the nodal ministry); Ministry of Home Affairs (MHA); Ministry of Health
and Family Welfare (MoH & FW); Ministry of Labour and Employment (MoLE); Ministry of
Agriculture (MoA); Ministry of Shipping, Road Transport and Highways (MoSRT & H);
Ministry of Defence (MoD); Ministry of Chemicals and Fertilizers (MoC & F); Ministry of
Petroleum and Natural Gas (MoP & NG), Department of Atomic Energy (DAE); state
governments and Union Territories (UTs) and the chemical industries.
Haryana State Disaster Management Policy
The Haryana Disaster Management Policy (HDMP) has been prepared by the Centre for
Disaster Management (CDM), HIPA, and as of 2012, underwent revision for the purpose of
creating a third draft. The HDMP document not only points out the various hazards, risks
and vulnerabilities present within the state but also suggests practical and implementable
solutions. Through the implementation of policy, Haryana will comply with all the stipulations
of the National Disaster Management Act. The document also strongly advocates the
necessity of state-level leadership to allocate adequate funding for various Disaster
Management and also Disaster Risk Reduction (DRR) activities in order to avoid getting
stuck in the vicious cycle of post-disaster spending, every year. The Haryana State Disaster
Management Policy is certain to prove successful as long as all responsible persons
discharge their functions to the best of their ability.
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Institutional Framework
As per section 14(1) of the DM, Act 2005, the Haryana State Disaster Management Authority
headed by the Hon’ble Chief Minister has been formed and notified and will lay down
policies and plans for DM in the Haryana State. It will, inter alia, approve the State Plan in
accordance with the Guidelines laid down by the NDMA, coordinate the implementation of
the State Plan, recommend provision of funds for mitigation and preparedness measures
and review the developmental plans of the different departments of the State to ensure
integration of prevention, preparedness and mitigation measures.
District Disaster Management Authority (DDMA)
Each DDMA of Haryana will be headed by the Dy. Commissioner with the Chairman of Zila
Parihad as the Co-Chairperson. DDMA will act as the planning, coordinating and
implementing body for DM at District level and take all necessary measures for the purposes
of DM in accordance with the Guidelines laid down by the NDMA and HSDMA. It will, inter
alia, prepare the District DM plan for the District and monitor the implementation of the
National Policy, the State Policy, the National Plan, the State Plan concerning its own District
and prepare the District Plan. The DDMA will also ensure that the Guidelines for prevention,
mitigation, preparedness and response measures laid down by NDMA and HSDMA are
followed by all Departments of the State Government, at the District level and the Local
Authorities in the District.
Local Authorities
The Faridabad Municipal Corporation, Faridabad control and manage civic services. Hence,
Municipal Corporation, Faridabad has prepared its Disaster Management Plans in
consonance with the Guidelines of NDMA. The Municipal Corporation, Faridabad will also
ensure capacity building of their officers and employees for managing disasters, carry out
relief, rehabilitation and reconstruction activities in the affected areas.
Haryana Disaster Response Force (HDRF)
The Haryana Disaster Response Force has been constituted to create response capabilities
from within their existing resources. To start with, Haryana may aim at equipping and training
a company of Haryana Armed Force. The SDRF will also include women members for
looking after the needs of women and children. NDRF battalions and their training
institutions will assist the States/UTs in this effort. In addition the Haryana Police will also be
encouraged to include DM training in the basic and in-service courses of their respective
Police Training Colleges for gazetted and non-gazetted police officers.
Haryana Police Force, Home Guard and Fire Services
The Haryana Police Forces, the Fire and Emergency Services and Home Guards are crucial
and most immediate responders to disasters. The Police will be trained and the Fire and
Emergency Services upgraded to acquire multi-hazard rescue capability. Home Guards
volunteers will be trained in disaster preparedness, emergency response, community
mobilization, etc. The Haryana Government may take the help of NDMA for capacity building
and sensitization of their forces.
Ref No.
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REVISION No. 0
PAGE: 79
Civil Defense (CD) and Home Guards
The mandate of the Civil Defense (CD) and the Home Guards will be redefined to assign an
effective role in the field of disaster management. They will be deployed for community
preparedness and public awareness. A culture of voluntary reporting to duty stations in the
event of any disaster will be promoted. A proper CD set up in every District will be a boon for
disaster response as the neighborhood community is always the first responder in any
disaster. The proposal to make CD District centric and be involved in disaster response has
already been approved by the Govt. of India. Its phase wise implementation has also begun.
Haryana Government will ensure their operationalisation in their respective districts.
Ref No.
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PAGE: 80
Ref No.
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PAGE: 81
29.2 Integration of ERDMP with NDMP
This ERDMP document has been developed taking into account all possible Inputs on the
subjects from various stake holders. Efforts have also been made to synergize this with the
document on National Disaster Management Guide - Chemical Disasters (Industrial) as well
as Petroleum and Natural Gas Regulatory Board Gazette notification G.S.R. 39 (E) (Codes
of Practices for Emergency Response and Disaster Management Plan (ERDMP))
Regulations, 2010.
For the purpose of specialized response to a threatening disaster situation or
disasters/emergencies both natural and man-made such as those of CBRN (Chemical,
Biological, Radiological and Nuclear) origin, the DM Act, 2005 has mandated the constitution
of a NDRF. The general superintendence, direction and control of this force is vested in and
exercised by the NDMA and the command and supervision of the Force will vest in an officer
to be appointed by the Central Government as the Director General of NDRF. Presently, the
NDRF comprises eight battalions. Two additional battalions have been sanctioned by the
Government and are in the process of being formed. These battalions are located at
strategic locations and will be deployed proactively as required. NDRF units will maintain
close liaison with the designated State Governments/ UTs and will be available to them in
the event of any serious threatening disaster situation. While the handling of all natural
disasters rests with all the NDRF battalions, presently four of them have been equipped and
trained to respond to situations arising out of CBRN emergencies. Future plans exist to train
rest of the battalions also for CBRN response. The NDRF units will also impart basic training
to all the stakeholders identified by the State Governments in their respective locations.
Further, a National Academy will be set up to provide training for trainers in DM and to meet
related national and international commitments. The following battalions are made
responsible for CBRN disasters
The following battalions are made responsible for CBRN disasters.
- Kolkatta Battalion
- Arakkonam battalion
- Pune Battalion
- Ghaziabad Battalion
In the support of NDRF, SDRF are the available forces At state level. In some cases SDRF
has not been created. These battalions are equipped to handle all types of the chemical
emergencies. These battalions are trained at various places. In emergency these nearby
teams should be called for help as per table given below:
LOCATION
Bhatinda
Ghaziabad
AREA OF RESPONSIBILITY FOR
NATURAL DISASTER
Chandigarh, Punjab, J&K, Himachal
Pradesh
U.P., Uttar Khand, Haryana, Delhi
AREA OF RESPONSIBILITY
FOR CBRN EMERGENCY
Gaziabad battalion (Grater
Noida)
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PAGE: 82
29.3 Security Threat Plan
(1) With increase in terrorist activities towards the end of 20th
century and
installations having, significant role in national economy, sabotage and bomb threats to
such installation should also be
considered in the disaster
management
plan. Such as high level of alertness measures, strengthening security measures by
security gadgets mechanical and electronic security gadgets. In any of such situation,
city police/ administration should be informed immediately and their help should be
sought.
(2) Installation has a separate detailed bomb threat management plan. In case of sabotage and
bomb threat following action will taken:
(a.)
(b.)
(c.)
(d.)
(e.)
(f.)
The persons inside the Plant would be evacuated as soon as possible;
All the vehicles in the plant premises would be evacuated to safer places;
Plant personnel immediately contact to district authorities;
Any new or doubtful thing should not be touched;
All pipeline and tank valves would be closed and all the operations inside
the Installation would be stopped;
In case of fire, firefighting equipments will be operated and city fire brigade would
be called immediately during emergency.
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PAGE: 83
30.0 MISCELLANEOUS
(1) Whenever any deviation from this code of practices is required to be implemented, the
BPCL, Piyala Installation shall inform and obtain approval of the Board with mitigation
measures proposed to be carried out giving full details and justification for such
deviation.
(2) If any dispute arises with regards to the interpretation of any of the provisions of these
regulations, the decision of the Board shall be final. Further, the Board may at any
time effect appropriate modifications in these regulations.
Ref No.
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REVISION No. 0
Annexure-1: Site Plan of Installation
(2- KM RADIUS SURROUNDING MAP)
PAGE: 84
Ref No.
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REVISION No. 0
Annexure-2: Layout Plan (Assembly Point, Escape route)
PAGE: 85
OF
REVISION No. 0
Ref No.
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PAGE: 86
Annexure-3: Material Safety Data Sheet
1. CHEMICAL NAME
Chemical Name
: Motor Spirit
Synonyms
: Gasoline
Formula
:Hydrocarbon
Mixture
Regulated
Shipping Name
Identification
Code/Lable
CAS No.
: 8008-20-6
: Gasoline
: 3, FLAMMABLE LIQUID
HAZARDOUS INGRDIENT
CAS No.
1. Motor Spirit
8008-20-6
2.
2. PHYSICAL/CHEMICAL DATA
0
0
Boiling Point/Range C
: 60-199 C
Physical State
0
Melting/Freezing Pt. C
0
: -40 C
Chemical Classification
Trade Name
UN No.
Vapour
Pressure
Solubility in
0
Water at 30 C
pH
Hazchem No.
Hazardous
Waste
Identity No.
HAZARDOUS INGRDIENT
3.
4.
: Liquid
Appearance
0
: 6 - 10 at 38 C
Odour
: Fuel (Paraffin
: Petrol
: UN 123
: 3YE
: 05
CAS No.
: Orange (Octane 87)
Red(Octane 93)
: Aromatic Odor
Vapour Density, (Air =
: 3.0 - 4.0
: Insoluble,
Others
: Soluble in petroleum
1)
Floats on Water
solvent
Specific Gravity,
: 0.733gm/l
: Not Pertinent
0
(Water = 1)
at 15 C
3. FIRE AND EXPLOSION HAZARD DATA
0
Flammability
: Yes
L.E.L.
: 1.4%
Flash Point F
: Data Not Available
(OC)
0
TDG Flammability
:3
U.E.L.
: 7.4%
Flash Point F
: -36
(CC)
0
Auto Ignition temp. : 390 C
Explosion Sensitivity to Impact
: Stable
0
C
HazardousCombusti
: Acrid smoke, fumes and Explosion Sensitivity to Static : May Explode
on Product
vapours of NOX, SOXCO2 & Electricity
CO
Hazardous
: Will not occur
Polymerisation
Combustible Liquid
: Yes
Explosive Material
: No
Corrosive Material
: No
Flammable Material
: Yes
Oxidiser
: No
Others
Cyrophoric Material
: No
Organic Peroxide
: No
4. REACTIVITY DATA
Chemical Stability
: Stable under normal condition of use and storage.
Incompatibility with other Material
: Incompatible with oxidising agents.
Reactivity
: Can create with oxidising agents.
Hazardous Reaction product
: Heated decomposition may yield acrid smoke, fumes and vapours of NOX, SOXCO2
& CO
5. HEALTH HAZARD
Route of Exposure
: Inhalation, Ingestion, Skin contact, Eye contact,.
Effects of
: Inhalation causes irritation of respiratory track, nausea, dizziness, high conc. may cause
Exposure/Symptoms
depression of CNS, loss of consciousness, coma and sudden death. Ingestion may cause
irritation of GI Track, vomiting, systemic effects like colic & diarrhea, .Skin contact causes
irritation producing dermatitis. Vapour are irritant to eyes, splashes may cause pain, redness.
Emergency
: Inhalation: Rush to fresh air. And resuscitate. Ingestion: Aspiration Hazard. Vomiting may occur
Treatment
spontaneously, but DO NOT INDUCE VOMITING, give paraffin olive oil or some other
vegetable oil to prevent absorption of kerosene. Call Medical Assistance. Skin: Remove clothes
and shoes, flush with plenty of water, don't use oil or ointments. Eye: wash with plenty of water
call for medical assistance.
3
3
TLV (ACGIH)
: 300 ppm
: 900 mg/m
STEL
: 500 ppm
: 1500 mg/m
3
3
Permissible
Odor
Threshold : 0.25 ppm
: 300 ppm
: 900 mg/m
: 300 mg/m
Exposure Limit LD50.
Limit LD50
NFPA
HAZARD
Health
Flammability
Reactivity
Special
RATING
1
3
0
Nil
6. PREVENTIVE MEASURE
Personnel Protective : Safety glasses, Gloves, PVC aprons, Safety boots and Self Contained Breathing Apparatus in
Equipment
case of high conc. Of vapors or fumes.
Handling
and : Use all protective equipment during handling, AVOID CONTACT. Store in cool, well-ventilated
Storage Precautions
area with adequate water scrubbing facility, container to be properly bonded and earthen to
check generation and accumulations of static charge. Storage Color Code- Red (Flammable),
storage away from heat and ignition source.
7. EMERGENCY AND FIRST AID MEASURES
Ref No.
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REVISION No. 0
PAGE: 87
FIRE
Fire Extinguishing Medium
Special Procedure
Unusual Hazard
EXPOSURE
First-Aid Measures
SPILLS
Antidotes/Dosages
Steps to be taken
: Foam, CO2, Dry powder.
: Vapours may cause flash fire. Keep the container cool by spraying with
water if exposed to heat or flame.
: Poisonous gas/fumes may be produced, wear self-contained breathing
apparatus.
: Inhalation: Rush to fresh air. And resuscitate. Ingestion: Aspiration
Hazard. Vomiting may occur spontaneously, but DO NOT INDUCE
VOMITING, give paraffin olive oil or some other vegetable oil to prevent
absorption of kerosene. Call Medical Assistance. Skin: Remove clothes
and shoes, flush with plenty of water, don't use oil or ointments. Eye:
wash with plenty of water call for medical assistance.
: -NA: Shuts off the leakage, Ventilate, remove source of ignition. Recover,
unrecovered to be removed with sand.
: Contain the leaked liquid with sand or earth. Dispose as per regulations.
Waste Disposal Method
8. ADDITIONAL INFORMATION
Highly flammable Liquid, vapor my cause Flash Fire Reported in EPA TSCA Inventory, EPA Genetic Toxicology program,
On Community Right-to-know List.
9. MANUFACTURER AND SUPPLIERS DATA
Name of the Firm
Contact Person in Emergency
:
:
Mailing address
Local Bodies Involved
:
:
Telephone/Telex No.
Standard Packaging
:
:
Telegraphic address
Term Card
:.
:
10. DISCLAIMER: Information contained in this material data sheet is believed to be reliable but no representation,
guarantee or warranties of any kind are made as to its accuracy, suitability for a particular application of result to be
obtained from them. It is up to the manufacture/seller to ensure that the information in the Material Safety Data Sheet is
relevant to the product manufacture/handled or sold by him as the case may be. The Government makes no warranties
expressed or implied in respect of the adequacy of this document for any particular purpose. Information given here is nonexhaustive.
Ref No.
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PAGE: 88
1. CHEMICAL NAME
Chemical Name : High Speed Diesel
Synonyms
: Gas oil
CAS No. :
Formula
: Hydrocarbon Mixture
Regulated
Shipping Name
: Diesel Oil
Identification
Code/Lable
HAZARDOUS INGRDIENT
1. High Speed Diesel
2.
0
0
Boiling
: 150 - 400 C
0
Point/Range C
0
Melting/Freezin
: - 18 C
0
g Pt. C
Vapour Density, : 18-46
(Air = 1)
CAS No.
Trade Name
UN No.
Hazchem No.
Hazardous
Waste
Identity No.
HAZARDOUS INGRDIENT
3.
4.
: Fuel (Paraffin
: Diesel Oil
: UN 1202
: 3Z
:5
CAS No.
Physical State
: Liquid
Appearance
: Olive Brown to yellow
Vapour
Pressure
Solubility in
0
Water @ 30 C
: < 0.1 psi at
0
38 C
: Insoluble,
Floats on Water
Odour
: Aromatic Odor
Others
: Sulfur content 1%
(Max.)Soluble in petroleum
solvent
Specific
: 0.81-0.91 at
pH
: Not Pertinent
0
Gravity, (Water
20 C
= 1)
0
0
Flammability
: Yes
L.E.L. :
1.6 %
Flash Point C
: > 30
(CC)
0
TDG Flammability
:3
U.E.L. :
6.0 %
Flash Point C
: Data Not Available
(OC)
0
Auto Ignition temp. : 256.6 C
Explosion Sensitivity : Stable
0
to Impact
C
Hazardous
: Acrid smoke, fumes and vapours of NOX, Explosion Sensitivity : Stable
Combustion Product SOXCO2 & CO
to Static Electricity
Hazardous
: Will not occur
Polymerisation
Combustible Liquid
: Yes
Explosive Material : No
Corrosive Material : No
Flammable Material
: Yes
Oxidiser
: No
Others
:
Cyrophoric Material
: No
Organic
Peroxide No
:
4. REACTIVITY DATA
Chemical Stability
:
Stable under normal condition of use and storage.
Incompatibility with other Material
:
Incompatible with oxidising agents.
Reactivity
:
Can create with oxidising agents.
Hazardous Reaction product
:
Heated decomposition may yield acrid smoke, fumes and vapours of NOX,
SOXCO2 & CO
5. HEALTH HAZARD
Route of Exposure
Effects of
: Inhalation causes irritation of respiratory track, nausea, dizziness, Ingestion may cause irritation
Exposure/Symptoms
of GI Track, vomiting, rapidly developing chemical pneumatics. Skin contact causes irritation
producing dermatitis. Vapour are irritant to eyes, splashes may cause pain, redness.
Emergency
Treatment
spontaneously, but DO NOT INDUCE VOMITING, give paraffin olive oil or some other vegetable
oil to prevent absorption of kerosene. Call Medical Assistance. Skin: Remove clothes and shoes,
flush with plenty of water, don't use oil or ointments. Eye: wash with plenty of water call for medical
assistance.
3
3
STEL
TLV (ACGIH)
: Not Listed ppm
mg/m
: Not Listed
ppm
mg/m
3
3
Odor
Threshold : Not Listed ppm
Permissible
: Not Listed
ppm
mg/m
mg/m
Limit LD50
Exposure Limit LD50.
NFPA HAZARD
Health
Flammability
Reactivity
Special
RATING
1
2
0
Nil
Personnel Protective
: Safety glasses, Gloves, PVC aprons, Safety boots and self-contained Breathing Apparatus
Equipment
in case of high conc. Of vapors or fumes.
Handling and Storage
: Use all protective equipment during handling, AVOID CONTACT. Store in cool, wellPrecautions
ventilated area with adequate water scrubbing facility, container to be properly bonded and
earthen to check generation and accumulations of static charge. Storage Color CodeRed(Flammable), storage away from heat and ignition source.
Ref No.
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PAGE: 89
FIRE
Fire Extinguishing Medium
Special Procedure
: Vapours may cause flash fire. Keep the container cool by spraying with
water if exposed to heat or flame.
Unusual Hazard
apparatus.
EXPOSUR
First-Aid Measures
: Inhalation: Rush to fresh air. And resuscitate. Ingestion: Aspiration Hazard.
E
Vomiting may occur spontaneously, but DO NOT INDUCE VOMITING, give
paraffin olive oil or some other vegetable oil to prevent absorption of
kerosene. Call Medical Assistance. Skin: Remove clothes and shoes, flush
with plenty of water, don't use oil or ointments. Eye: wash with plenty of
water call for medical assistance.
Antidotes/Dosages
: -NASPILLS
Steps to be taken
: Shuts off the leakage, Ventilate, remove source of ignition. Recover,
Waste Disposal Method
: Contain the leaked liquid with sand or earth. Dispose as per regulations.
Name of the Firm :
Contact Person in Emergency :
Mailing address
:
:
Telephone/Telex No.:
Standard Packaging
:
Telegraphic address :
Term Card
:
OF
REVISION No. 0
Ref No.
BPCL/PYL/OSEP
PAGE: 90
1. CHEMICAL NAME
Chemical Name : Superior Kerosene Oil
Synonyms
: Jet Fuel, Coal Fuel
Formula
: Hydrocarbon Mixture CAS No.
: 8008-20-6
Regulated
Shipping Name
: Kerosene
Identification
Code/Lable
HAZARDOUS INGRDIENT
CAS No.
1. Superior Kerosene Oil
8008-20-6
2.
0
0
Boiling Point/Range C
Physical State
: 193-293 C
0
0
Trade Name
UN No.
Hazchem No.
Hazardous Waste Identity
No.
HAZARDOUS INGRDIENT
3.
4.
: Liquid
Appearance
Melting/Freezing Pt. C
: -43-48 C
Vapour Pressure
: 0.05-0.5psi at
0
38 C
Odour
Vapour Density, (Air =
1)
: 4.5
Solubility in Water at
0
30 C
: Insoluble
Others
Specific Gravity,
: 0.81 – 0.85
pH
0
(Water = 1)
at 15 C
Flammability
: Yes
L.E.L.
TDG Flammability
:3
U.E.L.
0
Auto Ignition temp. C
0
: 210 C
: Fuel (Paraffin
: Kerosene
: UN 123
: 03
: 05
CAS No.
: Pale Yellow to
water white
: Mild
Characteristic
Odor
: Soluble in
petroleum
solvent
: Not Pertinent
: 0.7%
: 5.0%
Flash Point
Flash Point
0
0
C
C
Explosion Sensitivity to
Impact
Static Electricity
0
: 35
: Not
Pertinent
: Stable
(CC)
(OC)
Hazardous
Combustion : Acrid smoke, fumes and vapours of
: May Explode
Product
NOX, SOXCO2 & CO
Hazardous Polymerisation
: Will not occur
Combustible Liquid
: Yes
Explosive Material
: No
Corrosive Material
: No
Flammable Material
: Yes
Oxidiser
: No
Others
Cyrophoric Material
: No
Organic Peroxide
: No
4. REACTIVITY DATA
Chemical Stability
: Stable under normal condition of use and storage.
Incompatibility with other : Incompatible with oxidising agents.
Material
Reactivity
: Can create with oxidising agents.
Hazardous
Reaction : Heated decomposition may yield acrid smoke, fumes and vapours of NOX, SOXCO2 & CO
product
5. HEALTH HAZARD
Route of Exposure
Effects of
: Inhalation causes irritation of respiratory track, nausea, dizziness, may cause depression of CNS,
Exposure/Symptoms
prolonged inhalation may cause hallucination, delirium and manic. Ingestion Pulmonary
pneumonia aspiration effects in case of vomiting, systemic effects, .Skin contact causes irritation
producing dermatitis. Vapour are irritant to eyes, splashes may cause pain, redness.
Emergency
Treatment
spontaneously, but DO NOT INDUCE VOMITING, give paraffin olive oil or some other vegetable
oil to prevent absorption of kerosene. Call Medical Assistance. Skin: Remove clothes and shoes,
flush with plenty of water, don't use oil or ointments. Eye: wash with plenty of water call for
medical assistance.
3
3
TLV (ACGIH)
: 33 ppm
100 mg/m
STEL
: Not Listed.
mg/m
3
3
Permissible
Exposure : Not Listed
Odor Threshold Limit LD50
: 1 ppm
mg/m
mg/m
Limit LD50.
NFPA HAZARD
Health
Flammability
Stability
Special
RATING
1
2
0
Nil
Personnel
Protective : Safety glasses, Gloves, Aprons, Safety boots and Self Contained Breathing Apparatus in
Equipment
case of high conc. Of vapors or fumes.
Handling and Storage : Use all protective equipment during handling, AVOID CONTACT. Store in cool, wellPrecautions
ventilated area with adequate water scrubbing facility, container to be properly bonded and
earthen to check generation and accumulations of static charge. Storage Color Code- Red
(Flammable), storage away from heat and ignition source.
Ref No.
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REVISION No. 0
PAGE: 91
FIRE
Fire Extinguishing
Medium
Special Procedure
: Vapours may cause flash fire. Keep the container cool by spraying with water if
exposed to heat or flame.
Unusual Hazard
apparatus.
EXPOSURE
First-Aid Measures
: Inhalation: Rush to fresh air. And resuscitate. Ingestion: Aspiration Hazard.
Vomiting may occur spontaneously, but DO NOT INDUCE VOMITING, give
paraffin olive oil or some other vegetable oil to prevent absorption of kerosene.
Call Medical Assistance. Skin: Remove clothes and shoes, flush with plenty of
water, don't use oil or ointments. Eye: wash with plenty of water call for
medical assistance.
Antidotes/Dosages
: -NASPILLS
Steps to be taken
: Shuts off the leakage, Ventilate, remove source of ignition. Recover,
Waste
Disposal : Contain the leaked liquid with sand or earth. Dispose as per regulations.
Method
Name of the Firm
:
:
Mailing address
:
:
Telephone/Telex No.
Standard Packaging
:
:
Telegraphic address
Term Card
:
:
OF
REVISION No. 0
Ref No.
BPCL/PYL/OSEP
PAGE: 92
1. CHEMICAL NAME
Chemical Name :
Ethyl Alcohol
Synonyms
Chemical Classification :
Aliphatic
Hydrocarbon
:
Trade Name
:
Ethanol, Alcohol, Denatured Alcohol, Spirit, Grain
Alcohol
CAS No.
:
UN No.
:
Formula
:
64-17-5
1170
C2H5OH
Regulated
Shipping Name
:
Ethyl Alcohol
Hazchem No.
:
3
Identification
Code/Lable
:
Hazardous Waste I.D. No.:
3, FLAMMABLE
LIQUID
HAZARDOUS INGRDIENT
HAZARDOUS INGRDIENT
CAS No.
CAS No.
1.Ethyl Alcohol
64-17-5
3.
2.
4.
0
Physical State
Appearance :
Boiling
Liquid
Colorless
78.3 C
0
Point/Range C:
:
0
2
Odour
:
Melting/Freezin
Vapour Pressure
Mild Pleasant Odor,
-114 C
40mmHg/cm
0
0
g Pt. C:
@ 35 C mm Hg :
Wine Like
Vapour Density
Solubility in Water Miscible
Others
:
1.59
Miscible in most of the
0
(Air = 1) :
@ 30 C
organic solvents like
alcohol, chlorofoam etc.
0
pH
:
Specific Gravity
NA
.0790 at 20 C
Water = 1) :
Flammability :
Yes
L.E.L. :
3.3%
TDG Flammability :
U.E.L. :
19% at 60 C
0
Auto Ignition temp. C :
Data not
available
0
422 C
Impact :
Explosion Sensitivity to Static
Electricity :
0
Flash Point
0
C :
Flash Point
0
C :
0
12 C
(OC)
(CC)
Stable
Hazardous Combustion
Data not available
Product :
Hazardous Polymerisation
Will not Occur
Combustible Liquid :
Explosive Material :
Corrosive Material : No
Yes
No
Flammable Material :
Oxidiser
:
Others
:
Yes
No
NA
Pyrophoric Material :
Organic Peroxide :
No
No
4. REACTIVITY DATA
Chemical Stability :
Stable (100% Alcohol is hygroscopic in nature)
Incompatibility with
Incompatible with wide range of oxidants.
other Material :
Reactivity
Reactive with wide range of oxidants.
Hazardous Reaction
Data not available
product
:
5. HEALTH HAZARD
Route of Exposure :
Inhalation, Ingestion, contact Skin & eye
Effects of Exposure/Symptoms :
Irritation of eyes, nose and throat. Headache may occur. Liquid causes
intoxication.
Emergency Treatment :
Inhalation: Remove victim to fresh air, administer oxygen call for medical
assistance, speed is of importance. Flush with water incase of eye and skin
exposure
3
3
STEL :
TLV (ACGIH) :
5000 ppm for 15
mg/m
1000 ppm
mg/m
min.
3
3
Odour Threshold
Permissible Exposure
10 ppm
mg/m
1000 ppm
mg/m
Limit LD50 :
Limit LD50. :
NFPA HAZARD
Health
Flammability
Stability
Special
RATING
0
3
0
Personnel Protective Equipment :
Avoid contact with liquid. Inhalation of vapor. Provide all purpose canister,
Butyl Rubber Gloves, Safety Goggles.
Handling and Storage Precautions :
Store in well ventilated cool, dry area away from heat, spark, flame, and
oxidizing material.
Ref No.
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PAGE: 93
FIRE
Fire Extinguishing medium :
Special Procedure :
Unusual Hazard :
EXPOSURE
First-Aid Measures :
SPILLS
Antidotes/Dosag :
Steps to be taken :
CO2, Dry Chemical Powder, Foam.
Keep containers cool by spraying with water if exposed to heat
Flash back along the vapor trail may occur.
Inhalation: Remove victim to fresh air, administer oxygen call for
medical assistance, speed is of importance. Flush with water incase of
eye and skin exposure
Not Available
Shut off leak with risk. Contain leaking liquid on sand, cloth or earth.
Wash surface with water.
Not Specified
Waste Disposal Method :
Ethyl alcohol is a purified fermentation product. It has usually small amount of water as impurity. In few case of acute ethyl
alcohol exposure effects has been that of carcinogen's. intoxication is common feature recovery and removal have been
the rule. Physical examination periodic is recommended. A dangerous fire hazard when exposed to heat or flames. Vapors
may be explosive when exposed to heat or flame.
Name of the Firm
Mailing address
Telephone/Telex No.
Standard Packaging
Telegraphic address
Term Card
expressed or implied in respect of the adequacy of this document for any particular purpose. However the information is
non-exhaustive.
Ref No.
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Annexure-4: Map showing Earthquake Zones
PAGE: 94
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PAGE: 95
Annexure-5: Vulnerable zones
Plotting of the vulnerable zone on layout plan for catastrophic failure of
15600 KL HSD Storage Tank no.5
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Plotting of the vulnerable zone on layout plan for
catastrophic failure of 26750 KL MS Storage Tank no. 2
Plotting of the vulnerable zone on layout plan for
PAGE: 96
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catastrophic failure of 8200 KL SKO Storage Tank no. 9
PAGE: 97
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PAGE: 98
Plotting of the vulnerable zone on area map for Thermal Radiation due to Fireball
(BLEVE) for catastrophic failure of LPG Bullet (1350 MT, 85% FILLED)
At neighbouring BPCL LPG Plant
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PAGE: 99
Plotting of the vulnerable zone on area map for Overpressure due to
Vapour Cloud Explosion for catastrophic failure of LPG Bullet (1350 MT, 85% FILLED)
At neighbouring BPCL LPG Plant
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PAGE: 100
Annexure-6: Layout of Fire Water Systems and Fire Fighting Equipment details
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PAGE: 101
Annexure-7: Process Flow diagram
PRODUCT RECEIVED THROUGH MMBPL PIPE LINE PRODUCT STORAGE TANKS TANK LORRY FILLING PUMP HOUSE TANK LORRY FILLING GANTRY
TANK LORRY OUT
LOADING OF RAKE
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P&I diagram
PAGE: 102
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PAGE: 103
Annexure-8: Name, Designation and telephone numbers of employees
Sr.No.
Name
1
Mr.Anil Srivastava
2
Mr.Manoj Kumar Patoa
3
Mr.Vikas Rastogi
4
Mr.Hirender Singh Negi
5
Mr.Yogesh Chinchole
6
Mr.Rajinder Kanojia
7
Mr.Shobhit Kumar Yadav
8
Mr.Anoop Kumar Sharma
9
Mr.Amber Zaidi
10
Mr.Rohit Lihite
11
Ms.Siva Parvathi
12
Mr.Rajnish Meena
Designation
Sr.Manager I/C
Manager-Ops
Manager-Ops
Manager-Ops
Dy.Manager-HSSE
Dy. Manager-Ops
Executive Ops
Executive Ops
Executive Ops
Maagement Trainee
Executive Ops
Management Trainee
Contact Nos.
9414161962
9650102721
9811953640
8826724068
8802880351
9958507499
9650456778
9560821619
9958826054
9654442672
9968300342
9766290791
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PAGE: 104
Annexure-9: Contact numbers of district administration
Sr.No. Designation
Fire Brigade Faridabad
1.
Police Station Control room ,Faridabad
2.
Fire Brigade Ballabhgarh
3.
Fire Station Officer ,Ballabhgarh (Mr.Rajinder)
4.
Fire Brigade,NIT
5.
Fire Brigade Palwal
6.
Deputy Collector ,Faridabad
7.
S.S.P. Faridabad
8.
S.D.M. (Ballabhgarh)
9.
S.H. Office (Ballabhgarh)
10.
Senior Asst.Director -Industrial Safety & Health
11.
C.M.O.,B.K. Hospital ( Faridabad)
12.
13.
14.
15.
16.
17.
Escort Hospitals –Faridabad
Metro Hospital ,Mr.Deepak
Fire Station Ballabhgarh -Mr.Subay
Fire Station Ballabhgarh -Mr.Jaibir
Fire Station Ballabhgarh -Mr.Satish
Mutual aid industry
Piyala LPG Plant
18.
Indian Oil Lube Belnding Unit,Asaoti
AVI Oil ,Asaoti
Balmer Lawire
19.
20.
21.
State Pollution Control Board
Petroleum and Explosive Safety Organization (PESO)
Sr. Asstt. Director (Industrial Safety & Health)
Contact Nos.
101
100
2309744
9911901224
2412666
951275-252101
2227935 /2227936
2226263
2304500
2241341
2227244 /2249962
102, 2415623
5419999/2416096/2416
097
8586931127
9991303831
9991118897
9953640499
2205285 /2205286 /
2205030
0129 -2205102
2205103/104/105/22050
99/2205062
2205265 / 2205280
/2205701 ,2 ,3
0129-2215090
/9910889155
0172-2577870-73
0129-2410734/2410732
0129-2227244/2249962
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PAGE: 105
Annexure-10: Addresses and Telephone Directory of Technical Support Services
1
Director General
Council of Scientific & Industrial Research,
Anusandhan Bhawan’
2-Rafi marge, New Delhi-110001
STD Code-011
Telefax-23710618
23717053 (O)
2
Chairman, Central Pollution Control Board
Parivash Bhawan, CBD cum Office Complex
East Arjun Nagar, Delhi-110032
STD Code-011
Fax-22304948
22305233 (O)
22307233(O)
3
Joint Secretary (Chemical)
Department of Chemical and Petrochemicals,
Ministry of Chemicals and Fertilizers, Shastri
Bhawan
Dr. Rajendra Prasad Road, New Delhi-110001
STD Code-011
Fax- 23070104
23383756 (O)
4
DG (ICMR) & Secretary (MR)
Indian Council of Medical Research
Post Box No. 4911, Ansari Nagar, New Delhi110029
STD Code-011
Fax-26588662
26589620 (D)
26588204 (O)
5
DG, NDRF, Civil Defence
Ministry of Home Affairs
East Block-7, Level-7, R. K. Puram, New Delhi110066
STD Code-011
Fax-26105912
26715303 (O)
26712851 (O)
6
Fire Advisor
Ministry of Home Affairs
East Block-7, Level-7,R. K. Puram, New Delhi110066
STD Code-011
Telefax-26712832
26712832 (O)
7
2510103 (O)
Chief Controller of Explosive
Deptt. of Explosive, Ministry of Commerce &
Industry
CGO Complex, Block-A, 5th Floor, Seminad Hills,
Nagpur-440006
STD Code-0712
Fax-2510577
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8
Joint Secretary
Department of Road Transport & Highways
Parliament Street, Parivash Bhawan, New Delhi110001
STD Code-011
Fax-23311802
23717294 (O)
9
Director (Industrial Safety & Health)
Office of Directorate Industrial Safety & Health,
Commerce Centre, 5th Floor, Tardeo, Mumbai400034
STD Code-022
Fax-23522651
Director General
Factory Advice Service & Labour Institute
CLI, Mankikar Marge, Sion
Mumbai-400022
STD Code-022
Fax-24071986
Director
Indian Institute of Toxicology Research
Mahatma Gandhi Marg, Lucknow-226001
STD Code-0522
Fax-2628227/2611547
Director
National Institute of Occupational Health
Indian Council of Medical Research,
Meghani Nagar, Ahmedanad-380016
STD Code-079
Fax-22686110
Director
Centre for Fire, Explosive & Environment Safety
(DRDO, Ministry of Defence)
Brig. S. K. Mazumdar Marg, Timarpur, N. Delhi110054
STD Code-011
Fax-23819547
23522230 (O)
10
11
12
13
24074358 (O)
24092203 (O)
2621856 (O)
2613357 (O)
22866142 (O)
22686330 (O)
22686851 (O)
23813239
65498030
PAGE: 106
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PAGE: 107
Annexure-11
Pipeline route map and details of various facilities such as sectionalizing Valve (SV),
intermediate Pigging (IP) stations, intermediate pumping stations (IPS) across
pipeline route
Ref No.
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PAGE: 108
CHECK LIST-1
(Refer Regulation 10.1(d))
Emergency Response and Disaster Management Plan (ERDMP)
Hazard Identification
Sl.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
CHECKPOINT
Hazard Analysis & Risk Assessment
Whether any of the following procedures or techniques for hazard
identification has been used in the terminal/ installation :
1) HAZOP
2) Accident Consequences & Analysis
3) Event Tree Analysis.
4) Fault Tree Analysis
5) Failure Modes, Effects & Criticality Analysis.
6) Risk Assessment
7) What If, analysis.
8) Other accredited practice
Hazard Identification :
Is the terminal / installation covered under the definition of “Major
Accident Hazard Installation” as per the Manufacture Storage &
Import of Hazardous Chemicals Rules 1989?
If yes, whether major accident hazards identified and steps taken
for their prevention
Whether design deficiencies, failures or errors which can
contribute to hazards and cause abnormalities leading to an
accident are identified.
What are the measures undertaken to counter above deficiencies
or, errors
Consequences of a major accident on the workers, people in the
neighbourhood and the environment are considered
Steps envisaged for mitigation of the consequences of such
accident
Does the installation produces / handle / use / import / store any
hazardous chemicals as defined under MSIHC Rules 1989?
If yes, whether a list of these chemicals, preferably in alphabetical
order with their maximum licensed storage quantities is displayed
Are material safety data sheets (MSDS) of these chemicals are
prepared / obtained in the prescribed format as per MSIHC Rules
and State Factory Rules?
Whether a system for disseminating information about these
MSDS to concerned workers are existing
Are there a system of labelling of containers / storage tanks for the
chemicals / hazardous substances
Whether estimation of maximum possible quantity of each
hazardous substance are considered including any vehicle
(TT/TW) on site or within 500 mtrs of the site.
Whether location, configuration and condition under which the
hazardous substances are stored & handled are clearly declared
Vulnerability Analysis :
Whether zones of influence or vulnerable zones are estimated by
considering the maximum single storage of hazardous substance
& maximum loss scenario
YES NO REMARKS
1.
2.
3.
4.
5.
6.
7.
8.
YES
YES
No
No
No
YES
No
No
YES
YES-covered in QRA
Report
YES-covered in QRA
Report
YES, Location is
Designed as per OISD
guidelines
YES
YES
YES
YES-Displayed near
Admin building
YES
YES
YES
YES
YES
YES
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PAGE: 109
16
17
18
19
20
21
22
23
24
25
Whether effects of influence on the vulnerable zones are made
after considering the population, facilities & environment
encompassed inside that zone
Risk Analysis :
Whether a relative measure of the probability & consequences of
various possible hazardous events are taken into account.
Whether risks are calculated by multiplying the probability of
occurrence of each event by the consequences of that event and
then summing up the results
Whether all types of events possible in petroleum installations are
considered including i) storage tanks on fire, ii) pool fire [burning
pool of liquid fuel], iii) Flange joint leakage in pipelines, iv) Fire in
TT or TW gantry, and v) rupture of hoses.
Risk Reduction Measures :
Whether measures for reduction of identified high risks are
included by reducing the consequences thru’ hazard
Mitigation measures.
Whether steps have been consider to reduce risks to the
exposed population by increasing safe distances by acquiring
property around the facility, if possible
HAZOP Study
Whether the above method is applied if the location handles more
than specified storage and / or critical operations
Whether the study systematically identifies all possible
deviations from normal operations
Whether risk levels are established for each deviation after
considering the probability & consequences of each such events
Whether potential means for detection of such events &
preventive measures are recommended by the study
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
Ref No.
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PAGE: 110
CHECK LIST-2
(Refer Regulation 11.3 (Xii))
Incident Prevention Measures
Sl.
1
2
3
4
5
8
9
10
11
13
14
15
16
17
18
19
20
21
CHECKPOINT
Whether Safety, Health and Environment Policy of the location is
displayed
Whether the Safety Policy is documented and duly approved by the
top management
Whether the Safety Policy is well structured to cover all elements of
Safety, Health and Environment protection
Whether the layout is convenient from operation & safety aspects and
meets minimum distance norms as per OISD-118
Whether a duly constituted Safety Committee is functioning in the
location with representation from workmen/staff
Whether all unsafe developments & likely risks are deliberated in the
meetings and appropriate steps are recommended for eliminating
such risks
Whether compliance status of recommendations of earlier Safety
Committee meetings are discussed before taking up new issues.
Whether performance & shortcomings observed during recent mock
disaster drills form part of the discussions in safety committee
meetings
Is the safety committee minutes are recorded & signed by all the
attending members
Whether periodical safety audits & inspections by internal and
external audit teams are conducted in defined intervals
Whether a system of regular monitoring of such audit compliances by
controlling offices / HO are in place
What is the composition of external audit teams to ensure impartiality
of audit findings
Whether Work Permit System in line with OISD-105 have been
implemented
Whether work permits are issued for hot work, cold work, electrical
work & vessel entry jobs
Whether the location-in-charge remain the issuer for all hot work &
vessel entry permits for enhanced safety & control
Whether work permits are duly closed at completion of the stipulated
jobs, duly certified by the supervising officer
Whether heat detectors in tank sprinkler systems, high level alarms of
tank farm management system are provided & checked for regular
functioning
Whether in-built safety interlocks provided in the design of the
terminal are adequately specified & checked for regular functioning
YES NO
REMARKS
YES-in Hindi and
English
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
NO
YES
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PAGE: 111
CHECK LIST-3
[Refer Regulation 12.1(i)]
MUTUAL AID / MOCK DRILLS
SR.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
CHECK POINT
Whether mock fire / emergency response drills are held
If yes, periodicity of emergency response drills
Mock drills cover all types of probable emergencies
Does the location have Mutual Aid Plan
If yes, the details of other members including names and
contact nos. of concerned officials
List of fire fighting equipment’s available with each Mutual
Aid members including District Fire Service
Compatibility
of
safety
equipment
of
all
Mutual
Aid
members including District Fire Services with said location
has been tested and documented in the DMP
Details
of
water
storage
available
with
Mutual
Aid
member including District Fire Service and mechanism to
utilize the same in the said location well documented in
the DMP
Details
of
fire
fighting
foams
concentrate/chemicals
available with Mutual Aid members including nearest Fire
Service has been incorporated
Details of lead time for response of Mutual Aid members
including District Fire Service has been documented in the
DMP
Periodicity of safety training for officers, staff, contractor
workers, n crew and security personnel mentioned in the
ERDMP
Mutual Aid Plans
Does the location have established Mutual Aid Plans
Which are the Mutual Aid Team members and the
assistance offered?
Does the plan clearly indicate types of possible hazards
and fire fighting measures required?
Does the plan include expected assistance from each
members
Does the Plan spell out the communication protocol and
the channels in times of emergency
Periodic
joint
exercise
and
meetings
for
practice,
familiarization and identifying and resolving compatibility
issues.
YES NO
REMARKS
YES
Quarterly
YES
YES
Yes mentioned in
written mutual
aid plan
Clause 11.2
YES
YES
YES
YES
As per HSE
Training policy
YES
Clause 12.3
YES
YES
YES
YES
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PAGE: 112
CHECK LIST-4
[Refer Regulation 13.0]
ERDMP Response Measures /Infrastructure
Sl.
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
1
2
CHECKPOINT
Zones, maps & layouts
Does the Location have Emergency Zones clearly identified for
accident prone areas
Do the Maps indicate location of Emergency Assembly Points and
Emergency Control Rooms
Is the process Lay-out prominently displayed
Does the P&I Diagram include emergency control valves, shutdown
system, isolation valves, important control valves etc.
Does the Fire Hydrant Layout conspicuously displayed.
Manpower
Is the Fire Organogram clearly displayed.
Does the Organogram include all duties to be attended in connection
with an emergency.
Is the organogram include key personnel by their names or, work
position
Does it have the alternate coverage to take care of the absence of a
particular person [ in cases where organogram is developed basis
names]
Does it include assignment of all key co-ordinators viz. the Incident
Controller, Administration & communication Controller & Safety
Coordinator.
Emergency Control Centre
Does the ECC well defined & clearly marked on the displayed layout
Is it strategically positioned to be outside the periphery of immediate
affected area.
Does the centre have adequate communication channels including
internal & external telephone connections, PA, paging & VHF systems
Does a list of key personnel & essential telephone nos. are
prominently displayed.
Does the layout of fire fighting system, different hazardous zones,
Assembly Points are prominently displayed.
Emergency Assembly Points
Does the EAPs well defined & clearly marked on the displayed layout
Does the EAPs have pre-defined in-charges during emergencies who
keeps in touch with the Emergency Control Centre and Administrative
Controllers and updates on the roll call on people reporting.
YES NO
REMARKS
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
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PAGE: 113
CHECK LIST-5
[Refer Regulation14.2.1 (a)]
Review & Updation of ERDMP
Sl.
1
2
3
4
5
6
CHECKPOINT
Frequency of mock-drills for practice, refinement & updation.
Does the records for periodic Mock drills maintained in a well
defined format.
After each drill, whether assembly meetings involving all staff
and contract personnel are conducted to share experience of
the event as also to identify the shortcomings and scopes for
further improvement in procedures. Whether the issues are
discussed & the plan modified suitably.
Does the review ensures efficiency of the plan particularly
w.r.t. response, communication & coordination aspects.
Do the Mutual Aid members participate in the drills and based
on the actual response & difficulties experienced, corrective
actions initiated for refinement of the plan.
Does a procedure exist in incorporating the findings/learning
of the actual disaster management handling, if any so that the
plan can be revised accordingly.
YES NO REMARKS
Monthly FIRE DRILL
AND HALF YEARLY
MOCK DRILL
YES
YES
YES
YES
YES
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PAGE: 114
CHECK LIST-6
[Refer Regulation 17.0 (5)]
Availability of resources [Internal / External]
Sl.
1
2
3
4
5
6
7
8
9.
CHECKPOINT
Details of firefighting equipment of the location is
incorporated in the DMP
Information on critical resources like no. of fire hydrants, water
monitors, fire fighting pumps, static water storage, portable firefighting
equipment and foam systems are included
Available resources as per SCHEDULE-IV
Location has storage of water for 4 hours fire fighting. In case water
availability is less, a plan for replacement from nearby sources
Details of drainage system including Oil Water
Separator is available in DMP, wherever applicable.
Requirement & availability of Personal Protective
Equipment
Whether manpower available during regular as well as idle shift hours
including security personnel clearly indicated in the plan
External & Internal Resources for combating Emergency
Does the plan enumerate the following resources available internally
with the location as also from external agencies including Mutual Aid
Members and govt. agencies like fire brigade, police, municipal
authorities etc. :
a. Water – from static reservoir as also mobile water tankers
b. Fire Hoses
c. Specialized nozzles e.g. fog, jet, triple purpose etc.
d. Mobile water monitors
e. Fire Extinguishers – type & capacity
f. Water Gel Blankets
g. Foam Compounds
h. First Aid material, Medicines, Stretchers
i. Mobile / fixed ladders
j. Vehicles available
Trained manpower for combating emergency
Any other resources considered necessary
YES NO
REMARKS
YES
YES
YES
YES
YES
YES
YES
YES
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
Ref No.
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PAGE: 115
CHECK LIST-7
(Refer Regulation 26.0 (2))
ERDMP Recovery Measures
Sl.
1
2
3
4
5
6
7
8
9
10
11
12
13
17
18
19
20
21
CHECKPOINT
Post Emergency Recovery
Salvage of product
Check that spilled / accumulated product contents are transferred to
the OWS or collected in drums.
Check whether the quality & quantity estimation of the product
extracted from OWS has been done for further disposal in line with
standing QC guidelines by either transferring to service tanks or to
nearest refinery for blending / reprocessing or not.
Check that correct stock accounting of spilled product as loss has
been completed in accounting system.
Check that affected area has been completely cleaned and dried after
evacuation of spilled product.
Declare that affected area after salvage operations is fully clean &
safe for movement of the working personnel.
Check that all drains are not having any residual oil and are
thoroughly cleaned & dried.
Check that all control valves on product lines & OWS lines outside
dyke area and drains are completely closed after removal of the
spilled product.
Check that interlocking system of tanks / gantry has been reactivated
for normal operations.
Check whether the soil testing of the affected area, if required, has
been done to assess the soil contamination level to meet the
Environmental – SPCB norms / requirements.
Taking care of affected manpower
Whether physical accounting of all personnel on duty during & after
the incident are ascertained by the Main Incident Controller and
reconciled immediately
Whether the first-aid treatment & post-incident health check of the
affected personnel has been undertaken in time
Whether these personnel are declared fully physically fit before
allowing them to resume their normal duties
Whether the records for such first aid & treatment of the affected
personnel are maintained in a well-defined format
Addressing media & outside bodies
Whether the DMP event was appropriately informed to the local
media in line with the respective company’s Press & Media Policy
Whether the role of neighbouring population during the drill / disaster
is suitably informed to the population during subsequent meetings
with local administration/ Panchayat etc. for necessary improvements
Whether the awareness & preparedness on disaster is regularly
assimilated / shared with nearby public / societies and stake holders.
Reporting
Check whether that disaster incident report was communicated to
respective controlling office / HQ on time in a standard format.
Whether the incident reports are also sent to concerned State Level
Industry Coordinator on time.
YES NO
REMARKS
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
Ref No.
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PAGE: 116
22
23
24
25
26
27
28
29
30
31
32
33
34
35
Check that detailed report on disaster in proper format was
communicated to PNGRB/ Factory inspector / Labour inspector /
SPCB / District Magistrate /PESO.
Investigation
Whether investigation teams are constituted as per respective
company policies
Whether RCA (Root Cause Analysis) of the disaster is conducted by
the investigating team
Whether detailed analysis including effective functioning of interlocks,
detection devices, automation controls & applicable norms are carried
out to find out possible improvements in design / construction /
operations / maintenance & training aspects
Whether a system of initiating appropriate corrective measures
including suitable revisions to the Disaster Management Plan are
adopted based on findings of the investigation
Damage Assessment – Monetary & Physical
Check the valuation / cost of product loss / down gradation on
account of contamination, if any / Property / Structures / damaged
assets – equipment.
Whether repairs & maintenance cost of property, assets & equipment
are assessed.
Whether any penalty by statutory authorities like SPCB / Factory
Inspector and Labour Commissioner are assessed.
Whether possible impact on environment are also assessed &
appropriate measures are taken
Whether damage assessment also include potential erosion of
reputation – from company, industry & national perspectives
Clean up and Restoration
Whether the affected area has been fully cleaned and cleared after
due clearance from investigation team
Check whether heat detectors, high level alarms, in built safety
systems (NRV, TSV etc.) are fully functional after the disaster
incident.
Check whether all fire fighting equipment like – hoses / nozzles / Fire
Extinguishers etc. have been put back at designated places and are
fully ready for reuse
Whether a clearly defined steps are in place to allow resumption of
normal operations
YES
YES
YES
YES
YES
YES
YES
NO
YES
YES
YES
YES
YES
YES
 Photograph of green belt.

details of additional details sought vide mail dated 18.08.2015 for

Transcription

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