CHAPTER - XVI

SAFETY

Safety

16.0

SAFETY PRECAUTIONS & PRACTICES

Safety is the prime responsibility of every employee. You cannot do the job properly unless you do it safely. 16.1 Safety Responsibility Safety is the most important consideration in any operation. BPCL-Kochi Refinery considers safe working conditions and safe working habits an absolute necessity for the operation of the plant. No unit or part of a unit should be operated in an unsafe condition or manner. Also no operator should perform any work in an unsafe manner. There is a safe way to do a job and it is the responsibility of the operator to be aware of this way. Do not proceed with a job if you are not clear of the consequences of the steps taken by you. Consult your Supervisor when in doubt and get with the job only after understanding thoroughly every phase of it. Accomplishing a job efficiently and without injury to oneself or others necessitates clear thinking and attention to the job. The operator must guard against the possibility of daily routine dulling his senses resulting in careless handling of even the simplest of jobs. It is the responsibility of the operators to be familiar with characteristics of the product and chemicals which he handles, as they apply to fire and personal protection. Safety instructions and proper procedures for working in operating area have been issued. Equipments are designed with safety in mind. Personal protection gears have been provided at operating areas for operators use. In addition to all these operators must act safety and do their job in a safe manner. Every employee should develop safety consciousness. It is the responsibility of the operator to bring to the attention of the supervisor, any potential hazards involved in their job in the process area and recommend proper protective equipment / remedial action. All employees are required to go through The safety Hand Book, Chemical Safety Hand Book, Pocket Fire Guide and Fire Emergency Procedure issued to them and thoroughly acquaint themselves with the contents. 16.2 House keeping In general a clean plant is a safe plant. Always keep your work area clean and in order. Allow no debris to collect. You should not allow any spills or leaks. In case they happen, clean them off immediately, provided ample space, do not

Safety

allow it to get filled. See that the materials that must be kept in the area are always kept in an orderly manner. Place all trash in containers provided. Form a habit of daily clean up. 16.3 Few Cardinal Rules Rules of Safety 1. 2. 3. 4. 5. 6. Use your common sense on the job and mentally check out every action before you do the job. When in doubt ask your Supervisor. Do not sacrifice safety for haste. Do not day dream. Keep alert. Think of your job. Use protective equipment and cloth wherever required. Keep alert to unsafe working conditions, fire hazards etc. Remove any hazards within your power, also report them to your supervisor. Safety is a major part of your job. You cannot do your job unless you do it safely.

7.

16.4 16.4

Draining Draining or venting Hydrocarbon & Other dangerous chemicals When it is required to drain/vent hydrocarbon or other dangerous chemicals, it is necessarily required that a man should be present at the spot till the draining or venting is stopped. Hot and heavy hydrocarbon pose a fire hazard on contact with air. It should be ensured that such products are cooled down to a safe temperature before they are drained and steam hose or water spray kept nearby for use in case of emergency. Likewise, light hydrocarbons will evolve flammable vapour when drained or vented and they should be drained or vented in controlled quantities. The operator draining such product should stand upwind, so as to avoid these products spraying on to his body or cloth. In case of body contact, wash the area immediately with lot of water. Care should be taken in opening plugged drain/vent valve. If valve is opened beyond normal there is the danger of plug blowing out under pressure and hydrocarbon gushing out at an uncontrolled rate. So do not open a plugged valve beyond its normal opening. In this case either get a new valve attached to the plugged one or use a pressure proof bleed reamer.

16.5

Sign Boards Various sign boards indicating Note, Caution and Warning can be seen at various points inside the Refinery. These sign boads indicate: Note : Highlights and essential elements of a procedure to assure correctness.

Safety

Caution : Indicates a procedure, practice etc. which, if not strictly observed could result in damage or destruction of equipment. Warning: Indicates a procedure, practice, etc. which could result in personal injury or loss of life if not followed correctly. 16.6 Hazards of Petroleum Products

16. 16.6.1

Physiological effect All petroleum products give out vapours in quantity depending upon the type of product. These varpours in a confined space will tend to make the atmosphere leaner in oxygen content, thus making it difficult to sustain breathing. (asphyxiation). The hydrocarbon vapours heavier than air collected at low points near ground level. The vapours have anaesthetic effects. If inhaled for 5 minutes at a concentration of 0.1%, the person feels giddy. If concentration is 0.5% and exposure is A minute, the person exhibits symptom similar to drunkenness. A concentration of 1.0% will cause rapid on set of drunkenness which may lead to unconsciousness and death if exposure continuous. At 2% concentration, paralysis may occur rapidly followed by death.

16.6.2 Explosion/Fire

When the proportion of hydrocarbon in the hydrocarbon air mixture fall within the explosive limits (table 16.1) an explosion or fire could occur, triggered by a source of ignition. The hydrocarbon air mixture can spread on the ground over a considerable distance initiating a flash back. When the explosive mixture get ignited an explosion takes place which could lead to other explosions or fires, even at large distances, depending upon its intensity. Hydrocarbon dust or vapour cloud can also get ignited causing severe damages of catastrophic proportions.

Table 16 16.1

Explosive limits of Hydrocarbons

Product

Lower

Higher explosive

Safety

Hydrogen Methane Ethane Ethylene Propane Propylene Butane Pentane Hexane Gasolene Naphtha Kerosene Hydrogen sulfide Ammonia Toluene LPG Diesel Benzene

explosive limit (LEL % vol/vol air) 9.5 5.3 3.2 2.75 2.37 2.0 1.6 1.45 1.2 1.3 1.1 0.7 4.5 15.5 1.27 1.9 0.7 1.3

limit (HEL vol/vol air) 65.2 14 12.5 28.6 9.5 11.1 8.5 7.5 6.9 6.0 6.0 5.0 45 27 7.0 9.0 5.0 7.1

16.7 6.7 16.7.1

Sources of Ignition Auto Ignition Normally for combustion, a combustiable material, sufficient quantity of oxygen and a source of heat are required. In free air there is no risk of ignition if the hydrocarbon vapour temperature is less than the ignition temperature. However, if the temperature of the hydrocarbon vapour equals its ignition temperature, the vapour can catch fire on mixing with oxygen from atmosphere even without the help of a flame or spark. This is known as auto ignition. The risk of auto ignition is generally more as the molecular weight of hydrocarbon increases. Table 16.2 lists the auto ignition temperatures of some of important hydrocarbons.

16.7.2 Electrical Apparatus Electrical apparatus includes all machines, equipments and fittings in which conductors are used or of which they form a part, eg. Electric switches, push buttons, circuit breakers, starters, motors, etc. These may provide arcs or

Safety

sparks and are capable of raising surface temperatures above the spontaneous ignition temperature.

Table 16 16.2 Auto ignition temperature Product Hydrogen Ethane Ethylene Propane Butane Pentane Hexane Gasolene Kerosene Lube oil(light) Hydrogen sulphide Ammonia Lube oil (Heavy) Reduced crude Naphtha Diesel Furnace oil Toluene Temperature C 530 576 450 466 430 309 247 257 254 417 250 651 248 300 287 257 407 580

16.7.3 Stray Electric Currents It may occur when very high voltage is applied. Welding machines may also become sources. 16.7.4 Static Electricity Static electricity is produced by friction or by the mere contact and separation of unlike substances. Explosions and fire can be caused by a static spark whenever flammable or explosive chemicals, liquid, gases or dusts are being handled. Static electric is generated when : Liquid passes through pipes/filters (tanker loadings/fillings) Solids settle in liquid (rust and sludge settles in tanks)\

Safety

Droplets of liquid settle down in another liquid (water in oil) Free fall of a liquid column is interrupted (overhead tank filling) Gas bubbles through liquid (trapped air rising through liquid) Jets or bubbles are broken up by splashing (splash filling of tanks, high speed ejection of liquid from nozzles). Solids and solids impinge (sand blasting)

16.7.5 Lightning Lightning can fall on metallic object, especially tall objects such as chimneys, towers, tanks and buildings. Lightning may lead to damage as well as ignition. Vents and safety relief at high points are vulnerable. 16.7.6 Non Electrical Electrical Sources Smoking Internal combustion engines spark ignition system, dynamo, battery, hot particles or flame from exhaust system. Spontaneous ignition (Oil soaked rags/insulation) Pyrophoric Iron (Fes): Pyrophoric substances (Black or grey powder) can be seen inside the column at its top section, over head system, flare and fuel gas lines, effluent treatment and sewerage system. In general, pyrophoric iron can be present in the scales of all systems handling hydrocarbon containing sulphur. This is so exothermic that it can melt metal and start ignition. Frictional heat/spark (Falling of iron tools).

16.8

Hazards in handling Chemicals

16.8.1

Caustic Soda(NaOH) This is extremely alkaline and highly corrosive to body tissue. Contact with body tissue will result in severe burn and tissue damage. Continuous contact of dilute solution may result in dermatitis. Contact with eyes is extremely dangerous and may result in blindness. In case of body contact, wash affected area with running water as long as possible before getting medical attention. Always wear protective equipment viz face shield, rubber gloves, gum boots, apron etc, while handling caustic soda. Identify and familiarise the location of eye wash and safety shower in the area.

16.8.2 Chlorine Chlorine Cl2

Safety

Chlorine is detected even at a very small quantities due to its pungent odor. It is very corrosive when wet and will damage any mucous membrane ( eye, throat, lungs etc.) by forming HOCl/HCl. Chlorine cylinder should always be kept in a well ventilated area and also make sure that the cylinder outlet is from the gas side. In case of any leaks, respiratory protective equipment which gives full protection for eyes also are to be used. If leak developed in the liquid side, turn over the cylinder to ensure that only gas is leaking out. Affected person may give soda or lime water and oxygen if he has breathing troubles. He should be allowed to rest and given glucose rich diet.

16. 16.8.3 Diethanol Amine(HOCH2CH2)2NH DEA is used as absorbent for acid gases like hydrogen sulphide from LPG. It causes irritation to skin, mucous membrane and eyes. Breathing vapours may cause coughing, a smothering sensation, nausea, headache. Unconciousness or convulsion may occur if DEA is swallowed. The affected part should be immediately flooded with plenty of water. No problem is likely to occur when inhaled. Get medical attention if ill effects develop.

16.8.4 Ammonia Uses: For neutralizing acid vapours in distillation columns. Physical Properties: Boiling point : Physical state : Odour : Soluble in water 33.4oC Liquefied compressed gas. Strong pungent odour. : Moderately soluble in Alcohol.

Fire & Explosion data : Flammability : LEL 16% UEL : 25% Auto ignition temperature : 651oC

Safety

Hazardous Combustion products ammonia and Nox Not flammable. Health Hazard data: Routes Of entry Effects of exposure

Emits

toxic

fumes

of

: Inhalation, skin or eyes. : 700 ppm causes eye irritation and permanent injury may result if prompt remedial measures are not taken. 5000 ppm may cause death from spum inflammation, or EDEMA of the LARYNX. Contact of the liquid with skin freezes the tissues and causes the caustic burns.

Emergency treatment: Inhalation : Remove the victim to fresh air and provide artificial respiration or oxygen. : Wash the affected area with plenty of water for 15 minutes. 25 ppm : 350 mg/Kg. : 25 ppm : 35 ppm

Skin & Eyes Permissible exposure limit: LD50(Oral-rat) TLV STEL

Personal Protection Equipment: Rubber boots, safety goggles, self contained breathing apparatus(SCBA), gas mask and protective clothing in case of liquid ammonia. Emergency/Fire Aid measures: Fire or fog. Keep containers cool by spraying water if exposed to heat or flame. Unusual hazard : Gas is suffocating. : Fire extinguishing media: use water spray

Safety

16.8.5 Phosphate Moderately toxic by injestion, irritant to tissue. Flush the affected area with sufficient quantity of water, seek medical attention. 16.9 GENERAL SAFETY GUIDELINES The following general safety rules are applicable to plant operations. must be known to and strictly observed by all personal. Safety Rules in general general 1. 2. 3. 4. 5. 6. 7. Smoking is strictly prohibited inside the refinery premises Contaminated clothes must be removed immediately and a shower taken Defective tools should not be used. Only non-sparking tools should be used Use the proper tool for the work involved Do not overstress tools or equipments Use safety belts of life lines when working above 3 meter height, where it is not practical, make other provisions to prevent falling. To prevent falls: Look around while going around Do not run / jump in work place Stand on ladders or platforms and not on makeshifts. Use handrails on stairs and do not run Face trolley when carrying load on the same. Tools and objects should not be dropped from height. Do not stand/walk under suspended object. This

8. 9. 10. Electrical Safety 1. 2. 3. 4. 5.

Do not tamper with electrical apparatus Do not remove light bulbs to plug in power equipment Use only approved fittings Electrical equipment must be properly grounded An extension wire, if used, must be properly laid

Safety

16.9

SAFETY PRACTICES FOR PARTICULAR OPERATIONS OPERATIONS

16.10.1 Sampling and purging Before opening a purge/sample connection ensure that the product is not hot enough to start a fire or cause burns. Hot & heavy products are most dangerous as they are near their auto ignition temperature. Sample connections of hot products are normally through coolers. Vents/drains of hot products which are not in regular use should be capped/blinded. If a hot product is to be vented, connect it through a cooling coil. Vents must be opened slowly and the person doing so shall be present on the spot till the same is closed. Also the plug/cap/blind should be put back when the operation is complete. Sample and purge connections on iquefied products shall have two valves. Always open the upstream valve fully and adjust flow by the downstream valve. By doing so in case of frosting, u/s valve will be operable. 16.10.2 Isolation of safety valves Safety valves are provided with bypass and also with valves upstream and downstream. This is to facilitate maintenance. Always ensure that the safety valve is in line.. When one valve is taken out of line the spare should be put on line. An equipment should never be taken on line without a safety valve. 16.10.3 Furnace operation While lighting burners in a furnace, it should be purged thoroughly with steam/air. Sometimes a number of trails are to be taken to light a burner. It is important to purge the furnace every time a burner fails and trial for relighting is made. It should also be noted that each burner be lighted by pilot burner and not by the flame or heat of the adjoining burner. Sometimes during a furnace shutdown all the burners are put off. If it becomes necessary to relight some burners do not forget to purge the furnace. 16.10.4 High point point vents and relief valve discharges These are normally on closed system with the flare. In rate cases venting to atmosphere may be unavoidable but pose hazard due to lightning. So in this case purging steam must be opened to the vent especially during monsoon seasons.

Safety

16.10.5 Flare system operation It is essential that the pilot burner at the flare tip is always is on. Always maintain a small purge gas to prevent air ingress into the system. Maintain proper hydraulic seal in the water seal drum all times when flare is operating. 16.11 FIRE FIGHTING FACILITIES In case of fire, operating personnel should identify the source of fuel and cut out the same as soon as possible. Movement of all process fluids to the affected area should be stopped. Attempts should be made to extinguish fire immediately using extinguishers, water, steam, sand etc, provided in the plant area. If this is not possible convey the emergency as fast as possible to the fire station by breaking the nearest fire alarm points glass or by phone or by informing the supervisor or by all three at the same time. The personnel should be fully conversant with the fire fighting system provided in the plant and with the reporting procedure. Every person must attend the fire training conducted every Friday by the Fire Dept. atleast once a year. They should also be familiar with the disaster plan organogram displayed in the notice board. The fire fighting systems comprises of the following: 1) Fire Alarm Points

Whenever a fire is sighted and external help is required, first break the glass of the fire alarm point. The alarm is received at the fire station with exact location indication and also at all control rooms, medical centre, and other important locations for caution and action. If it is a major fire it may be decided to sound the fire siren for information and caution to neighbours as well. We also have a mutual aid scheme between BPCL-KR, HOC & FACT (CD). In case of a fire in any of this member industries, to fight the same together. In case the fire turns out to be of disastrous proportions, our disaster plan will start functioning with immediate effect. 2) Portable Fire Extinguishers

Fire should be killed at the initial stage before it can cause much damage or it can spread. Portable extinguishers are very useful to fight small fires. All strategic areas are provided with a 10 kg/75 kg wheeled DCP extinguishers

Safety

3)

Gas Alarm Monitor systems

Gas sensing elements are provided at different locations in the plant which sense the hydrocarbon vapour/gas and H2S present in the atmosphere and the convey the same as percentage of lower explosive limit to the main control room which houses the gas alarm monitor panel. The alert sign is flashed at 20% of LEL and alarm is sounded at 60% of LEL. This gives time for remedial action in case of gas leak. 4) a. Fire Water Network Type of Fire Protection Systems The following type of fire protection systems are envisaged for the plant. 1. 2. 3. 4. 5. 6. 7. Pressurised automatic hydrant system Fixed water spray system for tanks Fixed water spray system for equipments Semi fixed manually operated foam system for HSD and LSD tanks Clean agent total flooding system for control room Fire detection and alarm system for control room & substation. Portable fire extinguishers.

b.

Hydrant System The hydrant system shall mainly consist of fire water pumps, reservoir, pipe net work, hydrants, and monitors. The pipe lines are laid in rings around each area. Hydrants are fixed at regular intervals of 30 meters for plant and storage area and 45 meters for utility area on stand posts tapped from the ring mains. The mains are constantly charged with water to the system design pressure. The operation of the system is automatic through the pressure switches installed in the system. System Operation In case of fire In case of fire, one or more hydrants shall be opened. The system pressure shall fall down from the normal level. Immediately jockey pump shall comes into operation to compensate the loss of pressure in the system. Since the jockey pump cannot meet such high water demand the pressure shall

Safety

fall down further. When the pressure reaches 10.5 kg/cm2g pressure switch shall switch on the main fire water pump into operation. c. Fixed Water spray system

d.

Foam System.

16.12

GAS MASK There are three types of gas mask in general refinery service. They are canister type mask, the fresh air mask, and self contained breathing apparatus(trolley mounted BA set). Their uses are described below: I. The Canister Mask utilises a filter element to absorb the poisonous gas from the air. Different gases requires different type of filters. Information about the filtrs may be obtained from the Safety Dept. 1. Use this mask only in the open air or where the gas concentration is less than 2%, not in a tank or other confined space, except in an extreme emergency. A canister type of mask does not protect the user against the deficiency of oxygen. A lifeline should be used in questionable location. As seal is removed from a canister mask and after one year discard it regardless of how little it has been used. A record of amount of time that the canister has been used must be kept on a tag attached to the canister. Do not exceed the permissible time for a particular canister being used.

2.

3.

II

The fresh air mask has a remote air supply provided by hand operated blower through a lengthy hose. It is used mostly for rescue operations. 1. When a man must enter a tank, sewer or other confined area, where the atmosphere is 20% or more of the lower Explosive Limit or contain evidence of hydrogen sulphide or other toxic material, a fresh air mask must be used. The blower must be placed where only fresh air can enter it, but not more than 100 ft. of hose should be used.

2.

Safety

3.

A life belt and the rope should also be used with the end fixed so that it will not fall back into the tank or sewer. Be sure that the harness is buckled close to the wearers body so that it will not slip over his shoulder, if a rope rescue is necessary. One man who knows artificial respiration must be present on the outside.

4.

5.

III.

The self contained breathing apparatus has a self contained air supply carried on the back of the user. It is the only one of the three types that is completely independent of outside air. 1 This mask is to be used only be specially instructed personnel where there is little or no ventilation. It is used principally in emergencies. After use always notify the Safety / Fire Dept. so that they can recharge the tank.

2 3

16.13

GENERAL a. Maintaining Electrical ground continuity of system. In addition to the individual earthing of equipments and motors, a separate grounding system for the pipeline network is given. b. Centralised communication & monitoring

Personnel protection and first aid personnel protection equipments (PPE) of all ranges from disposable paper masks, canister masks, self contained masks with cylinder back up and remote air blowing facility to face shields, rubber, plastic and canvassed gloves and gum boots are provided within easy access. Two first aid boxes with all facilities to handle minor burns and injuries and water gel blankets for burn injuries are also provided in the control room. Further operating personnel are trained on first aid. Plant area is also provided with eye washes and drip showers. Notice boards displaying dos and donts as well as first aid practices for particular chemical contacts are provided at appropriate places.

Safety

FIRE PROTECTION AND COMMUNICATION SYSTEM FIRE FIGHTING FACILITIES In case of fire, the operating personal, should identify the source of fuel and cut out the same as soon as possible. Movement of all process fluids to the affected area should be stopped. Attempts should be made to extinguish fire immediately using extinguishers, water, steam sand etc, provided in the plant area. If this is not possible convey the emergency as fast as possible to the fire station by breaking the nearest fire alarm points glass or by phone or by informing the supervisor or by all three at the same time. The personnel should be fully conversant with fire fighting systems provided in the plant and with the reporting procedure. Every person must attend the fire training conducted by the fire section at least once a year. They should also be familiar with the disaster plan organogram. A) FIRE WATER NETWORK A reliable and adequate supply of water for fighting fire/cooling surface at all points in and around the plant is ensured by a pressurised fire water net work (12 kg/cm2g). Double outlet fire hydrants are provided spaced approximately every 30metre apart. Water monitors are also provided in the loop that can reach a height of 80metre. Inside the plant, fire hose reels are separately provided in hose boxes along with regular pressure hose reels. A fire proof suit is also provided for rescue operation etc. in daring situations. Eight sets of fire water pumps of capacity 616 m3/hr are provided for the hydrant system. Out of the eight pumps, four act as main fire water pumps and the other four are kept as standby. Four pumps are electric motor driven and the rest are diesel engine driven pumps. 2 numbers of electric motor driven jockey pumps of capacity 66 m3/hr are provided to maintain the system pressure and to compensate for any leakages. All the pumps are located in the fire water pump house. The fire water pumps are common for hydrant systems, water spray system and foam system. B) FIRE WATER RESERVOIR This is an exclusive fire water reservoir of capacity 15500m3 in two compartments. The bottom level of the tank is above the centerline of the fire water pumps in order to facilitate the fire water pump to work under positive suction. The total capacity of the fire water Total flooding system for control room (NAF SIII): NAF SIII Gas is a blend of hydro chloro fluro carbons (HCFCs). NAF SIII is manufactured in Italy by Saftey Hi-tech.Srl, under licence from North American Fire Guardian Technology Inc. NAF SIII is a clean, electrically non conductive and is efficient on class A, class B and class C fires. It leaves no residue on discharge. It is colourless and non corrosive. NAF SII is listed as an acceptable alternative to Halon 1301. NAF SII total flooding system is for control room, console area, engineering

Safety

room, equipment and rack room. 13 cylinders are used for maintaining 8.65% concentration. 13 cylinders are kept stand by, cylinder pressure is 25 bar. Smoke detection and alarm system: In order to ensure life safety and property loss there is a need to detect fires in the incipient stage which will provide a reasonable interval of time for inmates to escape to a place of safety and give fire fighters a reasonable chance to control and extinguish the fire with the minimum loss. Therefore the basic objective of any fire detective system is to respond to a fire and transform the response into an audiovisual signal, which would simultaneously alert the building occupants and inform others related to fire safety to take immediate measures. Smoke is the product of combustion and it refers to solid or liquid particles that are released during combustion. The traditional method of detecting smoke, have been with either ionisation or photoelectric smoke detectors. The ionisation smoke detectors, which are installed in our control rooms respond faster to those fires containing smaller particles and are more effective for detecting incipient fires from wood, paper etc., especially where very low amounts of visible smoke are generated. Portable fire extinguishers. Fire should be killed at the initial stage before it can cause much damage or it can spread. Portable extinguishers are very useful to fight small fires. All strategic areas are provided with 10kg and 75kg wheeled DCP extinguishers. All personnel must be acquainted with the exact location of these. COMMUNICATION COMMUNICATION NETWORK 1) FIRE ALARM POINTS Fire alarms are provided at several convenient places through out the plant. Whenever a fire is sighted and external help is required, first break the glass of the point. The alarm is received at the fire station with the exact location indication and also at all control rooms, medical centre and other important locations for caution and action. If it is a major fire it may be decided to sound the fire siren for information and caution to neighbours as well. We also have a mutual aid scheme between BPCL KR, HOC and FACT (CD). In case of a fire in any of these member industries, to fight the same together. In case the fire turns out to be of disastrous proportions, our disaster plan will start functioning with immediate effect. 2) PHONE NUMBERS i) EMERGENCY TELEPHONE NUMBERS: Fire station 101 Main fire station control room 1905/1922 DHDS fire station control room 1913 CDU-2 fire station control room 1908 ii) MEDICAL SERVICES: Medical centre 1425

Safety

Medical officer 1422/1428 iii) SECURITY: Main gate 2235 DHDS gate 2206 Jwalagiri main gate 2236 iv) DISASTER CONTROL ROOM: 1130-34 v) OTHER IMPORTANT NUMBERS: GM (O) 1104 DGM (MFG) 1800 CM (DHDS) 1802 CM (SHA) 1121/1122 5) FIRE ALARM: A centralised fire alarm hooters are provided in fire stations and inside the control rooms. The DGFAP (Data Gathering Fire Alarm Points) is replaced with M/s HONEYWELL (CPU 16 and 17) system in DHDS control room. The hooter will be sounded in DHDS control room and fire station in case of actuation of any MCP/ smoke detectors in DHDS area, which is displayed in M/s HONEYWELL system (CPU 16 and 17). The alarm will be sounded with displaying MCP number in M/s HONEYWELL system (CPU 16 and 17) in DHDS control room and fire station in case of actuation of any MCP/ smoke detectors any where in the refinery. 6) FIRE SIREN: The fire siren will be sounded in case of minor fire/ major fire/ disaster. Test siren will be sounded every Thursday at 13:30hrs which will be a continuous siren for 2minutes. Note: Closed Circuit TV (CCTV) system is provided in control rooms for closely monitored the plant area and flare flame. ONSITE EMERGENCY PLAN The type of emergency primarily considered here is the major emergency which may be defined as one which has the potential to cause serious danger to persons and / or damage to property and which tends to cause disruption inside and / or outside the site and may require the use of outside resources. Emergency is a general term implying hazardous situation both inside and outside the factory premises. Thus the emergencies termed on-site when it confines itself within the factory even though it may require external help and off-site when emergency extends beyond its premises. It is to be understood here, that if an emergency occurs inside the plant and could not be controlled, it may lead to an offsite emergency. The On-Site Emergency plan will come into effect on sounding of the fire siren (Wailing sound) as follows: i) Sound the fire siren continuously for 2 minutes. ii) Stop the fire siren for 1 minute.

Safety

iii) Sound the fire siren continuously for 2 minutes. iv) Stop the fire siren for 1 minute. v) Sound the fire siren continuously for 2 minutes. SOUND STOP SOUND STOP SOUND 2 MIN. 1 MIN. 2 MIN. 1 MIN. 2 MIN. Total duration of Siren for enforcement of On-Site Emergency plan will be eight minutes. Signal for withdrawal of On-site emergency control plan. / Fire siren will sound continuously for 2 minutes (Straight run siren). Signals for enforcement and withdrawal of the On-site emergency Plan are to be followed by announcement over the internal PA system, by Administration Section, on Chief Co-ordinators instruction, as to the enforcement/withdrawal of the OEP. For details please refer OEP manual.
16.14 16.14.1 SAFETY MEASURES PERTAINING TO THE UNIT Mechanical Design Safety - Fire & Explosion Proof Design

The sulphur plant normally operates under low pressure, at about 0.8 kg/cm2.g. However, the minimum design pressure of all equipment handling acid gas is 3.5 kg/cm2.g . Pressure safety valves designed for external fire are provided on all the KO drums. Possibility of explosion is greater during start-up of the unit with fuel gas and the system is cold than when unit is hot and switched to acid gas burning mode. Thus explosion proof design of Main burner & combustion chamber, waste heat boiler and Burner & Mixing chamber of incinerator will be a safeguard against possible explosion during start-up, shut-down and hotstandby mode. 16.14.2 .14.2 1. Personnel Safety Equipment H2S Detectors at strategic locations The following information deals with the prevention of possible danger hazards encountered in the Sulphur Recovery Unit. For the protection of the operating personnel H2S detector system is installed. Meter range : 0 - 100 PPM H2S.

When the concentration of H2S in the atmosphere, after the alarm is actuated, appears to increase considerably, the unit has to be shut-down

Safety

manually. The alarm is set at a value of 20 PPM by volume of H2S. It is advised to check the sensors every six months. Process gas leaks of minor nature can be detected by means of cotton waste soaked in ammonia. If this is brought into the vicinity of the leak, white fumes of ammonium salts will be formed. Also, filter paper wetted with lead acetate solution can be used. The lead acetate turns black when exposed to H2S. 2. Special Safety Measures and Industrial Hygiene This paragraph describes how to prevent hydrogen sulphide and sulphur dioxide poisoning and some suitable protecting equipment. a) Carelessness, negligence or ignorance of danger are often the causes of H2S and SO2 poisoning. Operators must be instructed to avoid inhalation of gas whenever possible, by working on the windward side of the place where gas is escaping. Furthermore, they should not stay unnecessarily without protection under process gas lines or equipment, since H2S and SO2 are gases heavier than air. b) Process staff and senior operating personnel have an additional responsibility and they should show by their own example that precautions should be taken. Instructive bulletins issued by the safety department and education are also very important. c) In places where high concentrations of gas may occur, especially in enclosed spaces, one should wear a compressed air breathing apparatus or hose masks connected to a clean air supply. If air is supplied by an air blower, care must be taken that the air blower has been placed upwind and clear of any source of gas, in order that the person wearing the mask will have a supply of uncontaminated air. d) When the aforementioned masks are in use an attendant should be stationed at the air supply point. As an extra precaution somebody equipped with a compressed air breathing apparatus should watch each hose and safety line and prevent them from becoming entangled. e) Personnel should not enter an enclosed space without a belt with a life line. Also an attendant should remain in a safe location at the other end of the life line at all times. f) Even at low concentrations of H2S and SO2 a canister type mask may not be worn, as this type is unreliable. g) To prevent irritation of the eyes full goggles with water dams are recommended. The water dams prevent fogging of the lenses, which should be made of safety glass. h) When loading or unloading catalyst, wearing of masks is recommended to prevent inhalation of catalyst dust.

Safety

3.

First Aid Measures If a person has lost consciousness by inhalation of H2S or SO2 gas, the following procedure is advised: a) Remove the patient to fresh air or a well ventilated room and loosen any restrictive clothing. b) In conjunction with 1 above, contact the medical department, and call immediately a doctor, stressing the nature of the accident. c) Application of oxygen to a patient should only be carried out by a person familiar with the use of oxygen inhalation apparatus. An attempt to apply oxygen by a person not familiar with the use of the apparatus may result in the loss of valuable time and/or may harm the patient. d) Keep the patient comfortably warm, but not hot. If the patient regains consciousness during this period, keep him as calm as possible as he might be in a state of shock. e) If, however, respiration of the patient has stopped, commence artificial respiration treatment at once and continue until professional assistance arrives. f) It should not be attempted to give anything to eat or to drink to an unconscious patient.

WARNING: Do not attempt to enter a gaseous area to render assistance before putting on a compressed air breathing apparatus or air hose mask.

Safety

16.14. 6.14.3 14.3 Toxicological Data Tables of H2S and SO2 effects are given below, followed by a summary of some of their properties. 1. Physiological Effects Of H2S SL. NO . 1. 2. 3 4 5 6 7 8 9 10 11 12 13 14 15 1) 2) DESCRIPTION PPM1 VOL. %

Limit for odour detection Weak odour hardly noticeable Noticeable odour Obnoxious odour MAC2 Slight signs of inflammation of the eyes after one hour Limit that can be stood for six hours without adverse effects Limit that can be stood for one hours without consequences effects Odour no longer disagreeable Distinct signs of inflammation of the eyes after one hour Danger to life within thirty to sixty minutes Fatal within thirty to sixty minutes Fatal after half an hour Causing immediate fainting Immediately fatal

0.14 0.77 4.6 7.0 10 50 - 100 78 - 128 170 - 255 198 - 283 200 - 300 355 - 496 425 - 580 500 - 700 700 - 1000 850 - 1980

0.0.1 0.05 - 0.01 0.008 0.013 0.017 0.026 0.02 0.028 0.02 0.03 0.036 0.050 0.043 0.058 0.05 0.07 0.07 - 0.1 0.085 - 0.2

PPM = volume parts of H2S per million parts of air 1 PPM = 1 cm3/m3 MAC = Maximum allowable concentration for an eight hours working day

2.

Physiological Effects of SO2 SL N O. DESCRIPTION PPM1 VOL. VOL. %

Safety

1. 2. 3 4 5

Limit for odour detection MAC2 Smallest amount causing immediate irritation of the eyes and through Maximum Allowable concentration for 30 - 60 minutes Danger even with short exposure 1)

3-5 2 20 50 - 100 more than 400

0.002 0.005 0.01 0.04

3.

PPM = volume parts of H2S per million parts of air 1 PPM = 1 cm3/ m3 2) MAC = Maximum allowable concentration for an eight hours working day H2S Properties and Toxic Effects H2S is a colourless, inflammable and very toxic gas having an offensive odour and sweetish taste. It has a specific gravity 1.17 times that of air. The offensive odour, like that of rotten eggs, is not reliable as a warning of dangerous concentrations, as persons differ greatly in the ability to detect smells, and furthermore the sense of smell deteriorates and is of little help in noting higher increased concentrations. H2S is almost as toxic as hydrogen cyanide and six times as toxic as carbon monoxide. The toxic effects vary considerably with the concentration and also to some extent with individual susceptibility. At low concentrations, it has an irritant action on the respiratory tract, which could result in sickness, vomiting and a feeling of pressure on the chest. Simultaneously it affects the nervous system. At high concentrations, H2S paralyses the nervous system. Consequently the respiration fails and death will follow immediately by suffocation. Even at low concentrations H2S affects the cornea of the eye.

4.

SO2 Properties and Toxic Effects Sulphur dioxide is a colourless gas, with a specific gravity 2.2 times that of air. In the presence of mist or water this gas forms sulphurous acid. The gas has a sour taste. It irritates the respiratory tracts because it forms, with the water present, sulphurous acid and further sulphuric acid. This acid etches the human tissue. At low concentrations, it irritates the mucous membranes. Inhalation of higher concentrations causes hoarseness, pain and a feeling of pressure on the

Safety

chest and bronchitis. It is sometimes impossible to speak or to swallow. Very high concentrations cause acute bronchitis, tightness of the chest, and a quick start of perturbance of consciousness. Instant death by poisoning seldom occurs. Suffocation, however, can cause death quickly. SO2 also causes an increase of haemoglobin in the blood. The toxic effects vary to some extent with individual susceptibility. A certain immunisation to SO2 is possible, to a maximum of 30 to 50 PPM. Human beings can withstand a maximum of 20 PPM without adverse effects. Higher concentrations can give the victim a pale appearance, cause an unpleasant taste in the mouth and can even make the gustatory nerves insensitive. Additional effects are loss of appetite and constipation. 5. Sulphur Dust Sulphur dust in the atmosphere has a highly Irritating effect upon the human eye. Therefore, it is advisable to wear safety goggles when working in an atmosphere where dust contaminates the air. This cannot be overemphasised.

Safety

16.14.4 .14.4 Fire And And Explosivity Data a. H2S The lower and upper limits for inflammability in a gas air mixture are 4.3 and 45.5 vol. %, respectively. In the stoichiometric ratio with oxygen, it explodes violently when ignited. It is therefore necessary to handle hydrogen sulphide by excluding all sources of ignition, open flames, sparks (including static discharges) and heat producing equipment from contact with this gas when mixed with air. The auto-ignition of 260 C. b. SO2 This is not an inflammable gas. c. Sulphur liquid At a temperature of approximately 230 C, auto ignition of liquid sulphur will occur when in contact with air. Therefore attention must be paid to ensure that the liquid sulphur temperature is maintained below the above mentioned value. Ignition of the sulphur will also occur when exposed in the area of an open flame, resulting in the formation of SO2. d. Sulphur Dust As stated above, liquid sulphur has a relatively low ignition point, 230 C; however, sulphur dust clouds will already ignite at a temperature of approximately 190 C. e. Hydrogen sulfide released from liquid sulfur Some hydrogen sulfide (as both monosulfide and polysulfide) is dissolved in Claus sulfur. The total sulfide solubility decreases as temperature decreases. Reported equilibrium compositions for molten sulfur in contact with H2S at atmospheric pressure ar given below: Temperature OC oF 125 257.0 0.0544 132 269.6 H2S wt% 0.0450 0.0441 0.0149 H2Sx (as H2S), wt% 0.0094 0.0590 Total (as H2S) wt% H2S in air will occur at a temperature of approximately

Safety

148 156 162 181

298.4 312.8 323.6 357.8

0.0432 0.0423 0.0414 0.0405

0.0418 0.0718 0.0838 0.1045 0.125

0.0850 0.114 0.145

16.14.5 .14.5 MATERIAL SAFETY DATA SHEET SULPHUR Section 1. Chemical Product Product Name Synonym : : Sulphur, Commercially formed solid elemental

Elemental sulphur, solid sulphur : : S8 Elemental sulphur is used as a raw material in the of sulphuric acid, as a soil conditioner, in pesticides and Sulphur Inorganic sulphur

Chemical name Chemical Family Chemical formulae: Material uses : manufacture in

rubber vulcanising. Section 2: Hazards identification Potential acute health effects: Sulphur dust can cause irritation of the skin, eyes, gastro intestinal or respiratory tract, characterised by burning, chapping, redness of the eyes, abdominal discomfort, diarrhea, sneezing, coughing, and difficulty in breathing. Contact with molten sulphur may cause severe burns. Molten sulphur may contain hydrogen sulphide gas which is extremely toxic and flammable. At low concentrations, hydrogen sulphide gas is irritating to the respiratory tract and has a rotten egg odor. Odor cannot be relied on as a means of detectin because at higher concentratinos, H2S causes olfactory paralysis. Even short term exposure of a concentration of 500 to 1000 ppm. Of H2S may lead to unconsciousness, respiratory paralysis and death. Potential chronicle health effects. Sulphur can irritate the respiratory tract in concentrations above 5 mg./M3. Possible, but not proven, effect on lung and airway function.

Safety

H2S may cause irritation, breathing failure, comma, and death without any warning odor being sensed. Prolonged or repeated skin contact may cause mild irritation. Can be irritating to eyes and may cause conjectivitis. Possible skin sensitisation. Susceptible individuals may have increased sensitivity to exposure. Section 3: First Aid measures Eye contact Check for and remove any contact lenses. IMMEDIATELY flush eyes with running water for at least 15 minutes, keeping eye lids open. DO NOT use an eye ointment. Seek medical attention if irritation persists. Skin contact: Remove contaminated clothing launder before reuse. Wash gently and thoroughly the contaminated skin with running water and nonabrasive soap. Get medical attention if redness or irritation occurs.

Inhalation Evacuate the victim to a safe area as soon as possible. If the victim is not breathing, perform artificial respiration. Administer Oxygen if available. Allow the victim to rest in a well ventilated area. Seek medical attention. Ingestion Do not induce vomiting because of danger of aspirating liquid into lungs. Get immediate medical attention. If victim is conscious and gastric decontamination is required, give activated charcoal tablets or mixture of charcoal with saline cathartic or sorbitol. Immediately transfer the victim to a forewarned hospital for medical assessment. Section 4 ; Fire fighting measures The product is : Readily ignitable, combustible solid. Auto ignition temperature : Ignites in air above 261 oC, in oxygen below 260 oC. (190 oC for sulphur dust) Flash points: Closed Cup 207 oC (405 oF) (NFPA) Flammable limits: Lower 35 g/m3 ; Upper 1400 g/m3 (dust)

Safety

Product of combustion: Releases of Sox, sulphur compounds, smoke and irritating fumes when heated to decomposition. Fire Hazards in presence of various substances : Do not cut, weld, heat, drill or pressurise empty container. Contain is may explode in heat of fire. Dust forms explosive mixtures with air, or in contact with oxidising materials. Molten sulphur can accumulate static charge. Vapour explosion hazard indoors, outdoors, or in sewers. Fire fighting media and instructions: SMALL FIRE: Use DRY chemicals, CO2, water spray or foam. LARGE FIRE: Use water spray, fog or foam. Do not use water jet. If tank, rail car or tank truck is involved in a fire, isolate for 800 meters in all directions. Also consider initial evacuation for 800 meters in all directions. Cool containing vessels with water spray in order to prevent pressure build up, auto ignition or explosion. If this is impossible, withdraw, from area and let fire burn out under controlled conditions. Withdraw immediately in case of rising sound from venting safety device or any discolouration of tank due to fire. Avoid flushing spilled material into sewers, streams or other bodies of water. Self contained breathing apparatus (SCBA) will be required. Special remarks on fire hazards: Small fires are virtually invisible. Larger fires will have pale blue flame. Fire may restart after it has been extinguished. Section 5: Accidental release measures: Small spill: Avoid contact and inhalation. Elminate all ignition sources; no flares, smoking or flames in hazard area. Stop leak if without risk. Contain spill. Purge with CO2 or other inert has to exclude air (avoid possible asphyxiation hazard). Recover or clean up spill solid sulphur by vacuum or a wet method to reduce dust formation. Collect and mix with 4 times weight of lime stone for land filling. DO not flush to sewers, streams or other bodies of water. Check with applicable jurisdictions for specific disposal requirements and clean up of contaminated materials and empty containers. Section 6: Handling & Storage Handing: Due to the possible release of hydrogen sulphide gas, care must be taken when handling or working with the solid elemental sulphur above its melting temprature (112 oC). Manipulate in a well ventilated area. Handle carefully to avoid spills and dust accumulation. In case of

Safety

insufficient ventilation, wear suitable respiratory equipment. Avoid contact with skin and eyes. Keep away from sources of heat and ignition. Use spark proof electrical equipment. Protect equipment against wet elemental sulphur erosion. Exposed clothing to sulphur dust should be removed before leaving the operating site. Wash hands after handling and before eating. Launder work clothes frequently or discard after use. Storage: Store in a closed containers in cool, dry, isolated, well ventilated area, away from heat, sparks, open flame, or any other ignition source and strong oxidising agents (such as chlorates, Nitrates). Section 7: Exposure controls for personnel protection. Engineering controls: General and local exhaust ventilation to maintain air borne dust concentration below 5 mg / m3. Use explosion proof mechanical ventilation suitable for group D atmospheres. General ventilation in storage is essential to avoid accumulations of undesirable levels of evolved hydrogen sulphide gas. Make up air should always be supplied to balance air removed by exhaust ventilation. Ensure that eye wash station and safety shower are close to the work station location. Personal protection: Chemicals splash goggles in case of splashing. From 550 mg/m3, wear full face mask with approved filters in areas with sufficient oxygen. Above 50 mg/m3, wear self contained or air supplied breathing apparatus. Wear protective gloves impervious to the passage of sulphur dust. Modest chemical protection (glove) required against acidity. Exposure of hair should be minimised. Wear loose, dust impervious full body coverage with modest protection from short term chemical resistance. Fire retardant fabrics recommended when handling solid sulphur. Exposure limit: Elemental sulphur may contain trace amount of hydrogen sulphide and / or sulphur dioxide. Release of hydrogen sulphide and sulphur dioxide is not a significant hazard with solid sulphur. However, release may occur on remelting the sulphur. It is recommended as 8 hour allowable exposure of 5 mg/m3 for respirable dust and 10 mg/m3 for total dust when handling dry solid sulphur; 14 mg/m3 (10 ppm) for hydrogen sulphide and handling molten sulphur. Section 8: Physical & Chemical properties Physical state and appearance: Loose crystaline solid, which may be in bulk, prilled or slated form.

Safety

Boiling point: 445 oC Melting point : Specific gravity : Vapour pressure : Vapour density : Volatility: Solibility 113 120 oC 1.96 (water 1) 5.28 x 10-6 kPa @30.4 oC 0.00005 lb/ft3 @32oC

Non volatile : Insoluble in water, very slightly soluble in alcohol, ether, chlorofom and benzene

Odor : Odorless or rotten egg odor when residual hydrogen sulphide is present. Taste: : Colour : Disagreeable Yellow

Section 9 : Stability & Reactivity Stability: The product is stable

Conditions to avoid: Will form explosive mixture with an oxidising agent or carbon: moist sulphur becomes extremely corrosive to metals. Incompatibility with various substances: Strong oxidising agents (Oxygen, peroxides, chlorine, permanganates, perchlorates), reducing agents, metals, acids and moisture. Decomposition products: combustion. Sulphur dioxide, H2S and smoke generated on

Corrosivity; Not applicable for soild, dry sulphur. Hydrogen sulphide gas may readily cause pipes and valves to corrode or become brittle. Atmospheric sulphur compounds, ( SO2, SO3 and Ammonium sulphate) react with the carbonate in lime stone and solomites, calcareous sand stone and mortars to form calcium sulfate (gypsum). This cause blistering, scaling, and loss of cohesion of the surfaces, and induces similar effects in neighbouring materials not themselves susceptible to direct attack.

Safety

Special remarks on reactivity: Highly reactive with halogens, carbides, zinc, tin, sodium, nical, phospersous, pottasium, calcium, aluminium, ammonia, ammonium nitrate, pottassium permanganage, ammonium perchlorate, barrium halites, bromates, calcium chlorate, calcium hypo chlorite, calcium iodate, charcoal, chlorates, chlorine oxides, chromic unhydride, flourine, hydrocarbons, iodates, lead halikes, lead dioxide, lithium, magnesium halides, mercury oxides,perchlorats, potassiium halides, pottassium perchlorates, silver halides, sodium halides, sodiumnitrates, and zinc halides. Section 10 : Toxicological information Inhalation, skin contact, eye contact and ingestion.

Routes of entry:

Toxicity to animals: Sulphur accute oral toxicity (LD 50): 12 g (human). Hydrogen Sulphide (H2S) LC 50: 600-1000 ppm with the upper value being immediately lethal. Chronic Effects on Humans: Sulphur can irritate the respiratory tract in concentrations above 5 mg/m3. Possible, but not proven, effect on lung on airway function. H2S may cause irritation, breathing failure, coma, and death without any warning order being sensed. Prolonged or repeated skin contact may cause mild irritation. Can be irritating to eyes and may cause conjunctivitis. Possible skin sensitization . Susceptible individuals may have increased sensitivity to exposure. Other toxic effects on humans: Sulphur dust can cause irritation of the skin, eyes, gastro intestinal or respiratory tract, characterised by burning, chapping, redness of the eyes, abdominal discomfort, diarrhea, sneezing, coughing, and difficulty in breathing. Contact with molten sulphur may cause severe burns. Molten sulphur may contain hydrogen sulphide gas which is extremely toxic and flammable. At low concentrations, hydrogen sulphide gas is irritating to the respiratory tract and has a rotten egg odor. Odor cannot be relied on as a means of detection because at higher concentratinos, H2S causes olfactory paralysis. Even short term exposure of a concentration of 500 to 1000 ppm. Of H2S may lead to unconsciousness, respiratory paralysis and death. Special remarks on chronic effects on Humans: Pre-existing bronchitis or asthma conditions may be aggravated by exposure to this product. Section 11: Ecological information

Safety

Eco-toxicity. Harmful to aquatic life in high concentrations. 10000 ppm / 96h/mosquito fish/TLm/fresh water; 16000 ppm/5h/gold fish/LC100/frsh water (colloidal suspension); 2 100 ppm,/1h/goldfish/LC100/fresh water. Section 12: Disposal considerations: Waste disposal: Landfill at licenced waste reclaimer facility approved for receipt of elemental sulphur, after mixing with lime stone. Reclamation of sulphur rich wastes is preferred over solid waste disposal. Consult your local or regional authorities. Section 13: Transport Information TDG classification: Shipping name: Sulphur, solid; class 4.1; UN 1350; Packing group III. Label required; Flammable solid. Special provisions for transport: rail, road and water. Acceptable modes of transportation: air,

mit 10. 10. WORK PERMIT SYSTEM INTRODUCTION The Work Permit System is an important tool for safety in hydrocarbon processing/ handling installation. The basic purpose of the work permit system is to ensure that work is carried out in the safest possible manner to prevent injuries to personnel, protect property from damage, avoid fire etc. The recommended Work Permit System is described covering various aspects like when a work permit is required, types of permits, responsibilities, check lists, validity etc. The success of a Work Permit System depends upon the training, motivation and participation of all individuals concerned with its implementation. Since several maintenance/ construction jobs are often carried out with assistance from contractors, it is essential to provide sufficient exposure to contractors and his/ their employees as well. The work permit system of BPCL Kochi Refinery has been formulated in line with the recommendations laid down by the Oil Industry Safety Directorate (OISD) Standard STD-105 Revision-I, September 2004 and STD-137, August 1990.

Safety

Work permit is a written authorization for performing any job within the Refinery, Jetty facilities, Water Quarries, Water treatment facilities at Chullichira, Water Pump House at Aluva, or on any facility belonging to the Refinery. GUIDELINES GOVERNING THE WORK PERMIT If a work has to be performed in Kochi Refineries by any person other than the owner personnel of that area, a duly authorised written permit shall be obtained by the person/ agency executing the work from the Owner of the area before commencement of the work. However, even for operating personnel, when work has to be performed outside their normal routine, an exclusive permit to that effect by the authorized person shall be obtained. It is the policy of the company to ensure the safety of people, equipment and materials when performing any work within the Refinery premises, Jetty Facilities, Water Quarries, Water treatment plant at Chullichira, Water pump house Aluva, any other facility belonging to the company. The Work Permit System shall always operate on "Owner-In-Charge" concept. The concerned Departments shall issue the appropriate authority limits for various installations and type of permits based on this concept. Separate forms shall be used for Cold Work, Electrical work, Hot Work including confined space entry permit and Radiography, Electrical Isolation & Energisation and Earth Work Permit. All jobs shall be performed only after obtaining the stipulated permits from concerned authorities. The permit forms in book form are printed serially and issued by Safety Section. All permits shall be issued/ renewed and received only by the personnel designated for the same and are to be signed by the issuing/ renewing and receiving personnel. The permit shall be signed and issued by the authorized person from the concerned owner department/ section. The permit shall be signed and received by the authorized person from the executing department. Where no such independent authorised person exists, the Owner-In-Charge can issue the permit to the contractors supervisor directly and obtain his signature. The concerned department shall issue the appropriate authority by name for various units as well as sections for issue/ renewal/ acceptance of permits. The list of authorised persons of each department for issuing/ renewing and receiving of various permits duly approved by the General Manager of respective departments shall be updated on yearly basis and forwarded to Safety section. The list shall be revised whenever there is a transfer/ new appointment to the department. All necessary checks and tests shall be conducted by issuing personnel to ensure safety of the job to be performed prior to issue of permits. All precautionary measures required to be taken shall be clearly indicated in the permit and their compliance ensured both by the issuing/receiving personnel.

Safety

Critical jobs are to be carried out under specific written procedure and reference of the same shall be noted down clearly in the permit so issued. The procedures for these critical jobs have to be prepared by the section heads of the owner department, Safety section and the executing department and to be concurred by the owner department head. Owner department shall initiate the preparation of such procedures. Permits shall be worded clearly so as to limit the work to the designated area/ equipment/ facilities, agencies and time. The work permit shall be filled up carefully and accurately in clear writing ensuring that detailed and complete information is provided in all the sections/ sub sections. Sketches should be attached wherever possible to avoid miscommunication. Additions and alterations on the original shall also be endorsed on all the copies. Should any of the conditions vary during the course of the work, which may affect the safety of human beings and equipments, the job shall be stopped, the permit withdrawn and given back to the issuer. Reasons for withdrawing the permit to be mentioned in the permit. If a permit is withdrawn, the work should be restarted only after safe conditions are established back and clearance obtained from the issuing/ renewing authority. Permits shall be readily made available at the work site for verification by concerned personnel. Failure to present the permit on demand shall result in stoppage of work. Permits are valid only for the time period specified in the permit. Normally the permits will be issued for the shift timings of the issuing authority. The site of hot work jobs should be indicated in the plot plans available in the control rooms and fire station with red pins. This helps the incoming supervisor/s (both in Fire and Operating departments) to get a quick idea of the hot jobs being undertaken and help in identifying the areas which require inspection/ attention, depending upon the criticality of the area and the job. A display board shall also be maintained in the control rooms and fire station furnishing details such as the area of hot work, equipment/ facility involved, executing agency (Department/ Contractors name wherever applicable), permit number and validity. The Shift-in-Charge/ Concerned persons of owner department will ensure that the display board is updated on issue/ renewal/ closing of the hot work permit. If the job is to be continued beyond the time limit specified in the permit, it has to be renewed at the beginning of the next shift. Jobs can continue on expiry of the shift after obtaining the signature of the authorized person from the owner department/ authorised personnel from the executing department in the original of the permit. The issuing authority subsequently can renew the permit after making a signature in both original and triplicate in the case of hot work permits/ electrical isolation and energisation permit and original and duplicate in the case of cold work permits. The authorised personnel of the executing department shall make his

Safety

signature in the copy available in the control room as early as possible as but not later than the expiry of the shift or before completion of the job whichever is early. Permits once issued shall be renewed up to a maximum 7 calendar days. The endorsement for renewal is to be done only in the space provided for the purpose. In case the job has to be continued even after the above period, a fresh permit has to be issued/ obtained for the same. The serial number of the old permit shall be mentioned in the new permit. During shutdown of a plant, deviation of the procedures laid down in the ROS, if any required, shall be made with the specific approval from a committee consisting of owner department DGMs, executing department DGMs (DGM- Maintenance, DGMP&U, DGM- E&C, DGM- Projects) and Chief Manager (Safety & Fire) While renewing a permit that has already been issued by authorized person of the concerned department, the issuing/receiving persons are in no way relieved of the duties and responsibilities specified for issuing/ renewing permits. At the time of renewal of a permit or when the job is in progress, if the issuing or renewing authority, feels that some additional conditions or precautious are to be stipulated or are not necessary based on the prevailing conditions, a new permit has to be issued incorporating the changes and the previous permit will remain cancelled. If the owner/ executing departments require any clarifications on the precautions to be followed for critical jobs, the same shall be consulted with Safety & Fire section and to be incorporated in the permits. All permits must be closed on completion of the job with signature for closure by the designated person of the executing department/ section as well as the owner department. Permits once closed cannot be renewed. No hot work shall be allowed to be included in the hot work permit already issued for other jobs. The work permit should be issued for one job only. Separate permits to be issued for performing separate work on same equipment. All the permits stands cancelled on declaration of emergency. Fresh permits/ Revalidation shall be taken on clearance of emergency. DUTIES AND RESPONSIBILITIES UNDER WORK PERMIT SYSTEM Before issuing any permit the authorized issuing authority shall give proper briefing of the work situation, including the possible hazards and the precautions to be taken, to the authorized executing authority or receiver of the permit and a noting to this effect should be made in the permit, at the space provided for special instructions. ISSUING/ RENEWING AUTHORITY The issuing/ renewing authority is primarily responsible for the safe execution of the job covered under the permit and as such is to perform the following duties. Analyse and determine the condition of the facility and the area involved and stipulate necessary precautionary measures to be taken to ensure safe execution of

Safety

the work. He shall ensure that all the columns of the permit forms are filled up. NR (Not required) shall be marked wherever that particular item is not required. He shall put his full signature along with name and badge number marked in the permit. Stipulate precautionary measures such as area preparation, blinding/ isolation/ tagging, provision of safety and fire protection equipment, standby personal etc. or special procedures required (in case of critical jobs) in the permits and ensure their compliance. Conduct preparatory, preventive and precautionary measures to be carried out by personnel of his department and ensure compliance of the same. Co-ordinate with other departments/ sections wherever precautions are necessary to be taken from their end also and counter signature to be obtained wherever needed before commencing the job Ensure verification and certification of installation and removal of blinds/ isolations and their tagging. Perform necessary gas and other required tests. As a pre-requisite to issue permit, particularly in the case of hot work/ vessel entry permit, gas test for hydrocarbons/ oxygen deficiency/ toxic gases shall be conducted as applicable. Ensure that the facilities and the area in and around the place where the permit is issued/ renewed are made safe prior to commencement and during the progress of the job. Follow up periodically the progress of the job permitted and stop the job if conditions become unsafe. Ensure that while hot work is in progress no other work likely to result in hazardous conditions are permitted in the vicinity (e.g. repairs to oil or gas lines, bleeding or sampling of flammable materials, draining of hydrocarbon, venting of gas, removal of blind from hydrocarbon lines etc.). Where gas-free conditions are not fully ensured for the duration of hot work, a system of monitoring either by automatic or by manual periodic verification shall be resorted to depending upon the prevalent conditions of the operating area. Ensure that all personal protective equipment/ clothing are available at site before commencement of work and the same is used by personnel while performing the work. The issuing authority shall inform the Chief Manager (Shift Administration) if a hot work permit is issued/ renewed beyond the normal office working hours. The issuing authority shall inform the fire station, of all the new as well as renewed hot work permits and get the token number before issuing a new hot work permit. The token number shall be written on the hot work permit in the column for token number.

Safety

After completion or stoppage of the job, the person to whom the permit was issued, should thoroughly check the area for clearing of debris, ensure safe working condition and then shall close the work permit. The issuer on receiving back the original permit duly closed by the receiver would satisfy himself regarding completion of the job and that the area has been cleared. Then he shall also sign the permit and hand over original permit to the receiver (except in the case of Energisation / Isolation permit in which the duplicate copy of the permit to be returned to the receiver and original permit to be retained by the issuer). Returned closed permits are to be preserved by the owner department for a minimum of 90 days. RECEIVING AUTHORITY/ EXECUTING PERSONNEL The fact that permits has been issued for performing a certain job in no way relieves the authorized person of the executing department or the personnel executing the work of their responsibility for safe execution and completion of the job. The receiving authority/ executing personnel is/ are responsible for the compliance of the precautions/ conditions prescribed in the permit. Their duties include the following: Secure necessary permit from the concerned department before commencement of the job. He shall put his full signature along with name and badge number marked in the permit. Provide for and comply with all necessary precautionary measures stipulated in the permits. Ensure that all safety equipment are in good working condition and available at site prior to commencement of the work. Take extra care when commencing the work, especially while breaking flange joints, cutting through lines, striking an arc for the first time etc. Ensure vigil and work diligently for safe completion of the job. When in doubt, stop the job and obtain clarification from concerned personnel. Ensure safe working practices throughout the job by continuous supervision (either by executing personnel or contractor personnel). Ensure the availability of all personal protective equipment/ clothing are available at site before commencement of work and also ensure that the same are used during the work. Stop the job if conditions become unsafe and report to the issuing/ renewing authority. Restart the job only after getting the clearance from the issuing/ renewing authority. Ensure that the permit is readily available at the work site for verification. Ensure that no blinds or other isolations, specified for the work are removed or disturbed during the work. Ensure that the grade area is barricaded by red & white colour tape to cover excavated area or in case of material handling at overhead. Ensure that 24 V (AC) hand lamps are used in the confined space.

Safety

Upon completion of the job, clear the area of all construction materials& scrap, removal of temporary electrical isolation and replace in its original location the facilities/ equipments used for the execution of the job. Maintain good house keeping. All permits must be closed on completion of the job and after clearing the area by the authorized person of the executing departments/ section. The receiver will sign for closure after specifying the job status at space provided at the back of the permit and return the original permit to issuer for signing. Permits once closed cannot be renewed. FIRE STATION PERSONNEL Fire station personnel has to register the exact location of the hot work, issue the token number for the work and to provide necessary additional/ special fire fighting facilities at the request of the issuing/ executing authority or as desired by them depending upon the nature of hot work and hazardous nature of the area. SAFETY OFFICER The Safety Officer/ Fire Officer authorised will make periodic check of the work sites and see that the work is being carried out as per conditions laid down in the permit. At any point of time, if he considers that the conditions are not safe enough for the work, he may bring to the attention of the issuing authority or suspend the work and inform the permit issuing authority as the case may be, to restore the safe conditions so that the work can be re-started. If the job has to be stopped and permit withdrawn, the permit to be given back to the issuer with reasons for withdrawing the permit mentioned in the same. TYPES OF PERMITS Depending on the nature of jobs to be performed, permits issued for carrying out jobs in the Refinery are of five types. They are: 1) Cold Work Permit/Clearance Certificate for Hot work. 2) Electrical Permit 3) Hot Work Permit 4) Electrical Isolation & Energisation permit. 5) Earth Work Permit