WELCOME Conquering New Horizon

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 Conquering New Horizon
SAFETY MESSAGE - FOR THE DAY

‘Safety comes in Cans,

I can,
You can,
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We can.’
 Conquering New Horizon

Safety In On Land Production Operations

Pankaj Kumar Goswami

Email: pankajgoswami@oilindia.in
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27.09.2012
 OIL: Rich Heritage of Building a Company…….

 Independent India’s first commercial oil discoveries were

made by Assam Oil Company
– Nahorkatiya, Assam – 1953
– Moran, Assam – 1956

 Incorporated as Joint Sector Company on 18 February, 1959

– 2/3rd Owned by Assam Oil Company / Burmah Oil
Company
– 1/3rd Owned by Government of India

 Became a Public Sector Undertaking, GOI on 14 October,

1981

 Six decades of experience in Exploration & Production

 Second largest national oil and gas company in India

 Navratna status awarded in April’ 2010, allowing it enhanced

autonomy

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 Our Business…….

Exploration

Production

Transportation

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 Our Business…….

A BRIEF ABOUT
OIL INDIA LIMITED

• Engaged in the business of

Exploration, Development and
Production of Crude Oil and Natural
Gas
• Transportation of Crude Oil
• Production of LPG.

• Produces over 3.9 million tons per

annum of crude oil
• Over 6 MMSCMD of Natural Gas
• Over 45,000 Tons of LPG annually.

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 The basic premises ……..

 Oil business is hazardous in nature

 Oil demand is increasing

 Oil business is profitable

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 What influences our design……

 Safe operations

 Employees health

 Pollution free Environment-Keep the installation dry

 Human resource availability

 Social licensing

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 What makes a design sustainable (social licensing )

Sustainable
Design
Logistics

Public Technically
Acceptable feasible

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 Oil Installation Design
Tank Separation Soil types
Distances
Site Selection
Corrosion Floating
Protection or Fixed
roofs
Flood Plains
Emergency
Response
Explosion proof lighting and electrical
redundancy
Tank
Fire systems
Design Containment
Considerations

Leak Detection Berm Design

Facility Design
Vapor recovery
Emergency response systems
and spill clean up
Shut off valves
Vehicle guard rails Physical
security
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 Statutory regime in India

E&P Industries in India are guided by...

 OMR under the Ministry of Labour

 OISD under the Ministry of MOP&NG

 Environmental Laws under the Ministry of E&F

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Applicable Rules & Regulations
• Mines Act , 1952
•Oil Mines Regulations, 1984
•Mines Rules,1955
•Mines Vocational Training Rules,1966
•Petroleum Act,1974
•Petroleum Rules,1976
•Explosives Act, 1884
•Explosives Rules,1983
•SMPV (unfired) Rules, 1981
•Indian Boiler Act ,1923 & Rules, 1961
•All OISD standards (Non-statutory ) under MOPNG
•Indian Electricity Rules ,1956
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National Environmental Legislations

1. Air (Prevention & control of pollution) Act, 1981.

2. The water (Prevention & control of pollution) Act,
1974.

3. The water (Prevention & control of pollution) Act,

1977.

4. EPA, 1986 (Environment Protection Act).

5. The Hazardous waste (Management & Handling)

rules, 1989.

6. The Public Liability Insurance (PLI) Act, 1991.

7. Environment Protection Act 1986

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 HSE Management System in OIL

The basic objective of all such guidelines are to reduce the

degree of risk in the typical hazardous oilfield operations and
prevention of losses due to accidents.

 Accordingly OIL adopted a HSE Management system for the

company with the basic objective of reducing the degree of risk
in the oilfield operations and prevention of losses due to
accidents.

 The issues of HSE management are not only limited to the

fulfillment of statutory requirement but also it covers the
achievement of HSE standards in our oilfield activities.

 The HSE Policy is being displayed in all the Production

installations.
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 Work Areas
Well- well head and associated equipment such as Xmas tree
Hazard areas Preventive Measures Mitigating measures

•Over pressure •The well head and associated • Emergency

equipment are designed and installed as response
•Loss of containment per applicable industry standards (API preparedness
SPEC 6A or ISO 10423)
•Proper design to take care that MAWP
is greater than maximum shut in
pressure.
•Safety devices are maintained and
calibrated at regular intervals.
•Integrity Management. Inspection,
maintenance and testing of well head
and associated equipment (SPEC 6A or
ISO 10423. .........Contd

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 Work Areas
Well- well head and associated equipment such as Xmas tree
Hazard areas Preventive Measures Mitigating measures
•Over pressure •Well design with system of sub surface • Emergency
closure based on risk assessment. (refer response
•Loss of containment API SPEC 14A and API RP 14B). preparedness
• Annuli (including outer annuli), tubing
head pressures and ABP is monitored
on regular basis for safety critical
parameters.
•Periodic checking and recording of well
head pressures.
•Identification of water resources for fire
fighting at remote areas.
•Intensive security arrangement

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 Work Areas
Pressure Vessel ( such as Separator)
Hazard areas Preventive Measures Mitigating measures

Over pressure Separator should be designed as per ESD /containment /

industry standards such as API SPEC blow down system.
Under pressure 12J.
Safe distances
Liquid overflow Safety devices {like High Pressure between equipment as
Sensor (PSH), Low Pressure Sensor per OISD-STD-118. (in
Loss of containment (PSL), Pressure Safety Valve (PSV), High on land operations)
due to equipment Level Sensor (LSH), Low Level Sensor
failure (LSL), Check Valve, and High
Temperature Sensor (TSH)} are installed.
Fire
Safety devices are maintained and
Low liquid level / gas calibrated at regular intervals.
blowby Contd......

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 Work Areas
Pressure Vessel ( such as Separator)
Hazard areas Preventive Measures Mitigating measures

Over pressure Adequately sized piping and valves.

Outlet of PSV is discharged safely as Fire protection
Under pressure per OISD- STD-106. (cooling) as per OISD-
STD-189. (in on land
Liquid overflow Adequate ventilation or provision of operations)
combustible gas detectors to shut-off
Loss of containment hydrocarbon source.
due to equipment
failure Each input source protected by safety
devices like PSH, PSL and PSV.
Fire
Separator is equipped with level
Low liquid level / gas controller valve to control the level and
blowby out flow from the vessel.
Contd.......

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 Work Areas
Pressure Vessel ( such as Separator)
Hazard areas Preventive Measures Mitigating measures

Over pressure
Level controller is maintained on regular Emergency response
Under pressure intervals. preparedness as per
OISD-STD-227
Liquid overflow Provision of make-up gas system if
pressure vessel is subjected to under-
Loss of containment pressure that could cause it to collapse.
due to equipment
failure Safety devices are maintained and
calibrated at regular intervals. PSV
Fire should be maintained and calibrated as
per OISD-STD-132.
Low liquid level / gas Contd.......
blowby

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 Work Areas
Pressure Vessel ( such as Separator)
Hazard areas Preventive Measures Mitigating measures

Over pressure Application of electrical standards and Emergency response

recommended practices such as API RP preparedness as per
Under pressure 500, API RP 14 F. OISD-STD-227

Liquid overflow Location of equipment as per standards

such as API RP 14J.
Loss of containment
due to equipment Safe operating procedures
failure Integrity Management.

Fire Health check of separator and

accessories is carried out as per OISD-
Low liquid level / gas STD-128 to ensure its integrity.
blowby

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 Work Areas
Fired and exhaust heated component ( such as fired vessels, tube type heater)
Hazard areas Preventive Measures Mitigating measures

Loss of containment Equipment is designed and installed as Emergency response

due to: per applicable industry standards API preparedness
SPEC 12K, API SPEC 12L, API RP 12N or Containment system
High temperature OISD-STD-111. (including fuel gas)
Safe distances
Corrosion Safety devices {like High Pressure between equipment as
Sensor (PSH), Low Pressure Sensor per OISD-STD-118 (in
Over pressure (PSL), Pressure Safety Valve (PSV), High on land operations).
Level Sensor (LSH), Low Level Sensor
(LSL), Flow Sensor ( FSL), Flame failure Fire protection
sensor (BSL), Check Valve, and High (cooling) as per OISD-
Temperature Sensor (TSH)} are installed. STD-189 (in on land
operations).

Contd......

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 Work Areas
Fired and exhaust heated component ( such as fired vessels, tube type heater)
Hazard areas Preventive Measures Mitigating measures

Fired vessels should be equipped with Emergency response

Direct ignition source pressure releasing device (PSV). preparedness
and excess fuel in Containment system
firing chamber in Safety devices are maintained and (including fuel gas)
case of fired calibrated at regular intervals. PSV Safe distances
component: should be maintained and calibrated as between equipment as
per OISD-STD-132. per OISD-STD-118 (in
Explosion on land operations).
Integrity Management. Inspection /
Backfire health check of fired vessels should be Fire protection
carried as per applicable industry (cooling) as per OISD-
standards OISD-STD-133. STD-189 (in on land
operations).

Contd......

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 Work Areas
Fired and exhaust heated component ( such as fired vessels, tube type heater)
Hazard areas Preventive Measures Mitigating measures

Direct ignition source Level controller is maintained on regular Emergency response

and excess fuel in intervals. preparedness
firing chamber in Containment system
case of fired Outlet of PSV is discharged safely as (including fuel gas)
component: per OISD- STD-106. Safe distances
between equipment as
Explosion Fired vessels is equipped with level per OISD-STD-118 (in
controller valve to control the level and on land operations).
Backfire out flow from the vessel.
Fire protection
(cooling) as per OISD-
STD-189 (in on land
operations).

Contd......

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 Work Areas
Fired and exhaust heated component (such as fired vessels, tube type heater)
Hazard areas Preventive Measures Mitigating measures

Loss of containment Motor interlocks for forced draft fan Emergency response
due to: motor preparedness
Containment system
High temperature Flame in the firing chamber is monitored (including fuel gas)
by BSL or TSL sensor. Safe distances
Corrosion between equipment as
Flame arrestor in natural draft burner. per OISD-STD-118 (in
Over pressure Explosion proof fire chamber on land operations).
Remote ignition system
Fire protection
Electrical systems is as per applicable (cooling) as per OISD-
industry standards and meeting the STD-189 (in on land
requirements of Indian Electricity Rules, operations).
1956.
Contd.......

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 Work Areas
Production Installations: Crude storage tanks
Hazard areas Preventive Measures Mitigating
measures
Loss of •Emergency
containment due •The storage tanks are designed and installed response
to: following applicable industry standards (API preparedness
Spec 12D, API Spec 12F or OISD-STD-108)
•Over flow
•There are two independent gauges with the
storage tanks to give audio-alarm at high level
and audio alarm & tripping at high-high level.

•Level gauges are calibrated on regular

intervals.

•Storage tanks have instrumentation (OISD-

STD-108.)

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 Work Areas
Production Installations: Crude storage tanks
Hazard areas Preventive Measures Mitigating
measures
Loss of •Emergency
containment due response
to: preparedness
•The flame arrestor type breather valve and
•Over pressure vent are installed and maintained on storage
tanks (as per OISD-STD-108 and OISD-STD-
132.)

•Crude oil stabilized before taking into

storage tanks.

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 Work Areas
Production Installations: Crude storage tanks
Hazard areas Preventive Measures Mitigating
measures
Loss of •Emergency
containment due response
to: preparedness

•Inter unit distances as per OISD STD 118.

• Fire
•Electrical systems (including control of stray
currents) -as per industry standards.

•Flame arrestor on tanks, as per OISD STD

129 Detection system (HC and fire detection)
on tanks (OISD STD 117, where applicable.)

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Work Areas
Production Installations: Crude storage tanks
Hazard areas Preventive Measures Mitigating
measures
Loss of •Emergency
containment due response
to: preparedness

•Corrosion •Inspection and health check (including

status of corrosion protection systems) of
storage tanks and associated equipment
(OISD-STD-129.)

•Competent personnel.

•Confined space entry procedures

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Work Areas
Production Installations: Pumps and prime mover
Hazard Preventive Measures Mitigating
areas measures
•Over •Equipment designed as per applicable •Emergency
pressure industry standard OISD-STD-119 and OISD- response
STD-121. preparedness
•Loss of
containment •Safety devices {like High Pressure Sensor
(PSH), Low Pressure Sensor (PSL), Pressure
•Fire Safety Valve (PSV), Check Valve and Shut
down valve} are installed.
•Safety devices are maintained and
calibrated at regular intervals.
•Flow dampener and pressure relief valve in
positive displacement pumps
•Casing vents and drains routed to safe
location.

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 Work Areas
Production Installations: Pumps and prime mover
Hazard areas Preventive Measures Mitigating measures
•Over pressure Sufficient protection – low pressure and Emergency response
high temperature – in case of preparedness
•Loss of containment pressurized lubrication system.
In case of gas engine, procedure
•Fire
includes control of hazards associated
with fuel gas, during start-up and
operations.
Equipment maintained as per industry
standard (OISD-STD-119 and OEM
guidelines)
Competent personnel
Job safety analysis / SOP

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 Work Areas
Well maintenance operation like scrapping, activation and stimulation jobs
Hazard areas Preventive Measures Mitigating measures

Loss of 1. Vehicles are placed at safe distance 1. Emergency

containment due response
to- 2. Wire line assembly including BOP is
preparedness
installed and tested as per DGMS (/
• Equipment failure OISD guidelines. 2. Safe disposal of
chemicals used for
• Failure of well 3. Job safety analysis / SOP refer OISD-
stimulation should
material GDN-182.
be ensured
4. Competent personnel
• Unsafe operation.

• Fire
.........contd

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 Work Areas
Well maintenance operation like scrapping, activation and stimulation jobs
Hazard areas Preventive Measures Mitigating measures

Loss of containment 5. Pressure of compressor line up to 1. Emergency

due to-
annulus is tested before applying the response
• Equipment failure compressor. preparedness
6. Pressure from annulus is released by 2. Safe disposal of
• Failure of well
using choke to prevent erosion of the chemicals used for
material
seat of annulus valve. stimulation should
• Unsafe operation. be ensured
7. Suitability of well head assembly,
casing and tubing is assessed during
• Fire
planning of stimulation job.
.......contd

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 Work Areas
Production Installations
Hazard Preventive Measures Mitigating
areas measures
Occupational Occupational Hazards such as handling of •SOP
hazards Chemical/ exposure to Noise/ slip/fall/falling
of object etc. is taken care by taking •Use of specified
preventative measures such as--- PPE
• Availability and display of MSDS
•House keeping
• Use of appropriate PPE.
• Fall prevention equipment – full body
harness etc.
• SOP / JSA
•Competent and trained manpower

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Administrative Control

•Statutory Trainings such as MVT, Fire Fighting Training, First

Aid Training etc. including contractor worker free of cost
either at onsite or offsite
•Periodic mock drills including drills in odd hours
•Disaster mock drill
•MOU with mutual aid partners of nearby hazardous industries
for fire safety
• Walk through survey of installation
• IME, PME

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Administrative Control

•Safety awareness Programme including family members

•Safety audit / Sudden Audit at Installations

•Safety week celebration

•Safety Conference

•Publications and communiqué

•Walk the talk

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 Is this enough…????

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 Thank You

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 Fee dback….????

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