Safety in Oil Movement & Storage Operations

Reliance Jamnagar

Jamnagar Refinery Overview

Jamnagar Refinery Overview

Tank farm facilities (OM&S)

Jamnagar Refinery Overview

JETTY

MTF

RTF

UNITS

RAIL

ROAD

GAIL PPL

OM&S facilities overview

APPROACH TRESTLE
3.6 km KNUCKLE PLATFORM

MARINE TANK FARM

SHORE LINK 1.4 km

Security Boat Patrolling Routes Chart-II

ONSHORE PIPELINES
2 km

ZERO POINT LO-LO JETTY

BERTH A BERTH B BERTH C BERTH D

A B C D
4.1 km

PORT OPERATIONS BUILDING RISER PLATFORM

SPM-4
22.8 km

28 km

SPM-5
26 km 11.1 km

48 PIPELINES

9.5 km

SPM-3 SPM - 2
3.1 km

Anchorage Area

SPM - 1 5 5

Introduction
Petroleum Refining Industry handles large quantities of highly flammable liquids and gases, which are potentially associated with fire and explosion hazards .. To support the refining processes all the Products , Crude oil and Intermediate streams are stored and handled via Oil Movement & Storage (OM&S) Section.

Due to storage of huge quantum of hydrocarbons, Safety Management in OM&S operations becomes a very vital function .

OM&S Mission
Oil Movements & Storage (OM&S) Sector of Reliance, Jamnagar is committed to seamless integration of their Refining and Petrochemical business with the entire supply chain by means of , Uninterrupted receipt and supply of raw materials, Storage of intermediate streams / finished products, Blending optimally to meet product specifications and evacuating the finished products by appropriate mode as per customer requirements, Meeting relevant statutory requirements, quality standards and best industry practices. While maintaining excellent housekeeping and HSEF standards.
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Corporate HSE - Objectives

Safety of a person overrides production targets. HSE Policy Conduct all activities in such a manner as to avoid harm to employees, contractors and the community. Promote Occupational Health of its employees and contractors. Sustainable development by continuously improving its environmental and practices and performance. Minimize adverse impact on environment and risks to the community that arise due to its operations and during transport and distribution of goods. Utilize energy resources in a responsible and efficient manner so as to reduce emissions and generation of Effluent and waste products. Comply will all statutory requirements concerning Health, Safety and Environment. Create a culture of learning and practicing Health, Safety and Environment system, Procedures and practices among its employees and contractors.
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OM&S Objectives
HSEF :
Zero Incidents PSM implementation Emissions better than statutory regulations

Quality:
Integrated Management System Minimize Quality deviation and reblending / reprocessing Ensure Customer delight

Reliability:
24 x 7 Plant and Equipment availability

OM&S Objectives
Process Automation:
APC & Online optimizers implementation Refinery at desktop Automate operation management processes

Production:

Production as per EPS plans Zero Operational upsets Maximize Plant availability

Productivity:
Optimize specific consumptions. Continuous improvement in efficiencies Maintain optimum inventory levels.
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OM&S Objectives
Energy Management: Eliminate Energy Wasters
Develop Low energy options in equipment & Processes

Audits & Benchmarking: Improve through effective & Optimized Audits

Improve through Benchmarking

Innovation: Develop and improve upon Best Practices

Implementation of suggestion scheme Six Sigma culture

HR/Training and development :

Effective Training & Validation system in place.
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OM&S Design Basis

All the storage facilities are designed as per Industry/OISD standards and specifications for ensuring intrinsic safety. This covers proper layout, interspacing, proper equipment / instrument selection ,safety release system and drainage facilities etc. API 650 : Welded steel tanks for oil storage. API 620 : Welded low pressure storage tanks. Further to above state of art DCS based automation facilities are provided in OM&S to ensure safety during normal operations. Various improvements carried out at the Design stage of SEZ Refinery based on the experience of DTA Refinery Operations.

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Storage Tank / Sphere Design Basis

Physical Properties - Product Vapor Pressure
Tank Type Cone Roof Floating Roof Int. Float Roof Dome Roof Horton Sphere Vap. Pr. in kg /cm2 <0.05 0.05-0.85 0.05-0.85 0.85-1.06 >1.06 Advantages

Reduces Breathing loss, fugitive emission IFR used wherever quality/safety is of importance Used for handling Liquifed Gases such as LPG/Propylene
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OM&S Safety features

Inbuilt safety features of storage tanks and spheres:
Auto tank RADAR Gauging ( ATG ) Tank overflow protection ( With dedicated ATG) Double seal / Liquid mounted seal Fire detection system in Rim seal area Tank roof safety valves i.e. PSVs and PVRVs. Double deck pontoons on the roof Side entry mixers trip on Tank low level Tank Auto change over through advanced software ESD switch for Emergency shutdown of Spheres. Pivot master for Floating roof drains. Tank dyke walls made of Concrete.
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OM&S in Built safety features

Inbuilt safety features of Pump houses:
Automatic pump changeovers via OMIS F&G system ( Gas, Fire detectors ) PLC based Pump managers Machine condition monitoring system ( MCMS ) for critical pumps Pump trip on Tank low level /Flow. Emergency pump stop facility from remote location Mechanical seals. Pressure differential transmitters ( PDT ) for suction strainers. Sprinklers in LPG pump house
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OM&S Safety features

Other Safety features: Inbuilt protection for over pressurization of lines due to Thermal expansion Process monitoring through Aspen software LPG Driers facility CTMs for material accountal Access control for Control rooms, Process buildings. CCTV cameras for process area monitoring. Emergency Sphere release to Flare system Loading arms with overflow protection system. Loading arms/SPM hoses provided with Breakaway couplings. Tank truck/wagon loading through meters. Effective communication system ( Walkie talkies, Paging, hot lines etc. )
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OM&S Fire protection measures

Fire and Gas detection system. Fixed foam pourer system . Automatic sprinkler system . Rim seal Fire detection for larger floating roof tanks. Gaseous Fire suppression system ( FM200 ) for plant interface buildings(PIBs) Placement of portable Fire fighting equipment at strategic locations. Fire water monitors and hydrants. Round the clock Fire management team. State of the art fire fighting equipment (Tenders, Foam nursers etc) . Regular checks and audits.
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OM&S Fire protection measures

Fire Protection Measures Salient details of F&G system
Purpose S.No Type of detectors Combustible gas 1 detector 2 Flame detectors 3 4 5 6 7 8 9 Locations Plant process area, HVAC, Pump houses Near hot Pumps, Gantries On Tank Roof

Hydrocarbon detection Detect flames Senses continuous rise in Linear Heat detectors Temperature Rate of rise Heat detectors Manual call point Optical smoke detector Ionization Smoke detector Toxic gas detector

Detects rise in Temperature at Pre defined rate Battery rooms To raise Alarm Detect thick smoke Detects invisible smoke Toxic Gas leak Plant area In substations/PIB's/Control rooms In substations/PIB's/Control rooms HVAC, Plant process area Battery rooms, Compressor house, Analyzer houses

Hydrogen gas detector Hydrogen Gas release Open path LEL detector

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Hydrocarbon detection

Pump house

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OM&S Automation- Salient points

Automatic Tank Gauging System (ATG) Tank Inventory System (TIS) Oil Movement Information System (OMIS) Blending Optimization & Supervisory System (BOSS) Crude blending supervisory system ( CBSS ) Terminal Automation system ( TAS ) ESD and DCS interlocks PLC based Pump manager. Motor Operated valves CCTV/ Paging systems/Video walls.

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Automation interface in OM&S

aw r he IS. t ive to T g ill ion w S mat C D for in

TIS OMIS

DCS

TI st a S w i tu ll g s a i ve nd th BO qu e t SS alit ank yt o

ATG , ANALYSERS ETC. DB fo wi r c ll o n co tro nve an l v rse d f alv w e e e o it h db p D ac era CS t io k n

MOV operation and feed backs

Movement Information

BOSS

DB

he t ive DB g ill o to w S r a ti S BO end bl

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Salient points of Automation:

TIS : Real time Tank inventory system All the Tank inventory calculations will be done by this software. OMIS: Automatically execute all specified types of movements and Tank swings.It minimizes line up errors and does the compatibility checks. BOSS : It controls the ratios of the components in a way that the blended product meets all the product quality specifications in optimum manner. TAS: Performs plant control functions such as Pump control, measurements, interlocks etc. Also helps in Traffic management by controlling access Automation helps in minimizing manual intervention there by ensuring complete process safety and efficient plant operations .
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Safety Management

Layout

In-built Safety Design

Safety Management
Process Safety Management

Operating Discipline

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Process safety Management

Process Safety Management is the application of management

systems and controls (standards, procedures, programs, audits, evaluations) to a manufacturing process in a way that process hazards are identified, understood and controlled so that the process related injuries and incidents are prevented. Process Safety Management is targeted at the prevention of catastrophic events which can result in a large number of fatalities and injuries, significant environmental and health damage, significant property damage, business interruption, loss of the right to operate, and resulting high costs that can jeopardize the existence of the business. In view of above Process Safety Management ( PSM ) is key to ensure continual improvement in the safety performance. 23

Process safety Management Why?

Historically greater emphasis has been given to Incident, Injury and related data to measure the safety performance . Main Causes of incidents , Slip, trip and fall. Fall from height . Falling objects. Struck by moving objects. Caught in between. Exposure to toxic vapors / substances. Electric flash. Most of these result due to improper housekeeping or non compliance to proper procedures.

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Accident / Incident Pyramid

Disabling injuries / Loss time case (LTC) First aid case (FAC) & Medical treatment case (MTC) Incidents ( Without injuries ) ( Near Misses ) Unsafe acts / conditions / habits ( critical situations )
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30

300

?000

History of Major Incidents)

1988: Piper Alpha (Occidental) 167 killed Cost: US$1.2 billion 1984: Union Carbide, 1991: Sleipner A Platform Bhopal Collapse (Statoil) Reported 3000 killed Cost: US$1.2 billion Cost: Disappearance of Union Carbide 1998: Longford Gas Explosion (Esso) 8 killed, 69 injured Cost: US$1 billion 2005: Texas City Refinery (BP) 15 killed, 170 injured Cost: US$3 billion+ 2001: P36 Sinking Platform (Petrobras) 10 killed Cost: US$515 million 1996: Enron Gas Pipeline explosion) 33 killed, 69 injured Enchova Central Platform (Petrobras) 1984: Explosion, 37 killed 1988: Gas Blowout Total Cost: US$461 million 1995: Nigerian Oil Rig Explosion (Mobil) 13 killed, 25 injured. 2006: Pipeline Explosion (Nigerian National Petroleum Corporation) 200 killed 2005: Bombay High North Platform (ONGC) 22 killed Cost :US$195 million

____________________________________________________________ __________ 1984 1990 1995 2000 2005

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Worldwide recent incidents

1. 2. 3. 4. 5. Fire and Explosion incident in Jaipur terminal, India. Oct 2009 BP, Gulf of Mexico, Louisiana coast. Explosion and fire on the Mobile Offshore Drilling Unit Deepwater Horizon.20th April 2010 Total group, Britain Lindsey Oil Refinery Fire heater Explosion. June 2010 Asphalt Tank leak in Paramount Petroleum corporation, June 2010. Crude oil pipe line leak in Iran, Abdan Refinery. June 2010

6. Pipeline Explosion in North eastern port city of Dalian, China. July 2010 7. Fire in residue Desulphurization unit of Mailiao Refinery, Formosa Petrochemical Corporation, Taiwan July 2010 8. Fire and Explosion in Petrochemical complex due to Gas pipeline rupture in Iran Aug 2010 27

Trend of Accidents

Technical Measures

No. of Accidents

Process safety measures BP -Deepwater horizon incident Human Factor measures

Bhopal Accident

1970

1980

1990

2000

2010
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Human Factor

As per Domino theory Unsafe conditions and Unsafe acts result into accident which arise from improper habitual behavior. All the Accidents and incidents , Whether of a technical or operating nature have human factor amongst their causes (88% -Henrich 1936 ). Identification of unsafe conditions, unsafe acts & improper behavior and elimination of same can prevent the accidents. Human error arises if Hazards are not clearly perceived and understood.

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Human Factor
Determinants of Human Behavior,
Experience, Learning process, Motivation Attitude

Behavior modification,
Training. Development of skills . Communication. Motivation.

Safety contacts, Tool box talks, Safety observations, Validation of work procedures and Operating discipline are effective tools for bringing positive behavior. 30

Human Factor

Incident investigation and safety /risk analysis are complementary processes towards reduction of accidents.
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Process safety Management

A positive Safety culture and commitment from higher management is essential for good process safety performance. Baker Panel Observations BP Texas city Refinery incident 2005. While BP has a inspirational goal No accidents ,No harm to people.BP has not provided effective leadership in making certain its management and US refining work force understand what is expected of them regarding process safety performance. BP mistakenly interpreted improving personal injury rates as an indication of acceptable process safety performance at its US refineries
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Process Safety Management Model

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Safety and health of personnel and protection of environment overrides all production targets. Mukesh D.Ambani
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HSEF Organization
Corporate HSEF council

Site Site President President Apex Apex Committee Committee Central Central HSEF HSEF Committee Committee District District Safety Safety Committee Committee HSEF HSEF CHIEF CHIEF Corporate-Group Corporate-Group ManufacturingManufacturing- HSEF HSEF

OCCUPATIONAL OCCUPATIONAL HEALTH HEALTH CHIEF CHIEF

SAFETY SAFETY CHIEF(DTA&SEZ) CHIEF(DTA&SEZ)

ENVIRONMENT ENVIRONMENT CHIEF CHIEF

FIRE FIRE CHIEF CHIEF

DOCTORS DOCTORS

SAFETY SAFETY MANAGERS MANAGERS (DTA+SEZ) (DTA+SEZ)

ENVIRONMENT ENVIRONMENT MANAGERS MANAGERS

FIRE FIRE OFFICERS OFFICERS

MEDICAL MEDICAL STAFF STAFF

FIREMEN FIREMEN

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Process safety Management

Management of PSM Elements
PSM element committee Committee Charter Plan of activities KPIs for the committee. Compliance Audits. Review meetings Progress report to site Apex team. Awareness and Training on each PSM element to plant personnel ( all levels ), this is one of the important step towards PSM implementation
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Operational Discipline
OperationalDiscipline elements 4.OD

(Operational Discipline)

KRA Resources Training and competency Communication Participation Procedures Job cycle checks RESOP Audits Assessment / Review

3.Implement PSMProgram

2.ManagementLeadershipand Commitment

1.BuildaSafetyCulture

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Operation discipline elements

KRA : Site KRA/ Team KRA / Individual KRA and KPI system Resources : Process Safety, Fire protection, special PPEs, Software etc. Training and competency : Required competency system. Communication : Pocket cards, HSE Flash, LFI, Tool box talks, Safety alerts, Quarterly safety performance , Corrective action tracking system, PSSR audits and Information sharing from other sites. Participation : Safety meetings, Suggestion schemes, Safety campaigns , Tool box talks, Table top exercises and Task validation. Procedures : SOP,SMP, SOC, MSDS, information on HSEF, Risk assessment and Job checklists. Job cycle checks for SOPs and checklists. Safety observation : Safety Observation and field discussion/ Counseling. Audits : PSM, Work permit , Contractor, Work place, Housekeeping, Fire protection facilities etc.. Assessment / Review : Periodic performance review, Improvement plans.
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HSEF - KPI
Zero accident / incidents. Incident reporting and investigation. Near miss reporting and investigation, wherever required. Compliance of recommendations . Safety awareness training. PME compliance. Validation of SOP/ SMPs. Permit audit compliance. Contractor safety performance. House keeping Audits . Mock drills and recommendation compliance. District safety committee meeting. Safety observations etc. Learning's from incidents ( In-house and outside )
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PSM Operational safety practices

Incident reporting and compliance monitoring system Interlock bypass procedure F&G bypass procedure Control valve bypass procedure Safety system bypass procedure Fire water network isolation procedure Deluge wet and dry testing schedules Preventive maintenance of fire fighting equipment. Procedure compliance audits Self safety audits Alarm monitoring and rationalization Work place audits Periodic Operational safety performance review
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Emergency Management Plan

Well documented Emergency Response & Control Planning Document to incorporate MCA Analysis findings Emergency Management Organization Clear Roles & Responsibilities Resource Identification & mobilization including Mutual Aid Assistance Emergency Communication System Training & Validation of emergency teams Periodic rehearsal of the plan

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Emergency Management Plan

Mock drills level 1 & 2 are carried out at plant level and the observations are duly discussed for closeout. Table top exercises are carried on the various emergency scenario to bring awareness and clear understanding of various aspects of emergency handling. Training on incident command course is mandatory for shift supervisory level. Level -3 Mock drills are carried out along with district administration and mutual aid members

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PSM Safety training

HSEF refresher Live Fire Fighting Fire fighting class room study Process Safety management familiarization Work permit system Safe Handling of Chemicals Personal Protective Equipment (PPE) Emergency management Risk Assessment First Aid, CPR Confined Space Entry Safety Audit Technique What went wrong Learning from Incidents (LFI) workshop

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Safety Campaign
To enhance Safety Awareness as well as compliance to various safety procedures periodic safety campaigns are launched on important safety elements like Line break , Confined space , Work permits , Scaffolds ,work at height and contractor safety etc. The above is carried by means of Safety contacts in routine meetings ,Tool box talks ,Training to target groups ,Issue of safety pamphlets , HSEF messages on desktop, Safety quiz and Inter plant audits etc. These measures help in continuous improvement in the overall safety performance.

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Performance review
TRC (FAC + MTC) Safety LTC Fire all category Spill all category Overdue recommendations (Incidents & accidents investigation) Audit recommendations F & G device disabled DVs isolated > 24 hrs (Other than M&I Purpose) Monitoring Isolation of Fire Water network QSP rating

Reliability

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Performance review
ESD bypassed Safety Trips / Interlock bypassed Controllers on manual DCS Alarms Per shift Tank Relief Devices disabled / incapacited PSV disabled / incapacited PSV overdue for calibration Online sealing No.of tanks/spheres under M&I Monitoring Emergency DG sets status

Reliability

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Performance review
SOC's deviation Safety ISO / OSHAS / IMS audits compliance Concession deviation requests, ISO SOC Deviation Reliability No of MOC's under review PSSR- A category pending points Leaking Roof Drain Pump Seal Leak Stem leaks Monitoring No of Critical jobs for the today

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Best operating Practices

Based on experience and learning's some of the important control measures for the operations of Oil movement & storage facilities are given below. This is not an exhaustive list but covers some of the important functions like, Monitoring & Control Process Safety, SOP Supervisory Control Reliability Static electricity
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Best operating Practices

Monitoring & Control
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Close coordination with process units during start up and shut down. All product routings and the changes shall be done with prior information. Close monitoring of product Rundown temperature and quality. Monitor trend of important process parameters. Deviation from standard operating condition(SOCs) to be checked promptly. Nitrogen blanketed tanks shall be closely monitored. Floating roof drains should be checked for any leaks during routine rounds. Inter tank gravitation operations shall be done in controlled manner to ensure transfer- rates with in specified limits. Piping joints of LPG / Naphtha / lighter service products to be closely monitored under LDAR checks. Pump out and receiving rates from tanks shall be monitored.
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Best operating Practices

Process Safety / SOP
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. No gas blow back from process units ( H2S ,H2 , N2 , Lighters etc.) to storage tanks . Defloating of roof shall be avoided during normal operations . Non process connections shall be adequately safe guarded for hydrocarbon mix-up. Tank dyke interceptor valves should be always kept in close condition. Process safety system bypass shall be done with authorization and proper procedure / safe guards. Non routine operations shall be done as per proper procedures. Ensure thermal expansion of idle and blocked process lines. Any job / modification pertaining to OWS system should be done under proper SOP / Supervision. All the facilities shall be properly marked / stenciled for clear identification. Pyrophoric iron hazards and safe work practices.
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Best operating Practices

Supervisory Control
1. 2. 3. 4. 5. Water draining from the tanks shall be done under constant supervision. High risk /critical jobs shall be carried out under close supervision. Erection jobs around the operating facilities shall be done with proper procedures under close supervision. Horton spheres and tank M&I activities shall be closely supervised. Close monitoring of Permit jobs, Modifications and Construction activities.

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Best operating Practices

Reliability
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Oil soaked insulation shall be promptly replaced. Steam tracer leaks under insulation to be identified and promptly attended. Stagnant lines shall be periodically checked ( by draining /inspection ). Small bore connection to be included in periodic inspection program. Valves which are not operated normally should be checked and greased. Periodic checks for the earthing and cathodic protection facilities of tanks shall be done . Periodic greasing of floating roof ladder hinges for free moment. Avoid use of flame arrestors in the heavier product service tanks. Spare safety valve to be kept isolated and normal safety valve to remain inline. Wafer type NRVs are not safe for LPG/Naphtha/Light product services. 52

Best operating Practices

Static electricity
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Side entry mixers ( SEMs) shall be operated in adequately submerged condition (0.60 1.00 m). Tank mixing operation shall be done after draining of water. Maintain safe velocity while commissioning the tanks. Steam coils operations ( Charging or isolation) shall be done when these are fully submerged.(Product level 1 M above the coil). Use only cotton rope for sample thief. Dip tape and sample thief should be of non-sparking material. Proper earthing continuity to be ensured during tank truck / wagon operation. Do not allow switch loading of products. Only cotton dress / overall shall be used in plant area. Anti static additive to be used for products where conductivity is less than 50 ps/m. Stop loading / dipping and sampling operations during severe electrical storms. Bottom loading shall be provided with splash deflectors.
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Thrust areas OM & S

Full tank fire fighting capability for large capacity storage tanks. Process Safety Management to become the way of life. Continual effort on Training and development , participation in PSM program there by building strong Safety culture. Technical exchange program with World leaders ( DuPont, Shell, Exxon mobil ) Mechanized handling and treatment of storage tank sludge. Ensuring M&I activities as per plan. Incident / accident free plant operations with full compliance to HSEF standards and Operational discipline.

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Thank you